Solar-grade multicrystalline silicon ingots as raw material for solar cells were obtained from upgraded metallurgical silicon by directional solidification in an axial magnetic field. The influence of preparation technology on the microstructural characteristics of silicon ingots was investigated. Governing equations were used to simulate the silicon fluid flow and thermal fields during directional solidification. The results show that appropriately increasing melt temperature and/or decreasing pulling-down rate can be conductive to the growth of a coarse columnar grain. Meanwhile, the axial magnetic field promotes the formation of low-energy ∑3 twin boundaries and reduces the dislocations and impurities, where the total concentration of major metal impurities is with a mean of 0.459 ppmw in the range of 1/9 to 8/9 of height along the growth direction. It is shown from the simulation results that suppressing silicon melt flow in both radial and azimuthal directions and reducing the growth rate in the edge regions contribute to the formation of a flat solid–liquid interface, which is more consistent with the experimental results. Moreover, the formation mechanism of the twins and removal mechanism of the impurities were discussed.

The growth advantage of twinned dendrites over regular columnar ones was systematically investigated during Bridgman solidification. An experimental approach was designed and the results indicated that the strong twin growth advantage lost its efficiency in the coexisting microstructure containing both twinned and regular dendrites at a low growth rate of 10 μm/s. The twin growth advantage derives from three essential components: the lateral twin propagation perpendicular to twin plane (Rx), the propagation parallel to twin plane (Ry), and the dendrite tip growth (Rz). The lateral extension component Rx played a vital role and would be limited at a low rate. Meanwhile, the tip undercooling of the twinned dendrite was estimated based on its plate-like growth morphology. Furthermore, the competitive growth between twinned dendrites was investigated in different feathery grains. When the included angle between twin planes was relatively large, the lateral twin propagation would keep down the in-plane twin propagation.

The microstructure evolution of the directionally solidified NiAl–Cr(Mo) planar eutectic lamellar structure was studied at 1150 °C and times of up to 400 h. The planar eutectic lamellar structure is obtained at the withdrawal rate range of 2.5–7.5 μm/s. The interlamellar spacing decreases gradually with increasing the withdrawal rate. The lamellar termination (like angular or smooth) commonly exists in the as-DS alloy. After high temperature treatment, the lamellar structure at 2.5 μm/s (interlamellar spacing, 3.7 μm) is almost stable, only a little migration of termination occurs at 400 h. When the withdrawal rate increases to 4.5 μm/s, the coarsening and migration of termination occur at 200 h. The adjacently coarsened terminations assemble when the coarsening processes to a certain degree, thus resulting in the formation of the blocky Cr(Mo) phase. Similarly, the above instable phenomenon occurs at 7.5 μm/s. The relevant instability mechanisms are discussed.

To prepare high quality large solidified Al2O3/ZrO2 eutectic ceramic, the preparation processing of the presintered ceramic as a feed rod was investigated via experiments; some parameters of the induction heating zone process were optimized via numerical modeling; an Al2O3/ZrO2 eutectic ceramic rod with a diameter 10 mm was prepared. The results show that increasing the sintering temperature could increase the presintered ceramic’s bulk density, while increasing sintering time had little effect. And the bulk density increased first and then decreased with the molding pressure increase. And the saucer coil obtained a higher temperature gradient than the tubbiness coil for a fixed crucible wall maximum temperature, and the coil turn’s increase could increase the melting zone height in the induction zone melting process. In the directionally solidified Al2O3/ZrO2 eutectic ceramics, Al2O3 phase is the matrix phase, and the ZrO2 phase embedded in the Al2O3 phase mostly with the rod shape, and little with lamellar. The hardness of directionally solidified eutectic ceramics reaches 16.17 GPa and the fracture toughness reaches 4.76 MPa m1/2, which are 1.7 times and 1.5 times of the presintered eutectic ceramic, respectively.

Ti–47Al samples with a diameter of 18 mm are obtained by electromagnetic confinement and directional solidification at different growth velocities. Controlled by a Ti–43Al–3Si seed, the α grains are aligned well and the parallel lamellar microstructure is obtained at the growth velocity of 10 μm/s. With the growth velocity increases to 25 and 50 μm/s, although the lamellar microstructures are still aligned well in the initial transition stage, the lamellar alignment fails due to the nucleation and growth of new β and α grains and then the inclined and perpendicular lamellar microstructures form eventually. The room temperature tensile properties of the different lamellar microstructures are measured and the results show that the desired lamellar microstructure has a tensile strength of 693 MPa and an elongation of 10.0% simultaneously. They are the maximum values that have been reported in binary γ-TiAl alloys so far and are far higher than those of the other two types of lamellar microstructures. The fracture behaviors of the lamellar microstructures are checked by scanning electron microscopy and transmission electron microscopy. Two models are used to illustrate the fracture mechanism of the different lamellar structures.

