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Alain Karma

Publications and source records attributed to Alain Karma.

At least 19 recordsLinked to original sources

Dealloying by peritectic melting

Peritectic melting of Ti--Ag has been shown experimentally to form bicontinuous structures, but the mechanism remains unclear. Here we use phase-field simulations to show that these structures arise from a morphological instability of liquid film migration in three dimensions: a Ti-rich solid growing through an Ag-rich liquid film develops a branched seaweed or dendritic structure whose side branches coalesce to form handles, generating a high-genus bicontinuous topology. A sharp-interface theory predicts a solidification-front velocity and an initial ligament width that are constant in time, in contrast to liquid metal dealloying; subsequent $t^{1/3}$ coarsening reproduces the experimentally observed final ligament width.

cond-mat.mtrl-sci

Microstructure evolution during rapid solidification of hypoeutectic Al-Ag alloys near absolute stability

Microsegregation-free microstructures can form by solidifying at velocities beyond the absolute stability limit ($V_{\text{abs}}$), where solute partitioning is suppressed by a stable, planar solid-liquid interface. Producing such microstructures is of considerable practical interest; however, $V_{\text{abs}}$ typically exceeds the ${\sim}1$ m/s growth rates encountered in additive manufacturing (AM). Here we demonstrate the absolute stability limit can be reached in sufficiently concentrated hypoeutectic Al-Ag alloys at growth rates well below the 1~m/s typically encountered in additive manufacturing. Dynamic Transmission Electron Microscopy (DTEM) of rapid solidification front evolution -- following laser spot melting of Al-Ag thin films -- combined with postmortem microstructural characterization, enables detailed quantitative comparison with both phase-field (PF) simulations and a sharp-interface linear stability analysis that uses a non-equilibrium, velocity-dependent phase diagram extracted from the PF model. The analysis predicts that $V_{\text{abs}}$ follows a trend similar to that of the miscibility gap, first increasing and then decreasing with Ag concentration. Predicted values of $V_{\text{abs}}$ are in good quantitative agreement with PF simulations over the entire hypoeutectic concentration range and with experiments for three concentrated alloys. These results inform the prediction and control of microstructural development in concentrated alloys near the absolute stability limit under AM conditions.

cond-mat.mtrl-sci

Benchmarking of Massively Parallel Phase-Field Codes for Directional Solidification

We present a detailed benchmark comparing two state-of-the-art phase-field implementations for simulating alloy solidification under experimentally relevant conditions. The study investigates the directional solidification of Al-3wt%Cu under high-velocity solidification conditions and SCN-0.46wt% camphor under microgravity conditions from National Aeronautics and Space Administration (NASA) DECLIC-DSI-R experiments. Both codes, one employing finite-difference discretization with uniform mesh and GPU-acceleration (GPU-PF) and the other one employing finite-element discretization with adaptive-mesh and CPU-parallelization (PRISMS-PF), solve the same quantitative phase-field formulation that incorporates an anti-trapping current for the solidification of dilute alloys. We evaluate the predictions of each code for dendritic morphology, primary spacing, and tip dynamics in both 2D and 3D, as well as their numerical convergence and computational performance. While existing benchmark problems have primarily focused on simplified or small-scale simulations, they do not reflect the computational and modeling challenges posed by employing experimentally relevant time and length scales. Our results provide a practical framework for assessing phase-field code performance as well as validating and facilitating their application in integrated computational materials engineering (ICME) workflows that require integration with realistic experimental data.

