The field of solidification has evolved from metallurgical alchemy to a predictive science over the past century. Our particular focus is on metals and their alloys, whose thermophysical properties tend to differ distinctively from that of organic systems. Rapid advances in modeling efforts and real-time experiments have yielded a wealth of new and quantitative information across relevant length- and time scales, thereby expanding our understanding of the liquid-to-solid phase transition. The articles in this issue highlight some important recent developments in the field, including solidification at extreme rates, as well as the state-of-the-art computational and experimental techniques that allow us to probe the otherwise improbable. In light of this progress, we identify critical issues and open questions that point to future research directions in solidification science.

Synchrotron x-rays are a powerful tool to probe real-time changes in the microstructure of materials as they respond to an external stimulus, such as phase transformations that take place in response to a change in temperature. X-ray imaging techniques include radiography and tomography, and have been steadily improved over the last decades so that they can now resolve micrometer-scale or even finer structural changes in bulk specimens over time scales of a second or less. Under certain conditions, these imaging approaches can also give spatially resolved chemical information. In this article, we focus on the liquid to solid transformation of metallic alloys and the temporal and spatial resolution of the accompanying segregation of alloying elements. The solidification of alloys provides an excellent case study for x-ray imaging because it is usually accompanied by the progressive, preferential segregation of one or more of the alloying elements to either the solid or the liquid, and gives rise to surprisingly complex chemical segregation patterns. We describe chemical mapping investigations of binary and quasi-binary alloys using radiography and tomography, and recent developments in x-ray fluorescence imaging that offer the prospect of a more general, multielement mapping technique. Future developments for synchrotron-based chemical mapping are also considered.

Rapid solidification gives rise to solute trapping, which decreases solute partitioning and alters equilibrium solidification velocity-undercooling relationships. These effects influence microsegregation, solidification morphology, and the emergent microstructure length scales. Here, we review solute trapping and solute drag in rapid solidification in terms of theory, simulation methods, and experimental techniques. The basic theory to describe solute trapping is contained in the continuous growth model. This model breaks down at high solidification velocities, where solidification transitions abruptly to complete trapping, a limit that can be captured with the local nonequilibrium model. Solute trapping theories contain unknown parameters. Their determination from atomistic simulations or pulsed laser melting experiments is discussed. Microstructural evolution in rapid solidification can be readily investigated with the phase-field method, various alternatives of which are presented here. Uncertainties related to kinetic parameters and heat transfer during rapid solidification can be studied by comparing phase-field simulations to dynamic transmission electron microscopy observations.

The understanding of adhesion and survival behavior of bacterial pathogens on implant surfaces are critical to control and reduce implant-associated infections. Herein, the authors investigate the interactions of Staphylococcus aureus, one of the most prevalent causes of implant infections, with Mg–4Zn–0.5Ca implants. It was found that within 60 min of exposure, 99.1% of adherent bacteria were inactivated. The combination of unique mechanical properties, biodegradation kinetics, and antimicrobial characteristics of Mg–4Zn–0.5Ca alloy makes it a promising candidate for future implant applications.

Soft magnetic metal amorphous nanocomposite alloys are produced through rapid solidification and thermal annealing yielding nanocrystals embedded within an amorphous precursor. Similar free energies in Co-rich and FeNi-based alloy systems result in multiple nanocrystalline phases being formed during devitrification. Studies of multi-phase crystallization processes have been reported for Co-rich alloys but relatively few have investigated FeNi-based systems. A detailed characterization of compositional partitioning and microstructure of an optimally annealed FeNi-based MANC (Fe70Ni30)80Nb4Si2B14 alloy is presented through complementary high-resolution transmission electron microscopy (HRTEM) and atom probe tomography (APT). HRTEM demonstrates orientation relationships between FCC and BCC nanocrystals, suggesting heterogeneous nucleation of nanocrystals in the amorphous matrix or a cooperative mechanism of nucleation between BCC and FCC nanocrystallites. APT results show evidence for (i) the segregation of Fe and Ni between nanocrystals of different phases, (ii) B partitioning to the amorphous phase, and (iii) an Nb-enriched shell surrounding nanocrystals.