Current FDA-approved permanent female sterilization procedures are invasive and/or require the implantation of non-biodegradable materials. These techniques pose risks and complications, such as device migration, fracture, and tubal perforation. We propose a safe, non-invasive biodegradable tissue scaffold to effectively occlude the Fallopian tubes within 30 days of implantation. Specifically, the Fallopian tubes are mechanically de-epithelialized, and a tissue scaffold is placed into each tube. It is anticipated that this procedure can be performed in less than 30 minutes by an experienced obstetrics and gynaecology practitioner. Advantages of this method include the use of a fully bio-resorbable polymer, low costs, lower risks, and the lack of general anaesthesia. The scaffold devices are freeze-cast allowing for the custom-design of structural, mechanical, and chemical cues through material composition, processing parameters, and functionalization. The performance of the biomaterial and de-epithelialization procedure was tested in an in vivo rat uterine horn model. The scaffold response and tissue-biomaterial interactions were characterized microscopically post-implantation. Overall, the study resulted in the successful fabrication of resilient, easy-to-handle devices with an anisotropic scaffold architecture that encouraged rapid bio-integration through notable angiogenesis, cell infiltration, and native collagen deposition. Successful tubal occlusion was demonstrated at 30 days, revealing the great promise of a sterilization biomaterial.

A novel freeze-cast porous chitosan conduit for peripheral nerve repair with highly-aligned, double layered porosity, which provides the ideal mechanical and chemical properties was designed, manufactured, and assessed in vivo. Efficacies of the conduit and the control inverted nerve autograft were evaluated in bridging 10-mm Lewis rat sciatic nerve gap at 12 weeks post-implantation. Biocompatibility and regenerative efficacy of the porous chitosan conduit were evaluated through the histomorphometric analysis of longitudinal and transverse sections. The porous chitosan conduit was found to have promising regenerative characteristics, promoting the desired neovascularization, and axonal ingrowth and alignment through a combination of structural, mechanical and chemical cues.

We develop a phase field model for the simulation of chemical diffusion-limited solidification in complex metallic alloys. The required thermodynamic and kinetic input information is obtained from CALPHAD calculations using the commercial software-package ThermoCalc. Within the case study on the nickel-base superalloy Inconel 718, we perform simulations of solidification with the explicit consideration of 6 different chemical elements. The stationary dendritic tip velocities as functions of the constant undercooling temperature obtained from isothermal solidification are compared with the stationary tip temperatures as functions of the imposed pulling velocity obtained during directional solidification. We obtain a good quantitative agreement between the two different velocity—undercooling functions. This indicates that the model provides a self consistent description of the solidification. Finally, the simulation results are discussed in light of experimental solidification conditions found in single crystalline casting experiments of Inconel 718.

The erosion behavior of a directionally solidified Fe–B alloy containing 3.5 wt% B in the different velocities of flowing liquid zinc is investigated by X-ray diffraction and scanning electron microscopy to clarify the effect of interaction between Fe2B and the erosion products on erosion performance using a rotating-disk technique. The results indicate that the Fe–B alloy erodes at a low and steady rate in flowing liquid zinc. The microstructure of erosion layers of the directionally solidified Fe–B alloy depends on the orientation relation between the growth direction of Fe2B phase and the erosion surface. When the growth direction of Fe2B is perpendicular to the erosion surface, the Fe2B and the erosion compounds form a compact and stable combining layer that effectively inhibits the erosion of flowing liquid zinc and further improves the erosion resistance of Fe–B alloy.

Freeze casting of traditional ceramic suspensions and freeze casting of preceramic polymer solutions were directly compared as methods for processing porous ceramics. Alumina and polymethylsiloxane were freeze cast with four different organic solvents (cyclooctane, cyclohexane, dioxane, and dimethyl carbonate) to obtain ceramics with ∼70% porosity. Median pore sizes were smaller for solution freeze casting than for suspension freeze casting under identical processing conditions. The pore structures, which range from foam-like to lamellar, were correlated to the Jackson α-factor of the solvent; solvents with low α-factors yielded nonfaceted pore structures, while high α-factors produced more faceted structures. Intermediate α-factors resulted in dendritic pore structures and were most sensitive to the processing method. Small suspended particles ahead of a solid–liquid interface are hypothesized to destabilize the dendrite tip in suspension freeze casting resulting in more foam-like structures. Differences in processing details were highlighted, particularly regarding the improved freezing front observation possible with solution-based freeze casting.