cond-mat.mtrl-sci

Phase-Field Model of Freeze Casting

Directional solidification of water-based solutions has emerged as a versatile technique for templating hierarchical porous materials. However, the underlying mechanisms of pattern formation remain incompletely understood. In this work, we present a detailed derivation and analysis of a quantitative phase-field model for simulating this nonequilibrium process. The phase-field model extends the thin-interface formulation of dilute binary alloy solidification with anti-trapping to incorporate the highly anisotropic energetic and kinetic properties of the partially faceted ice-water interface. This interface is faceted in the basal plane normal to the <0001> directions and atomically rough in other directions within the basal plane. On the basal plane, the model reproduces a linear or nonlinear kinetic relationship that can be linked to experimental measurements. In both cases, spontaneous parity breaking of the solidification front is observed, leading to the formation of partially faceted ice lamellae that drift laterally in one of the <0001> directions. We demonstrate that the drifting velocity is controlled by the kinetics on the basal plane and converges as the thickness of the diffuse solid-liquid interface decreases. Furthermore, we examine the effect of the form of the kinetic anisotropy, which is chosen here such that the inverse of the kinetic coefficient varies linearly from a finite value in the <0001> directions to zero in all other directions within the basal plane. Our results indicate that the drifting velocity of ice lamellae is not affected by the slope of this linear relation, and the radius and undercooling at the tip of an ice lamella converge at relatively small slope values. Consequently, the phase-field simulations remain quantitative with computationally tractable choices of both the interface thickness and the slope assumed in the form of the kinetic anisotropy.

cond-mat.mtrl-sci

Parity Breaking at Faceted Crystal Growth Fronts during Ice Templating

Directional solidification of water-based solutions has emerged as a versatile technique to template hierarchical porous materials, but this nonequilibrium process remains incompletely understood. Here we use phase-field simulations to shed light on the mechanism that selects the growth direction of the lamellar ice structure that templates those materials. Our results show that this selection can be understood within the general framework of spontaneous parity breaking, yielding quantitative predictions for the tilt angle of lamellae with respect to the thermal axis. The results provide a theoretical basis to interpret a wide range of experimental observations.

cond-mat.mtrl-sci

Phase-field model of alloy solidification far from chemical equilibrium at the solid-liquid interface

We further develop a recently introduced phase-field model of rapid alloy solidification [Ji et al., PRL 2023]. This model utilizes enhanced solute diffusivity within the spatially diffuse interface region to quantitatively capture solute trapping with a larger interface width, thereby making simulations on experimentally relevant length and time scales computationally feasible. The main developments presented here include testing the robustness of different variational formulations, extending the model to concentrated alloys by incorporating solid and liquid free energies from thermodynamic databases, as illustrated for hypoeutectic Al-Ag alloys with CALPHAD, extending convergence tests as a function of interface width to 3D, and carrying out simulations in both 2D and 3D to examine existing theories of microstructure development. Our results indicate that the simplest variational formulation that interpolates the bulk free-energy density between its solid and liquid forms is the most robust. Remarkably, for hypoeutectic Al-Ag alloys, this formulation yields a high-velocity nonequilibrium phase diagram that is independent of interface width, thereby demonstrating that the framework of enhanced solute diffusivity can be non-trivially extended to concentrated alloys. Other variational formulations have restricted ranges of materials or processing parameters that can be reliably modeled. We use 2D simulations to construct high-velocity microstructure selection maps for dilute Al-Cu alloys. Furthermore, 3D simulations demonstrate a good convergence similar to that observed in 2D as a function of interface width. Full 3D simulations reveal that the standard theory of absolute stability is a good predictor of the upper critical velocity beyond which steady-state growth becomes unstable, despite the different morphological manifestations of this instability in 2D and 3D.

cond-mat.mtrl-sci

Path differences between quasistatic and fatigue cracks in anisotropic media

The propagation path of quasistatic cracks under monotonic loading is known to be strongly influenced by the anisotropy of the fracture energy in crystalline solids or engineered materials with a regular microstructure. Such cracks generally follow directions close to minima of the fracture energy. Here we demonstrate both experimentally and computationally that fatigue cracks under cyclic loading follow dramatically different paths that are predominantly dictated by the symmetry of the loading with the microstructure playing a negligible or subdominant role.

cond-mat.mtrl-sci

Scaling laws for two-dimensional dendritic crystal growth in a narrow channel

We investigate analytically and computationally the dynamics of 2D needle crystal growth from the melt in a narrow channel. Our analytical theory predicts that, in the low supersaturation limit, the growth velocity $V$ decreases in time $t$ as a power law $V \sim t^{-2/3}$, which we validate by phase-field and dendritic-needle-network simulations. Simulations further reveal that, above a critical channel width $Λ\approx 5l_D$, where $l_D$ the diffusion length, needle crystals grow with a constant $V<V_s$, where $V_s$ is the free-growth needle crystal velocity, and approaches $V_s$ in the limit $Λ\gg l_D$.

