Professional Documents
Culture Documents
786–794
Review
Doru M. STEFANESCU
Department of Material Science & Engineering, The Ohio State University, 137 Fontana Laboratory, 116 W 19th Avenue,
Columbus, OH 43210, USA. E-mail: stefanescu.1@osu.edu
(Received on September 12, 2005; accepted on December 8, 2005 )
In today’s material world it is agreed that a complete understanding of the solidification path and of the re-
sulting microstructure can only be obtained by treating the alloys as mathematical systems, followed by vali-
dation of the models through definitive experiments. This paper will attempt to review the main recent ex-
perimental and mathematical efforts directed to the understanding of microstructure evolution in steel.
KEY WORDS: microstructure evolution; steel; peritectics; solidification; modeling.
tact with each other (Fig. 2). The peritectic g phase will
1. Introduction
grow along the solid/liquid (S/L) interface d /L, driven by
Iron-base alloys, that include steel and cast iron, are liquid super-saturation. Solute rejected by the g phase will
some of the oldest man made materials. However, they have diffuse through the liquid to the d phase contributing to its
enjoyed a remarkable longevity because of their superior dissolution. The g phase will also thicken in the direction
mechanical and physical properties, coupled with their perpendicular to its growth, by direct growth in the liquid
competitive price. They are the most widely used casting and at the expense of the d phase by solid state diffusion.
materials. Since properties are directly related to mi- Once the reaction is completed and all the d /L interface is
crostructure, a significant amount of research has been di- covered by g , the ‘peritectic transformation’ starts. The liq-
rected to the understanding of the evolution of steel mi- uid and the primary d phase are isolated by the g phase.
crostructure during solidification and subsequent cooling to The transformation d ⇒ g takes place by long-range solid-
room temperature. While steels are in principle solid solu- state diffusion through the peritectic g phase. The g phase
tion alloys, their microstructure evolution during solidifica- grows by direct solidification in the liquid.
tion is complicated by the existence of a peritectic. Many According to Fredriksson,5) under certain conditions it is
other metallic, ceramic and organic materials exhibit a peri- possible for nucleation and growth of the g crystals to
tectic transition including Fe–Ni, bronze (Cu–Sn), brass occur in the liquid without contact with the d crystals.
(Cu–Zn), Al–Ti, lanthanide magnets (Nd–Fe–B)1) and ce- Following nucleation, the secondary phase grows freely in
ramic superconductors (Y–Ba–Cu–O).2) Some of these ma- the liquid, while the primary phase dissolves.
terials have exotic applications. For example, the naphtha-
lene-capric acid system is a potential latent heat storage
3. Peritectic Microstructures
material.3) As shown in Fig. 1, at temperatures less than
1 498°C the solidification microstructure of low-carbon Direct evidence of these mechanisms has been provided
steel is single phase austenite. Yet, depending on the carbon recently through in situ dynamic observation of the
content the solidification path can be quite different. At car-
bon contents less than 0.16%, at the end of peritectic solidi-
fication both d ferrite and g phase coexist, while over
0.16% C liquid and g coexist. At carbon contents higher
than 0.53% only austenite solidifies from the liquid. Also
shown on the figure are the metastable extensions of the g
phase that could form at any composition directly from the
liquid if nucleation of the d phase is suppressed. Such sup-
pression of the properitectic phase has been demonstrated
in a number of peritectic binary melts, including Fe–Mo,
Co–Si and Al–Co alloys.4)
Fig. 5. Possible microstructures in peritectic alloys with compositions in the two-phase region. Solidification direction – upward.12)
face is constitutionally undercooled with respect to the resents the difference in growth kinetics between the den-
other phase. As the second phase nucleates and grows drites of the two phases. This equation was plotted in Fig.
ahead of the primary phase, the former phase cannot reach 6(b) as a function of composition for Fe–Ni alloys whose
the steady state. Similarly, the primary phase nucleates phase diagram is presented in Fig. 6(a). It is noticed that for
again during the transient growth regime of the second a given composition of 4.2 at% Ni, as the interface velocity
phase, preventing it for reaching the steady state. increases, a transition from d to g dendrites occurs at about
Consequently, a cycle is set up leading to the layered mi- 8·102 m/s.