The effect of Cr fibers on the deformation of directionally solidified NiAl–Cr eutectics, prepared at three different solidification speeds affecting the fiber diameter and fiber spacing, was studied at varying length scales using different micromechanical testing techniques. In situ tensile tests in a scanning electron microscope of individual Cr fibers showed high strength accompanied by ductile behavior. Comparative microcompression tests on single-phase NiAl pillars and NiAl pillars containing a single fiber showed that the pillars with the single fiber were marginally weaker than the single-phase pillars for similar pillar diameters. Composite pillars with multiple fibers exhibited an increase of 0.2% offset strength values with increasing solidification speed. Transmission electron microscopy of the composite pillars containing a single fiber after deformation revealed significant dislocation activity both in the fiber and the matrix. It is argued that the interface between the fiber and matrix acts as dislocation source promoting plastic deformation of the brittle NiAl matrix.

Effects of traveling magnetic field (TMF) on freckle formation of directionally solidified Pb–Sn alloys were investigated experimentally and numerically. The experimental results demonstrated that freckles could form without any magnetic field and with the upward TMF. In the former case, the formation location is the center. In the latter case, it diverted from the center to the surface with the increasing intensity of TMF. However, freckle could not form under the downward TMF. Numerical results indicated that the change of the formation location under upward TMF should be attributed to the different solid/liquid interface shape, and no formation under downward TMF should be attributed to the convection intensity driven by TMF. These magnetic fields are used to modulate melt flow, which is similar to the effects of the gravity. For eliminating freckle, a microgravity environment can be established under the suitable downward TMF.

The microstructure, room temperature compressive property, and elevated temperature tensile property of directionally solidified NiAl–Cr(Mo)–(Hf,Dy) hypereutectic alloy were investigated. The directional solidifications of liquid metal cooling technique (LMC) and zone melted liquid metal cooling technique (ZMLMC) were adopted. In the LMC alloy, the well-aligned and fully eutectic lamellar structure parallel to the growth direction is obtained. The interlamellar spacing gradually decreases with increasing the withdrawal rate, and the compressive yield strength gradually increases. In the ZMLMC alloy, the eutectic lamellar structure is disordered and not parallel to the growth direction, and the quantities of Cr(Mo) primary phases are observed. Compared to the ZMLMC alloy, the LMC alloy has a better combination property because of the well-aligned lamellar structure. The observations of crack propagation and fracture surface are performed to better understand the fracture behavior.

Ti–47Al–1.0W–0.5Si (at.%) alloy was directionally solidified in the range of growth rate (V) (V = 3–100 μm/s) at a constant temperature gradient (G = 18 K/mm). It was found that α phase was the primary phase of the alloy. Both primary dendritic arm spacing (λ) and interlamellar spacing (λs) decreased with increase of the growth rate (V) according to the relationship of λ ∝ V −0.356 and λs ∝ V −0.49, respectively. The Solidification segregation occurred since the enrichment of the solute element W in primary α phase during solidification. The degree of the segregation increased with the increase of the growth rate (V). The results also revealed that the lamellar orientation was not always perpendicular to the growth direction (GD) because the GD of primary α dendritic deviated from the preferred $\left\langle {0001} \right\rangle$ direction. The microhardness increased with increasing growth rate (V) according to H V ∝ 289.5V 0.12 because of the microstructure refinement.

By combining the techniques of directional solidification and coating Y2O3, a Cr–20Nb–40Ti alloy was manufactured successfully with various growth rates. The revolution of microstructures and corresponding mechanical properties was discussed to develop the Cr2Nb based alloys with good combination of mechanical properties. The results show that the favorable growth dynamics of plane (220) of Laves phase Cr2Nb was observed with the increase of growth rate. Phase selection took place in microstructures evolved from the primary Cr2Nb, via the dendrite-like eutectic Cr2Nb/β-Ti, and finally to the primary β-Ti, with increasing the growth rate from 5 to 200 μm/s. Based on the coupled zone of eutectic, the competitive growth of solidified phases in the directionally solidified Cr–20Nb–40Ti alloy was elucidated. In addition, the mechanical properties of alloy depended on the growth rate, and the fracture toughness of the alloy reached 16.50 MPa m1/2 at 200 μm/s, much larger than 1.40 MPa m1/2 for single-phase Cr2Nb.

