Controlled diffusion solidification (CDS): Conditions for non-dendritic primary aluminum phase in Al-Cu hypo-eutectic alloys

Controlled Diffusion Solidification (CDS) is a novel process wherein specific Al alloys can be cast by mixing two alloys of specific compositions and temperature and subsequently casting the resultant mixture. Contrary to conventional casting, the microstructure of the resultant casting in CDS is non-dendritic. In this study, a hypothesis is proposed to describe the critical details of the mixing two pre-cursor alloys and subsequent solidification process. Al - 4.5 wt% Cu is used as an example alloy system to explain the mechanisms.