cond-mat.mtrl-sci

Cell Invasion during Competitive Growth of Polycrystalline Solidification Patterns

Spatially extended cellular and dendritic array structures forming during solidification processes such as casting, welding, or additive manufacturing are generally polycrystalline. Both the array structure within each grain and the larger scale grain structure determine the performance of many structural alloys. How those two structures coevolve during solidification remains poorly understood. By in situ observations of microgravity alloy solidification experiments onboard the International Space Station, we have discovered that individual cells from one grain can unexpectedly invade a nearby grain of different misorientation, either as a solitary cell or as rows of cells. This invasion process causes grains to interpenetrate each other and hence grain boundaries to adopt highly convoluted shapes. Those observations are reproduced by phase-field simulations further demonstrating that invasion occurs for a wide range of misorientations. Those results fundamentally change the traditional conceptualization of grains as distinct regions embedded in three-dimensional space.

cond-mat.mtrl-sci

Microstructural Pattern Formation during Far-from-Equilibrium Alloy Solidification

We introduce a new phase-field formulation of rapid alloy solidification that quantitatively incorporates nonequilibrium effects at the solid-liquid interface over a very wide range of interface velocities. Simulations identify a new dynamical instability of dendrite tip growth driven by solute trapping at velocities approaching the absolute stability limit. They also reproduce the formation of the widely observed banded microstructures, revealing how this instability triggers transitions between dendritic and microsegregation-free solidification. Predicted band spacings agree quantitatively with observations in rapidly solidified Al-Cu thin films.

cond-mat.mtrl-sci

Microstructural pattern formation during liquid metal dealloying: Phase-field simulations and theoretical analyses

In recent years, liquid metal dealloying (LMD) has emerged as a promising material processing method to generate micro and nano-scale bicontinuous or porous structures. Most previous studies focused on the experimental characterization of the dealloying process and on the properties of the dealloyed materials, leaving the theoretical study incomplete to fully understand the fundamental mechanisms of LMD. In this paper, we use theoretical models and phase-field simulations to clarify the kinetics and pattern formation during LMD. Our study starts from a theoretical analysis of the 1D dissolution of a binary precursor alloy, which reveals that the 1D dissolution process involves two regimes. In the first regime, due to the low solubility of one of the elements in the melt, it accumulates at the solid-liquid interface, which reduces the dissolution kinetics. In the second regime, the interface kinetics reaches a stationary regime where both elements of the precursor alloy dissolve into the melt. Previous works revealed that in the early dealloying stage, the dealloying front is destabilized by an interfacial spinodal decomposition, which triggers the formation of interconnected ligaments. We extend this line of work by proposing a linear stability analysis able to predict the initial length-scale of the ligaments formed in the initial stage of the dealloying. Combining this analysis with the 1D dissolution model proposed here enables us to better understand the initial conditions (composition of the precursor alloy and the melt) leading to a planar dissolution without interface destabilization. Finally, we report a strong influence of solid-state diffusion on dealloying that was overlooked in previous studies. Although the solid-state diffusivity is four to five orders of magnitude smaller than in the liquid phase, it is found to affect both dissolution kinetics and ligament morphologies.

cond-mat.mtrl-sci

Topological Control of Liquid-Metal-Dealloyed Structures

The past few years have witnessed the rapid development of liquid metal dealloying to fabricate nano-/meso-scale porous and composite structures with ultra-high interfacial area for diverse materials applications. However, this method currently has two important limitations. First, it produces bicontinuous structures with high-genus topologies for a limited range of alloy compositions. Second, structures have a large ligament size due to substantial coarsening during dealloying at high temperature. Here we demonstrate computationally and experimentally that those limitations can be overcome by adding to the metallic melt an element that promotes high-genus topologies by limiting the leakage of the immiscible element during dealloying. We further interpret this finding by showing that bulk diffusive transport of the immiscible element in the liquid melt strongly influences the evolution of the solid fraction and topology of the structure during dealloying. The results shed light on fundamental differences in liquid metal and electrochemical dealloying and establish a new approach to produce liquid-metal-dealloyed structures with desired size and topologies.

