The microstructure evolution and mass transfer in mushy zone during high-pressure solidifying hypoeutectic Al-Ni alloy

The mushy zone of hypoeutectic Al-1.5 wt% Ni alloy during high-pressure synthesis was obtained by changing the structure of the graphite heater. Meanwhile, the evolution of the microstructure was investigated. The results demonstrated that three distinguished zones were successfully generated along with the direction of the temperature gradient, including the fully melted area consisting of the columnar dendrite. The mushy zone is composed of an α-Al phase, bulk β-Al₃ Ni phase, and a eutectic microstructure as well as a non-melted, solid region. In addition, the mass transfer velocity and the time required for the liquid pool to migrate through the mushy zone during thermal-stable treatment under different high pressures were also analyzed. The results showed that the mass transfer was greatly inhibited, and the minimum time required for a liquid droplet to go through the whole mushy zone at 1 GPa and 3 GPa was 746 h and 5523 h, respectively.