Microstructure development in alloy splats during rapid solidification

One-dimensional heat and mass transfer problems are numerically solved to predict microstructure development in alloy splats in rapid solidification. The model accounts for nonequilibrium solidification. The dendrite tip radius is estimated using an interface stability analysis. Model predictions are compared with microstructures of Sn–5 wt.% Pb splats produced by depositing mono-size droplets on a Sn substrate. The droplet temperature at impact is controlled adjusting the flight distance to the substrate. The microstructures of deposit produced with supercooled droplets primarily match those predicted by the numerical simulation.