crostructure.10,11) The approach described in the previous paragraphs can-
Several other structures can be obtained depending on not explain band formation, which is apparently the result
the relative importance of nucleation diffusion and convec- of nucleation and growth of the second phase during the
tion (Fig. 5).12) Theoretical models and experimental stud- initial transient of planar solidification of the primary phase
ies in thin samples suggest that the structures (a)–(e) can and vice-versa. According to Trivedi,10) the liquid ahead of
form under diffusive regime, while microstructure (f) re- the growing interface is constitutionally undercooled with
quires the presence of oscillatory convection in the melt. respect to the other phase. As the second phase nucleates
In an attempt to rationalize this plethora of peritectic mi- and grows ahead of the primary phase, the former phase
crostructures, prediction of phase and microstructure selec- cannot reach steady state. Then, the primary phase nucle-
tion was attempted by generating microstructure selection ates ahead of the growing second phase preventing it from
diagrams for peritectics. The main variables controlling mi- reaching steady state. Thus, a cycle leading to banded mi-
crostructure evolution include interface velocity (V), ther- crostructure is set up.
mal gradient (GT), alloy composition (Co) and nucleation By combining the maximum growth temperature criteri-
potential. on with nucleation considerations, Hunziker et al.13) devel-
Assuming that the leading phase, that is the phase that oped a microstructure selection diagram for peritectic al-
growth at the highest interface temperature is the kinetical- loys close to the limit of constitutional undercooling. The
ly most stable one, Umeda et al.1) developed an equation diagram, presented in Fig. 6(c) for Fe–Ni alloys, assumes
that describes the transition velocity from d dendrites to g negligible nucleation undercooling for both d and g phases
dendrites in directionally solidified alloys: and allows prediction of planar front, cellular, dendritic,
and band solidification. The transition lines on the
DL ∆Tmδ –γ Co ∆mLδ –γ
Vtrδ –γ G/V–%Ni graph are calculated with the equations presented
4π (Co mLδ (kδ 1)Γδ )1 / 2 (Co mL (kγ 1)Γγ )1 / 2
γ
in the following text and plotted on Fig. 6(c).
The transition from planar-to-cellular growth of the d
...........................................(1) phase is given by the limit of constitutional undercooling:
where DL is the liquid diffusivity, DTmd g and DmdLg are the
melting point difference and the liquidus slope difference G mLδ (CL Co ) mSδ (CoCδ )
.............(2)
between d and g , respectively, and ki and G i are the parti- V DL
tion coefficient and the Gibbs–Thomson coefficient of the g
or d phase. The numerator in the parenthesis represents the where CL is the composition of the liquid at the equilibrium
difference in liquidus temperature between the two phases peritectic temperature and mSd is the solidus slope of the d
(effect of phase equilibria on Vtr), and the denominator rep- phase. By substituting the superscript d with g , the equa-
9 DL Ω2 Cγ L Cγδ Cγ L Cγδ
Vγ with
Ωδγ and Ωγ L ......(9)
8π r (12Ω / π Ω 2 / 2π )2 Cγδ Cδγ CLγ Cγ L
CLγ CLδ where Dg is the diffusivity in the g phase, t is time and Cij
Ω .............................(7)
CLγ Cγ L are interface concentrations (see Fig. 10 for definitions).
This equation suggests that the thickness of the g phase and
where r is the radius of the leading edge (the plate will have the growth rate increase with higher undercooling and dif-
a thickness of 2r), and Cij are interface concentrations (see fusivity.
