Liquid phase separation and subsequent dendritic solidification of ternary Fe35Cu35Si30 alloy

Liquid Fe35Cu35Si30 alloy has achieved the maximum undercooling of 328 K (0.24TL) with glass fluxing method, and it displayed triple solidification mechanisms. A critical undercooling of 24 K was determined for metastable liquid phase separation. At lower undercoolings, α-Fe phase was the primary phase and the solidification microstructure appeared as homogeneous well-defined dendrites. When the undercooling exceeded 24 K, the sample segregated into Fe-rich and Cu-rich zones. In the Fe-rich zone, FeSi intermetallic compound was the primary phase within the undercooling regime below 230 K, while Fe5Si3 intermetallic compound replaced FeSi phase as the primary phase at larger undercoolings. The growth velocity of FeSi phase increased whereas that of Fe5Si3 phase decreased with increasing undercooling. For the Cu-rich zone, FeSi intermetallic compound was always the primary phase. Energy-dispersive spectrometry analyses showed that the average compositions of separated zones have deviated substantially from the original alloy composition.