Effect of cooling rate on the 3D morphology of the proeutectic Al3Ni intermetallic compound formed at the Al/Ni interface after solidification

doi:10.1016/j.jmst.2020.08.005

Abstract

Abstract:

Effect of cooling rate on the 3D morphology and the growth mechanism of the proeutectic Al₃Ni intermetallic compound (IMC) that forms at the Al/Ni interface after solidification was investigated by synchrotron X-ray microtomography in combination with EBSD analysis. The proeutectic Al₃Ni phase that forms under an average cooling rate of 0.1 K s^-1 shows a characteristic faceted growth behavior and presents a typical 3D morphology as partially hollow quadrangular prisms. On the contrary, that forms under an average cooling rate of 10 K s^-1 shows complicated dendritic morphology with asymmetrically distributed arms and faceted V-shape groove at the distal end, indicating a gradual transition of the growth behavior from non-faceted to faceted during the solidification process. These results reveal that the morphology of the proeutectic Al₃Ni is highly sensitive to the solidification condition so that fine control of the desired morphology may be achieved by carefully manipulating the cooling profile.

Key words: 3D morphology, Al₃Ni intermetallic compounds, Solidification, Cooling rate, Synchrotron radiation, Al/Ni interface

Liao Yu, Qiaodan Hu, Zongye Ding, Fan Yang, Wenquan Lu, Naifang Zhang, Sheng Cao, Jianguo Li. Effect of cooling rate on the 3D morphology of the proeutectic Al₃Ni intermetallic compound formed at the Al/Ni interface after solidification[J]. J. Mater. Sci. Technol., 2021, 69: 60-68.

Figures/Tables 12

Fig. 1. Schematic diagram of synchrotron X-ray microtomography, image processing, and 3D reconstruction procedures.

Fig. 2. SEM image of the Al-Ni IMCs after solidification at different cooling rates of (a) 0.1 K s-1 and (b) 10 K s-1. (c) and (d) the expanded view of the rectangular area in (a) and (b), respectively.

Fig. 3. EBSD mapping and pole figures of the proeutectic Al3Ni phase. (a) and (b) cooled at 0.1 K s-1, (c) and (d) cooled at 10 K s-1.

Fig. 4. (a) Radiographs captured during the 180° rotation at selected angles and (b) phase-retrieval slices at four selected distances away from the Al3Ni2/Al3Ni interface of the slow-cooled sample.

Fig. 5. (a) Radiographs captured during the 180° rotation at selected angles and (b) Phase-retrieval slices at four selected distances away from the Al3Ni2/Al3Ni interface of the fast-cooled sample.

Fig. 6. 3D morphology of the IMCs formed at the Al/Ni interface by furnace-cooling at 0.1 K s-1: (a) proeutectic and eutectic Al3Ni, (b) proeutectic Al3Ni, (c) eutectic Al3Ni, (d) front-, rear- and top-view of one proeutectic Al3Ni prism and its associated pole figures and (e) irregular Al3Ni particles near the Al3Ni2/Al3Ni interface. In (a)-(c) the Al3Ni2/Al3Ni interface is at the bottom.

Fig. 7. 3D morphology of the IMCs formed at the Al/Ni interface by air-cooling at 10 K s-1: (a) proeutectic and eutectic Al3Ni, (b) proeutectic Al3Ni, (c) one typical dendrite showing two-types of secondary arm. The inset figure is an expanded view of the V-shape groove at the distal end of a well-developed secondary arm; (d) one well-developed dendrite showing secondary, third and fourth arms. The inset figure is the expanded view of the dashed rectangular area mapped with Gauss curvature; (e) one dendrite with an abnormal sub-branch structure viewed from the top, front, left and rear. The inset figures are the 2D morphology as observed under SEM. In (a) and (b) the Al3Ni2/Al3Ni interface is at the bottom.

Table 1 Intersection angles between arms at various levels, and the transition angles of the secondary or third-level arms of a well-developed Al3Ni dendrite. The symbols are indicated in Fig. 7(d).

Main trunk and secondary arm	α₁	58°‒61°
Main trunk and secondary arm	α₂	55°‒58°
Secondary arm and third arm	β₁	57°‒61°
Secondary arm and third arm	β₂	30°‒33°
Third arm and fourth arm	γ	31°‒33°
transition angle of dendrite end	θ₁	150°
transition angle of dendrite end	θ₂	150°

Fig. 8. (a) Schematic of a screw dislocation and (b) the formation mechanism of a proeutectic Al3Ni hollow prism.

Table 2 The strain energy ratio between a cylinder and a prism with varying r.

r₀ (μm)	r (μm)	E_c/E_p
10^-4	0.01	0.908
	0.1	0.940
	1	0.951
	10	0.962
	100	0.967

Fig. 9. (a) V-shape grooves at the distal end of Al3Ni dendrites; (b) unit cell structure of an Al3Ni crystal and the intersection of (011) and (01-1) planes; (c) unit cell structure viewed from the [100] direction.

Fig. 10. Specific surface area of the fast-cooled proeutectic Al3Ni dendrites as a function of the volume. The inset figures are representative 3D morphologies of Al3Ni with abnormally high SA (I, II, III) and a typical dendrite with normal SA.

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Effect of cooling rate on the 3D morphology of the proeutectic Al₃Ni intermetallic compound formed at the Al/Ni interface after solidification

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