Fig. 8 for definitions). For substitutionally dissolved elements (e.g., Fe–Ni) the
Using the maximum growth rate theory14,15) it can be growth rate will be very low. Under normal casting condi-
shown that the thickness of g increases with lower solidifi- tions the amount of g phase formed through peritectic
cation velocity and with larger surface energy difference transformation will be negligible in comparison with that
(see Fig. 9): formed through precipitation from the liquid. However, for
D g g Lg g dg g Ld ...........................(8) the Fe–Ni system it was found that the solidification rate
was a function of the local temperature gradient rather than
However, in situ observation in Fe–C systems6) showed undercooling.7)
that the experimental velocities were much higher than the For interstitially dissolved elements (e.g., Fe–C) the dif-
ones predicted with this model. This suggests that the peri- fusion rates are much higher and the peritectic transforma-
tectic reaction is not controlled by carbon diffusivity in the tion is completed within 6 to 10 K of the equilibrium tem-
liquid, but perhaps by either massive transformation of d perature.15,18) The rate controlling phenomenon is carbon
into g , or direct solidification of g from the liquid. Sup- diffusion. Indeed, in situ observation in Fe–C systems6)
port of theses hypotheses was brought recently by the demonstrated that the growth of the thickness of the g
experimental work of Dhindaw et al.16) who studied the phase follows a parabolic law which supports the opinion
peritectic reaction in medium-alloy steel (0.22 mass% C, that carbon diffusion determines growth rate. Calculations
1.3 mass% Cr, 2.6 mass% Ni). Microsegregation measure- with a simple finite difference model19) showed good agree-
ments on directionally and isothermally solidified samples ment between calculated and experimental migration dis-
showed that when the segregation ratio for Ni was higher tances of the g /d and L/g interfaces in time.
than that fro Cr a peritectic reaction has occurred. However, Fredriksson and Stjerndahl20) expanded Hillert’s model to
when the segregation ratio for Cr was higher than for Ni, continuous cooling by assuming that the boundary condi-
the liquid was transformed directly into g without undergo- tions change during cooling and that the cooling rate is con-
ing a peritectic reaction. Based on the evaluation of the en- stant. From the isothermal equation they calculated that the
ergy of transformation through differential thermal analysis thickness of the g layer is given by:
the authors concluded that the transformation is a difusion-
less transformation d ß g .
Fig. 12. Banded structure in a Pb–33at%Bi alloy grown at G2.7 · 104 K/m and V0.56 m m/s (black – a phase, white – b
phase).26)
austenite grain diameter to cooling rate was used as nucle- with a solute diffusion model. An example of the calcula-
ation law. Apparently, the same relationship was used to tion of the growth of four ferrite particles during constant
calculate the number of d grains. Little validation was pre- cooling of a Fe–C alloy is shown in Fig. 15. Anisotropy was
sented for the liquid/solid transformation (no cooling not considered. Below the peritectic temperature single nu-
curves). Data were given for dendrite arm spacing (but no clei were placed on the four interfaces. It is seen that the
explanation on how it was calculated), and on dendrite peritectic g grows around the primary d by simultaneous
grain size, that should match experimental data anyway, consumption of both ferrite and liquid. The peritectic reac-
since they serve as an input in the model. tion is the fastest growth mechanism because at the peritec-
Recent developments in solidification modeling have al- tic temperature the carbon concentration in g is higher than
lowed the direct output and visualization of the phase mor- that in d but smaller than that of the liquid. Thus the fastest
phology resulting from solidification. Of particular interest growth will be where liquid and ferrite can directly react.
to this topic is the computational modeling of peritectic and Thus, the austenite grows around the ferrite.