cond-mat.mtrl-sci

Isotropic finite-difference approximations for phase-field simulations of polycrystalline alloy solidification

Phase-field models of microstructural pattern formation during alloy solidification are commonly solved numerically using the finite-difference method, which is ideally suited to carry out computationally efficient simulations on massively parallel computer architectures such as Graphic Processing Units. However, one known drawback of this method is that the discretization of differential terms involving spatial derivatives introduces a spurious lattice anisotropy that can influence the solid-liquid interface dynamics. We find that this influence is significant for the case of polycrystalline dendritic solidification, where the crystal axes of different grains do not generally coincide with the reference axes of the finite-difference lattice. In particular, we find that with the commonly used finite-difference implementation of the quantitative phase-field model of binary alloy solidification, both the operating state of the dendrite tip and the dendrite growth orientation are strongly affected by the lattice anisotropy. To circumvent this problem, we use known methods in both real and Fourier space to derive finite-difference approximations of leading differential terms in 2D and 3D that are isotropic at order $h^2$ of the lattice spacing $h$. Importantly, those terms include the divergence of the anti-trapping current that is found to have a critical influence on pattern selection. The 2D and 3D discretizations use an approximated form of the anti-trapping current that facilitates the Fourier-space derivation of the associated isotropic differential operator at $O(h^2)$, but we also derive a 2D discretization of the standard form of this current. Finally, we present 2D and 3D phase-field simulations of alloy solidification, showing that the isotropic finite-difference implementations can dramatically reduce spurious lattice anisotropy effects.

cond-mat.mtrl-sci

Oscillatory and tip-splitting instabilities in 2D dynamic fracture: The roles of intrinsic material length and time scales

Recent theoretical and computational progress has led to unprecedented understanding of symmetry-breaking instabilities in 2D dynamic fracture. At the heart of this progress resides the identification of two intrinsic, near crack tip length scales -- a nonlinear elastic length scale $\ell$ and a dissipation length scale $ξ$ -- that do not exist in the classical theory of cracks. In particular, it has been shown that at a high propagation velocity $v$, cracks in 2D brittle materials undergo an oscillatory instability whose wavelength varies linearly with $\ell$, and at yet higher propagation velocities and larger loading levels, a tip-splitting instability emerges, both in agreements with experiments. In this paper, using phase-field models of brittle fracture, we demonstrate the following properties of the oscillatory instability: (i) It exists also in the absence of near-tip elastic nonlinearity, i.e. in the limit $\ell\!\to\!0$, with a wavelength determined by the dissipation length scale $ξ$. This result shows that the instability crucially depends on the existence of an intrinsic length scale associated with the breakdown of linear elasticity near crack tips, independently of whether the latter is related to nonlinear elasticity or to dissipation. (ii) It is a supercritical Hopf bifurcation, featuring a vanishing oscillations amplitude at onset. (iii) It is largely independent of the fracture energy $Γ(v)$ that is controlled by a dissipation time scale. These results substantiate the universal nature of the oscillatory instability of ultra-high speed cracks in 2D. In addition, we provide evidence indicating that the ultra-high velocity tip-splitting instability is controlled by the limiting rate of elastic energy transport inside the crack tip region. Finally, we describe in detail the numerical implementation scheme of the employed phase-field fracture approach.

cond-mat.mtrl-sci

Stability and energetics of 2D surface crystals in liquid AuSi thin films and nanoscale droplets

