Reexamination of the solidification behavior of undercooled Ni–Sn eutectic melts

Abstract Employing a high-speed video, in situ recalescence behaviors of Ni–Sn eutectic melts under different undercooling conditions have been investigated. Based on the surface morphologies and cross-sectional microstructures that consist of independent eutectic colonies, copious nucleation is proposed to take place in Ni–Sn eutectic melt regardless of melt undercooling in the unconstrained solidification. The boundary with sharp contrast between the crystallized bright solid and undercooled dark liquid during recalescence is not the solid/liquid interface but the simultaneous thermal release of concentrated crystallizing eutectic colonies. It may not be feasible to measure growth velocities in free solidification of the system due to copious nucleation. The fluctuations in undercooled melts are proposed to activate a chain-like successive nucleation reaction once an effective nucleus is formed. The current observation urges that we should deliberate further the conventional concept that once an effective nucleus is formed in a deeply undercooled melt, the growth will be initiated promptly and the solid/liquid interface will sweep across the entire sample rapidly. The origin of anomalous eutectic formation and the growth have been discussed when the current nucleation phenomenon is taken into account. Based on the copious nucleation theory and the improved driving force for growth, the present recalescence frames and some other experimental phenomena concerning the free growth of the undercooled eutectic system can be well clarified.