Non-equilibrium dendrite microstructure during quasi-rapid solidification of Mg-Al alloy

The non-equilibrium dendrite growth of Mg-6wt.%Al alloy during quasi-rapid solidification is studied by combining phase-field simulations and comparative experiments (furnace/air/water cooling: 0.07/2.9/181 K/s). The kinetic behavior of the solid-liquid interface is characterized, and the solute trapping-drag competition is emphasized. The effects of undercooling (28-36 K), cooling rate, and orientation angle (0-π/6) on dendrite morphological evolution are systematically explored, and the laws governing the morphological transition of the interface front are analyzed according to the condition criterion of interface transition. The experimental primary dendrite arm spacing decreases from ~ 45 ± 4.2 μm (0.07 K/s) to ~ 5.5 ± 0.7 μm (181 K/s), matching the phase-field simulations (relative error less than 9%). The solid-phase Al concentration rises from 2.6 ± 0.22 wt.% to 5.4 ± 0.26 wt.% experimentally, consistent with the simulated trends. The simulated critical value for planar-to-cellular transition (1.2 × 109 K·s/m²) is lower than the theoretical value (1.48 × 1010 K·s/m²) due to solute drag. The analysis of the partial drag condition is extended by integrating thermodynamics and kinetics. The limitation of the current model in capturing the intermediate partial drag state and potential future direction to address this are discussed. Through combining with the experimental results under different cooling rates, the simulation results are further interpreted and validated in both quantitative and qualitative way. This research provides theoretical basis for the regulation of magnesium alloy microstructures under quasi-rapid solidification such as industrial die-casting process.