The molten-salt method was used to synthesize CaBi2Ta2O9 (CBTa) powder, and the influence of temperature on the structure and micromorphology of products was investigated using X-ray diffraction and the scanning and transmission electron microscope. The results showed that highly crystalline CBTa nanoplates exhibit single orthorhombic symmetry and could be obtained in the temperature range of 850–900 °C. Among which, the nanoplates prepared at 900 °C have optimal properties (average grain size of 1.7 μm and uniform size distribution). Above 900 °C, various CaO–Ta2O5 binary compounds, Bi2O3, and BiTaO4 formed due to the decomposition of CBTa and subsequent reactions of decomposition products, transforming plate-like grains to cuboid nano-particles with a small amount of prismatic grains. Possible reaction mechanisms at different synthesizing temperature were proposed. This work provides a method for the preparation of template grains to synthesize textured CaBi2Ta2O9 high-temperature piezoelectric ceramics by the template grain growth method.

The demands of modern materials are highly challenging as well as partially contradictory. For example, materials should be strong like steels but chemically inert like soft low-surface energy polymers. These conflicts can be overcome by effectively combining disparate materials in composites that allow fusing of the traditional material classes like ceramics, polymers, and metals. Such combinations require sufficient adhesion between the individual materials. If adhesion is based on mechanical interlocking, the chemistry and chemical compatibility of the individual materials play a negligible role for the adhesion, but the mechanical properties of the materials are exclusively important. This work focusses on a technologically relevant example of a micro-mechanical interlocking surface structure on grade 304 stainless steel (SST) by nanoscale sculpturing. Using a low aggressive/low toxic seawater-like and diluted HNO3-based electrolyte, the resulting structure is free from preferential grain-boundary etching. The sculptured surface is super hydrophilic with undercuts suitable for mechanical interlocking with polymers. In single-lap shear tests, different two-component adhesives failed cohesively on structured SST while showing more than a doubling of the ultimate shear strength compared to the state-of-the-art grit-blasted SST composites which only showed adhesive failure.

High-entropy alloys (HEAs) are proposed as potential structural materials for advanced nuclear systems, but little is known about the response of matrix chemistry in HEAs upon irradiation. Here, we reveal a substantial change of matrix chemical concentration as a function of irradiation damage (depth) in equiatomic NiCoFeCr HEA irradiated by 3 MeV Ni ions. After ion irradiation, the matrix contains more Fe/Cr in depth shallower than ~900–1000 nm but more Ni/Co from ~900–1000 nm to the end of the ion-damaged region due to the preferential diffusion of vacancies through Fe/Cr. Preferential diffusion also facilitates migration of vacancies from high radiation damage region to low radiation damage region, leading to no void formation below ~900–1000 nm and void formation around the end of the ion-damaged region at a fluence of 5 × 1016 cm−2 (~123 dpa, displacements per atom, peak dose under full cascade mode). As voids grow significantly at an increased fluence (8 × 1016 cm−2, 196 dpa), the matrix concentration does not change dramatically due to new voids formed below ~900–1000 nm.

Fe–Al–O ODS alloy prepared via mechanical alloying was subjected to three different heat treatments. Material basic state exhibited a fine-grained (300–500 nm) microstructure with fine dispersion of aluminum oxide particles (60% up to 20 nm). Heat treatment at 1100 °C for 3 h resulted in local grain and particles coarsening. Prolongation of the heat treatment to 24 h resulted in further grain (50 % up to 5 μm) and particle (25 % with size 25–40 nm) coarsening. Annealing at 1200 °C for 24 h led to a bimodal microstructure (35 % of grains with size 100–250 μm and 45 % of particles with size 30–60 nm) and substantial oxide particle coarsening. Microstructural changes resulted in tensile strength decrease and ductility increase. Tensile tests at 800 °C revealed a 90% decrease of tensile strength while ductility increased 4–6 times when compared to the room temperature tests. The hardening ratio was below 10 % for all the alloys and both test temperatures.