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Abstract
The effect of solidification history on the resultant microstructure in atomized Al–2.56 wt% Fe and Al–6.0 wt% Fe powders was studied, with particular emphasis on droplet size, undercooling, and phase stability. The atomized Al–Fe powders exhibited four microstructural features, i.e., Al3Fe phase (now known as Al13Fe4), Al + Al6Fe, α–Al dendrite, and a predendritic microstructure. The presence of these phases was noted to depend on alloy composition and a kinetic phase competitive growth mechanism due to the initial undercooling experienced by the powders. The occurrence of structures of the predendritic, cellular, and/or dendritic type was properly predicted by the theory of dendrite growth into undercooled alloy melts for the case of large undercoolings.
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