Two kinds of heavy-alloying β-type TiAl-based alloys Ti44Al6Nb1.0Cr2.0V (A1) and Ti44Al6Nb1.0Cr2.0V0.15Y0.1B (A2) are newly designed. They are prepared by vacuum consumable melting (VCM) and cold crucible directional solidification (CCDS). Via the theoretical analysis and tentative experiment, five alternative heat treatment (HT) schedules are proposed and studied that the corresponding microstructure and room temperature (RT) tensile property are investigated, and finally the optimized HT schedules are acquired. After HT5 (heat preservation in β phase region and at 1290 °C, and then ladder cooling), A2 alloy cast by VCM exhibits a better tensile property with average elongation of 1.20%. For the two CCDS ingots, after HT3 (mainly annealing at 1280 °C), B2 phase and (B2 + γ) blocky morphology are reduced, the columnar grains and small angle lamellas are reserved, and the tensile property also has a moderate improvement.

The effects of an axial high magnetic field on the growth of the α-Al dendrites and the alignment of the iron-intermetallics (β-AlSiFe phases) in directionally solidified Al–7 wt% Si and Al–7 wt% Si–1 wt% Fe alloys were investigated experimentally. The results showed that the application of a high magnetic field changed the α-Al dendrite morphology significantly. Indeed, a high magnetic field caused the deformation of the α-Al dendrites and induced the occurrence of the columnar-to-equiaxed transition (CET). It was also found that a high magnetic field was capable of aligning the β-AlSiFe phases with the <001>-crystal direction along the solidification direction. Further, the Seebeck thermoelectric signal at the liquid/solid interface in the Al–7 wt% Si alloys was measured in situ and the results indicated that the value of the Seebeck signal was of the order of 10 µV. The modification of the α-Al dendrite morphology under the magnetic field should be attributed to the thermoelectric magnetic force acting on the α-Al dendrites. The magnetization force may be responsible for the alignment of the β-AlSiFe phases under the magnetic field.

In the present study, the crystallographic features of bcc/T1/T2 three-phase microstructure in a directionally solidified Mo–32.2Nb–19.5Si–4.7B (at.%) alloy have been examined by electron back-scattering diffraction (EBSD) analysis. The alloy was directionally solidified using an optical floating zone (OFZ) furnace in a flowing Ar gas atmosphere at a constant growth rate of 10 mm/hour. The microstructure of the directionally solidified alloy is characterized by an elongated T2 phase surrounded by inclusions of bcc and T1 phases with an interwoven morphology. The T2 grains are faceted on the (001) planes and elongated along the [110] direction. The T2 phase has an orientation relationship of (001)T2 // (011)bcc and [130]T2 // [2${\rm{\bar 1}}$1]bcc with the bcc phase, whereas any particular orientation relationships of T1 phase with bcc and T2 phases have not been found. These crystallographic features of bcc/T1/T2 three-phase microstructure suggest that the primary T2 phase crystallizes and grows along the [110] direction in liquid phase, followed by nucleation of the bcc phase on the interface between T2 and liquid phases, resulting in bcc/T1 two-phase eutectic reaction surrounding the elongated T2 phase.

Three-dimensional (3D) morphological evolution and growth mechanisms of primary I-phase particles have been investigated in directionally solidified Al–6Mn–2.5Be (wt%) alloy at a wide range of growth rates (100–1500 μm/s). At relatively low growth rates (100–600 μm/s), the I-phase particles exhibit faceted growth with strong anisotropy, forming a hierarchical flower-like aggregate with icosahedral morphological symmetry composed of several attached irregular polyhedrons or pentagonal dodecahedrons. At higher growth rates (e.g., 1000 μm/s), the interface of the I-phases becomes unstable along the edges and corners of the pentagonal dodecahedron, thereby arousing growth perturbations. Correspondingly, a transition from faceted to nonfaceted growth occurs with increasing growth rate. Further increase of the growth rate leads to the formation of I-phase columnar dendrites' preferential growth along the 3-fold axis. The configurations of the flower-like aggregates can be adequately illustrated by a geometrical model in terms of the perfect and elongated pentagonal dodecahedrons. A growth mechanism for the flower-like aggregates has been proposed based on the clear understanding of the 3D morphological evolution of the I-phase particles.

A comprehensive understanding of the growth pattern of intermetallic compounds (IMCs) during solidification is critical to both the crystal-growth theory and its property optimization. In this article, growth pattern and three-dimensional (3D) morphology of primary Al6Mn IMC were investigated in directionally solidified Al–3 at.% Mn alloy at a wide range of growth rates. A transition from faceted (<60 μm/s) to nonfaceted growth (>100 μm/s) was observed with increasing growth rates. Correspondingly, 3D morphologies of primary Al6Mn change from a solid polyhedron to a hollow structure, and then to a dendrite. This kind of change is associated with the competitive growths of different crystal planes determined by the crystallographic anisotropy and growth kinetics of Al6Mn. A growth model based on atomic cluster attachment is proposed to reveal the growth transition, and a growth-rate ratio between different crystal planes is used to appropriately reveal the formation mechanism of different morphologies at low rates.