Overview: Application of heterogeneous nucleation in grain-refining of metals

In all of metallurgical processing, probably the most prominent example of nucleation control is the "inoculation" of melts to suppress columnar solidification and to obtain fine equiaxed grain structures in the as-cast solid. In inoculation, a master alloy is added to the melt to increase its solute content and to add stable particles that can act as nucleants for solid grains. This is important for alloys of many metals, and in other cases such as ice nucleation in living systems, but inoculation of aluminum alloys using Al-5Ti-1B (wt.%) master alloy is the exemplar. The key elements are (i) that the chemical interactions between nucleant TiB₂ particles and the melt ensure that the solid phase (α-Al) exists on the surface of the particles even above the liquidus temperature of the melt, (ii) that these perfect nucleants can initiate grains only when the barrier for free growth of α-Al is surmounted, and (iii) that (depending on whether the melt is spatially isothermal or not) the release of latent heat, or the limited extent of constitutional supercooling, can act to limit the number of grains that is initiated and therefore the degree of grain refinement that can be achieved. We review recent studies that contribute to better understanding, and improvement, of grain refinement in general. We also identify priorities for future research. These include the study of the effects of nanophase dispersions in melts. Preliminary studies show that such dispersions may be especially effective in achieving grain refinement, and raise many questions about the underlying mechanisms. The stimulation of icosahedral short-range ordering in the liquid has been shown to lead to grain refinement, and is a further priority for study, especially as the refinement can be achieved with only minor additions of solute.