Phase boundary anisotropy and its effects on the maze-to-lamellar transition in a directionally solidified Al Al2Cu eutectic

Solid-solid phase boundary anisotropy is a key factor controlling the selection and evolution of non-faceted eutectic patterns during directional solidification. This is most remarkably observed during the so-called maze-to-lamellar transition. By using serial sectioning, we followed the spatio-temporal evolution of a maze pattern over long times in a large Al-Al2Cu eutectic grain with known crystal orientation of the Al and Al2Cu phases, hence known crystal orientation relationship (OR). The corresponding phase boundary energy anisotropy ($γ$-plot) was also known, as being previously estimated from molecular-dynamics computations. The experimental observations reveal the time-scale of the maze-to-lamellar transition and shed light on the processes involved in the gradual alignment of the phase boundaries to one distinct energy minimum which nearly corresponds to one distinct plane from the family $\{120\}^{\rm{Al}} //\{110\}^{\rm{Al2Cu}}$. This particular plane is selected due to a crystallographic bias induced by a small disorientation of the crystals relative to the perfect OR. The symmetry of the OR is thus slightly broken, which promotes lamellar alignment. Finally, the maze-to-lamellar transition leaves behind a network of fault lines inherited from the phase boundary alignment process. In the maze pattern, the fault lines align along the corners of the Wulff shape, thus allowing us to propose a link between the pattern defects and missing orientations in the Wulff shape