Liquid immiscible alloys

The microstructure formation, during casting, of alloys being immiscible in the liquid state such as copperlead or aluminium-lead has gained renewed scientific and technical interest during the last fifteen years. Especially, a new experimental tool, research under reduced gravity conditions, was able to cast new, unexpected results and theories into the discussion on the nature of the complex process of microstructure evolution in such alloys. Prior to the first experiments performed at reduced levels of gravity acceleration, it was generally agreed that the process of phase separation during cooling through the miscibility gap is dictated solely by gravity-induced effects such as natural convection and sedimentation. Fundamental and applied research in space and in earth laboratories could show that there are other mechanisms operating concurrently and under suitable conditions with equal strength. In addition applied research was able to utilize the often unexpected results from space experimentation to develop new casting processes which allow one to produce microstructures on earth suitable for bearings in automotive applications. Therefore this article describes the extensive progress that has been made during the last decade and also the fundamentals of immiscibles. In addition it will be shown that the combination of classical laboratory research, research under reduced gravity conditions and a newly developed computational modelling technique seems to be just becoming available to solve the problems of decomposition, spatial phase separation and microstructure evolution during cooling of an alloy through the liquid miscibility gap.