Rapid advances in atomistic and phase-field modeling techniques as well as new experiments have led to major progress in solidification science during the first years of this century. Here we review the most important findings in this technologically important area that impact our quantitative understanding of: (i) key anisotropic properties of the solid-liquid interface that govern solidification pattern evolution, including the solid-liquid interface free energy and the kinetic coefficient; (ii) dendritic solidification at small and large growth rates, with particular emphasis on orientation selection; (iii) regular and irregular eutectic and peritectic microstructures; (iv) effects of convection on microstructure formation; (v) solidification at a high volume fraction of solid and the related formation of pores and hot cracks; and (vi) solid-state transformations as far as they relate to solidification models and techniques. In light of this progress, critical issues that point to directions for future research in both solidification and solid-state transformations are identified.

Solution-based thermodynamic modeling, aided by first-principles calculations, is employed here to examine phase transformations in the Al-Sm binary system which may give rise to product phases that are metastable or have a composition that deviates substantially from equilibrium. In addition to describing the pure undercooled Al liquid with a two-state model that accounts for structural ordering, thermodynamic descriptions of the fcc phase, and intermediate compounds (Al4Sm-β, Al11Sm3-α, Al3Sm-δ, and Al2Sm-σ) are reanalyzed using special quasirandom structure and first-principles calculations. The possible phase compositions are presented over a range of temperatures using a "Baker-Cahn" analysis of the energetics of solidification and compared with reports of rapid solidification. The energetics associated with varying degrees of chemical partitioning are quantified and compared with experimental observations of the metastable Al11Sm3-α primary phase and reports of amorphous solids. Keywords Ames Laboratory Disciplines Condensed Matter Physics | Engineering Physics | Materials Science and Engineering CommentsThis article is from Physical Review B 78 (2008) Solution-based thermodynamic modeling, aided by first-principles calculations, is employed here to examine phase transformations in the Al-Sm binary system which may give rise to product phases that are metastable or have a composition that deviates substantially from equilibrium. In addition to describing the pure undercooled Al liquid with a two-state model that accounts for structural ordering, thermodynamic descriptions of the fcc phase, and intermediate compounds ͑Al 4 Sm-␤, Al 11 Sm 3 -␣, Al 3 Sm-␦, and Al 2 Sm-͒ are reanalyzed using special quasirandom structure and first-principles calculations. The possible phase compositions are presented over a range of temperatures using a "Baker-Cahn" analysis of the energetics of solidification and compared with reports of rapid solidification. The energetics associated with varying degrees of chemical partitioning are quantified and compared with experimental observations of the metastable Al 11 Sm 3 -␣ primary phase and reports of amorphous solids.