dendritic phases through the phase field (PF) or the cellular Results of simulation of directional solidification under
automaton (CA) methods. Both methods have been demon- constant thermal gradient are shown in Fig. 16. The d -den-
strated to be suitable for the problem at hand. While the PF drite produced by morphological instability growth in the
method is more rigorous, it is computational intensive and liquid until the peritectic temperature is reached. At this
as such relegated for the time being to the role of a tool for temperature, some random nucleation of g was imposed on
scientific investigation. Initially used to model dendrite so- the system, and then austenite continued to grow on the un-
lidification (see for example Ref. 31), its applicability to the dercooled dendrite consuming both the ferrite and the liq-
modeling of peritectic solidification has also been estab-
lished.32,33)
An example of dendrite growth simulation through the
PF method is given in Fig. 14.34) At low nucleation rate
there is enough space to develop a full dendritic morpholo-
gy. Similar effects of nucleation rate and undercooling were
demonstrated through the CA technique.35,36)
Tiaden37) simulated the microstructure evolution during
peritectic solidification of Fe–C alloys using a multiphase
field approach. It was assumed that the process is non-equi-
librium, diffusion controlled. Three phases, liquid, ferrite Fig. 14. Phase field simulation of two-dimensional anisotropic
and austenite, were considered, and phase fields were de- multigrain solidification as a function of composition
and nucleation rate in the Cu–Ni system at 1 574 K. (a)
fined for each phase. The phase field model was coupled
low nucleation rate; (b) high nucleation rate.34)
Fig. 15. Simulation of peritectic solidification at constant cooling. The carbon concentration is illustrated by the gray
scale.37)
Fig. 16. Simulation of directional peritectic solidification. The morphology of the primary ferrite becomes unstable and a
dendrite evolves. Under the peritectic temperature austenite is formed and coats the dendrite.37)
uid. This model was later expanded to ternary systems (see grow fastest where liquid and a have direct contact. The
Fig. 17).38) primary a phase is soon isolated from the liquid by the b
The CA method is more suited for engineering applica- phase (Figs. 18(b) and 18(c)). As the peritectic transforma-
tions, but needs to overcome skepticism over its quantita- tion proceeds, the thickness of the b layer increases by con-
tive capabilities. As for the PF method, its suitability for suming both the liquid and a phase (Fig. 18(d)).
modeling the evolution of the peritectic structure has been As noted by the authors,35) while randomization was used
demonstrated. Indeed, Zhu and Hong35) have developed a to generate the crystallographic orientations of dendritic
CA method that can simulate microstructure evolution dur- nuclei, the resulted dendrites are parallel to the grid or ori-
ing eutectic and peritectic solidification. Their model, con- ented at 45 degrees. This is caused by the growth algorithm
siders nucleation, growth and crystallographic orientation, which adopts a neighborhood configuration including 8
and is coupled with the curvature and solute redistribution neighbors.
both in liquid and solid phase during solidification. The au- Significant progress has recently been made in eliminat-
thors recognize model limitations such as cell size and den- ing the mesh dependency of early CA models. Beltran-
drite orientation dependency. Nevertheless, they claim that Sanchez and Stefanescu39) developed a quantitative model
the model is capable of predicting realistically complex nu- for simulation of dendrite growth controlled by solutal ef-
cleation and growth in both eutectic and peritectic systems. fects in the low Péclet regime. The model, based on CA
The Zhu and Hong model was applied to simulate the concepts36) but using virtual tracking of the sharp S/L inter-
peritectic transformation of a Fe–0.3mass%C alloy. The face, produces realistic pictures of dendrite growth support-
cooling rate and peritectic undercooling were chosen to be ed by validation. An example is provided in Fig. 19. The
10 K/s and 1 K, respectively. Other physical parameters new model proposed a solution for the problem of mesh
were taken from Ref. 37. The simulation results are present- anisotropy valid for any grain orientation. The solution in-
ed in Fig. 18. As the temperature decreases under the liq- cludes new methods for calculation of SL interface curva-
uidus, primary a dendrites grow from the melt (Fig. 18(a)). ture, normal velocity, increment of the solid fraction, and
When the temperature is below the peritectic temperature, b trapping rules for interface cells. It also introduces a tech-
crystals nucleate at the a /liquid interface, followed by the nique to minimize the mesh anisotropy by spreading the arc
growth of b phase around the primary a phase, since b can length of the SL interface over more than one cell, allowing
Fig. 18. Simulated peritectic microstructure evolution during the solidification of a Fe–0.3mass%C alloy with various
elapsed times: (a) 0.55 s, (b) 1.17 s, (c) 1.20 s, and (d) 3.40 s.35)
Fig. 19. Simulation of growth of a single dendrite of Fe–0.6mass%C dendrite. The asymmetry of the solutal field be-
cause of the proximity of the upper and lower boundaries induces asymmetric growth of the dendrite.39)
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