Dynamic evolution process of multilayer core-shell microstructures within containerlessly solidifying Fe(50)Sn(50) immiscible alloy

Experimental investigations and phase-field simulations of triple-phase-separation kinetics within liquid ternary Co-Cu-Pb immiscible alloys

The phase-separation kinetics and microstructure evolution mechanisms of liquid ternary Co_{43}Cu_{40}Pb_{17} immiscible alloys are investigated by both the drop tube technique and phase-field method. Two successive phase separations take place during droplet falling and lead to the formation of a three-phase three-layer core-shell structure composed of a Co-rich core, a Cu-rich middle layer, and a Pb-rich shell. The Pb-rich shell becomes more and more conspicuous as droplet diameter decreases. Meanwhile, the Co-rich core center gradually moves away from the core-shell center. Theoretical analyses show that a larger temperature gradient inside a smaller alloy droplet induces the accelerated growth of the surface segregation shell during triple-phase separation. The residual Stokes motion and the asymmetric Marangoni convection result in the appearance of an eccentric Co-rich core and the core deviation degree is closely related to the droplet size and initial velocity. A three-dimensional phase-field model of ternary immiscible alloys, which considers the successive phase separations under the combined effects of Marangoni convection and surface segregation, is proposed to explore the formation mechanisms of three-phase core-shell structures. The simulated core-shell morphologies are consistent with the experimental observations, which verifies the model's validity in reproducing the core-shell dynamic evolution. Numerical results reveal that the development of three-phase three-layer core-shell structures can be attributed to the primary and then secondary phase separations dominated simultaneously by Marangoni convection and surface segregation. Furthermore, the effects of droplet temperature gradient on the growth kinetics of the surface segregation shell are analyzed in the light of phase-field theory.

Nucleation and growth of a core-shell composite nucleus by diffusion

The critical radius of a core-shell-type nucleus grown by diffusion in a phase-separated solution is studied. A kinetic critical radius rather than the thermodynamic critical radius of standard classical nucleation theory can be defined from the diffusional growth equations. It is shown that there exist two kinetic critical radii for the core-shell-type nucleus, for which both the inner-core radius and the outer-shell radius will be stationary. Therefore, these two critical radii correspond to a single critical point of the nucleation path with a single energy barrier even though the nucleation looks like a two-step process. The two radii are given by formulas similar to that of classical nucleation theory if the Ostwald-Freundlich boundary condition is imposed at the surface of the inner nucleus and that of the outer shell. The subsequent growth of a core-shell-type postcritical nucleus follows the classical picture of Ostwald's step rule. Our result is consistent with some of the experimental and numerical results which suggest the core-shell-type critical nucleus.