A Model for the Anomalous Velocity-Undercooling Behaviour of Levitated Al-Ni Alloys On-board the International Space Station

Al-Ni alloys (for Ni < 45 at.%) show a unique property in that, over at least part of the accessible undercooling range, the recalescence velocity measured in electromagnetically levitated samples is observed to decrease as the undercooling increases. This result has been subject to careful validation, including microgravity experiments utilising the TEMPUS levitation facility on-board the International Space Station (ISS). In these experiments, anomalous growth is observed to coincide with a recalescence morphology comprising multiple circular growth fronts [Herlach et al. Phys. Rev. Mat. 3, 073,402 (2019)], termed “scales”. In this paper we present an analysis of high speed video data from the ISS experiments in which we show that such scale-like growth is consistent with a recalescence front that is initially confined to a thin layer on the surface of the sample. This then nucleates a slower, radial inward growth, which is consistent with microstructures observed in Al-Ni droplets. We show that such surface recalescence would be favoured for samples which were surface enriched in Ni, wherein the recalescence velocity (at fixed nucleation temperature) increases rapidly with Ni-concentration. Moreover, it is shown that the anomalous velocity behaviour can be matched in all compositions studied if the surface enhancement in Ni is a linear function of the nucleation temperature with a gradient of 0.03 at.% K−1. Analysis of historical results from the literature indicates that such surface Ni-enhancement may have been present, but overlooked, in other experiments on Al-rich Al-Ni droplets.