Segregation at surfaces of metal-covalent binary liquids is often non-classical and in extreme cases such as AuSi, the surface crystallizes above the melting point. In this study, we employ atomic-scale computational frameworks to study the surface crystallization of AuSi films and droplets as a function of composition, temperature and size. For temperatures in the range $T_s^\ast=765-780$K above the melting point $(T_s^\ast\approx1.3\,T_m)$, both thin film and droplet surfaces undergo a first order transition, from a 2D Au$_2$Si crystalline phase to a laterally disordered yet stratified layer. The thin film surfaces exhibit an effective surface tension that increases with temperature and decreases with Si concentration. On the other hand, for droplets in the size range $10-30$ nm, the bulk Laplace pressure alters the surface segregation as it occurs with respect to a strained bulk. Above $T_s^\ast$ the size effect on the surface tension is small, while for $T<T_s^\ast$ the surface layer is strained and composed of 2D crystallites separated by extended grain boundary scars that lead to large fluctuations in its energetics. As a specific application, all-atom simulations of AuSi droplets on Si(111) substrate subject to Si surface flux show that the supersaturation dependent surface tension destabilizes the contact line via formation of a precursor wetting film on the solid-vapor interface, and has ramifications for size selection during VLS-based routes for nanowire growth. Our study sheds light on the interplay between stability and energetics of surfaces in these unique class of binary alloys and offers pathways for exploiting their surface structure for varied applications such as catalytic nanocrystal growth, dealloying, and polymer crystallization.

cond-mat.mtrl-sci

Crack Path Selection in Orientationally Ordered Composites

While cracks in isotropic homogeneous materials propagate straight, perpendicularly to the tensile axis, cracks in natural and synthetic composites deflect from a straight path, often increasing the toughness of the material. Here we combine experiments and simulations to identify materials properties that predict whether cracks propagate straight or kink on a macroscale larger than the composite microstructure. Those properties include the anisotropy of the fracture energy, which we vary several folds by increasing the volume fraction of orientationally ordered alumina platelets inside a polymer matrix, and a microstructure-dependent process zone size that is found to modulate the additional stabilizing or destabilizing effect of the non-singular stress acting parallel to the crack. Those properties predict the existence of an anisotropy threshold for crack kinking and explain the surprisingly strong dependence of this threshold on sample geometry and load distribution.

cond-mat.mtrl-sci

Configurational stability of a crack propagating in a material with mode-dependent fracture energy -- Part II: Drift of fracture facets in mixed-mode I+II+III

In earlier papers (Leblond et.al., 2011, 2019), we presented linear stability analyses of the coplanar propagation of a crack loaded in mixed-mode I+III, based on a "double'' propagation criterion combining Griffith (1920)'s energetic condition and Goldstein and Salganik (1974)'s principle of local symmetry. The difference between the two papers was that in the more recent one, the local value of the critical energy-release-rate was no longer considered as a constant, but heuristically allowed to depend upon the ratio of the local mode III to mode I stress intensity factors. This led to a much improved, qualitatively acceptable agreement of theory and experiments, for the "threshold'' value of the ratio of the unperturbed mode III to mode I stress intensity factors, above which coplanar propagation becomes unstable. In this paper, the analysis is extended to the case where a small additional mode II loading component is present in the initially planar configuration of the crack, generating a small, general kink of this crack from the moment it is applied. The main new effect resulting from presence of such a loading component is that the instability modes present above the threshold must drift along the crack front during its propagation. This prediction may be useful for future theoretical interpretations of a number of experiments where such a drifting motion was indeed observed.

cond-mat.soft

Vulnerable Window of Yield Strength for Swelling-Driven Fracture of Phase-Transforming Battery Materials

Despite numerous experimental and theoretical investigations of the mechanical behavior of high-capacity Si and Ge Li-ion battery anodes, our basic understanding of swelling-driven fracture in these materials remains limited. Existing theoretical studies have provided insights into elasto-plastic deformations caused by large volume change phase transformations, but have not modeled fracture explicitly beyond Griffith's criterion. Here we use a multi-physics phase-field approach to model self-consistently anisotropic phase transformation, elasto-plastic deformation, and crack initiation and propagation during lithiation of Si nanopillars. Our results reveal the existence of a vulnerable window of yield strength inside which pillars fracture during lithiation. They identify two different modes of fracture inside that window with and without surface localization of plastic deformation prior to fracture for lower and higher yield strength, respectively, and highlight the importance of taking into account this localization to accurately predict the onset of fracture within Griffith theory. The results further demonstrate how the increased robustness of hollow nanopillars can be understood as a direct effect of anode geometry on the size of this vulnerable window. Those insights provide an improved theoretical basis for designing mechanically stable phase-transforming battery materials undergoing large volume changes.

physics.app-ph