Growth and form of spherulites

Many structural materials (metal alloys, polymers, minerals, etc.) are formed by quenching liquids into crystalline solids. This highly nonequilibrium process often leads to polycrystalline growth patterns that are broadly termed "spherulites" because of their large-scale average spherical shape. Despite the prevalence and practical importance of spherulite formation, only rather qualitative concepts of this phenomenon exist. It is established that phase field methods naturally account for diffusional instabilities that are responsible for dendritic single-crystal growth. However, a generalization of this model is required to describe spherulitic growth patterns, and in the present paper we propose a minimal model of this fundamental crystal growth process. Our calculations indicate that the diversity of spherulitic growth morphologies arises from a competition between the ordering effect of discrete local crystallographic symmetries and the randomization of the local crystallographic orientation that accompanies crystal grain nucleation at the growth front [growth front nucleation (GFN)]. This randomization in the orientation accounts for the isotropy of spherulitic growth at large length scales and long times. In practice, many mechanisms can give rise to GFN, and the present work describes and explores three physically prevalent sources of disorder that lead to this kind of growth. While previous phase field modeling elucidated two of these mechanisms--disorder created by particulate impurities or other static disorder or by the dynamic heterogeneities that spontaneously form in supercooled liquids (even pure ones)--the present paper considers an additional mechanism, crystalline branching induced by a misorientation-dependent grain boundary energy, which can significantly affect spherulite morphology. We find the entire range of observed spherulite morphologies can be reproduced by this generalized phase field model of polycrystalline growth.