We use a quantitative phase-field approach to study directional solidification in various three-dimensional geometries for realistic parameters of a transparent binary alloy. The geometries are designed to study the steady-state growth of spatially extended hexagonal arrays, linear arrays in thin samples, and axisymmetric shapes constrained in a tube. As a basis to address issues of dynamical pattern selection, the phase-field simulations are specifically geared to identify ranges of primary spacings for the formation of the classically observed "fingers" (deep cells) with blunt tips and "needles" with parabolic tips. Three distinct growth regimes are identified that include a low-velocity regime with only fingers forming, a second intermediate-velocity regime characterized by coexistence of fingers and needles that exist on separate branches of steady-state growth solutions for small and large spacings, respectively, and a third high-velocity regime where those two branches merge into a single one. Along the latter, the growth shape changes continuously from fingerlike to needlelike with increasing spacing. These regimes are strongly influenced by crystalline anisotropy with the third regime extending to lower velocity for larger anisotropy. Remarkably, however, steady-state shapes and tip undercoolings are only weakly dependent on the growth geometry. Those results are used to test existing theories of directional finger growth as well as to interpret the hysteretic nature of the cell-to-dendrite transition.

We use a computationally efficient phase-field formulation ͓B. Echebarria et al., Phys. Rev. E 70, 061604 ͑2004͔͒ to investigate the origin and dynamics of sidebranching in directional solidification for realistic parameters of a dilute alloy previously studied experimentally ͓M. Gorgelin and A. Pocheau, Phys. Rev. E 57, 3189 ͑1998͔͒. Sidebranching is found to result either from noise amplification or from deterministic oscillations that exist both in two dimensions and in a three-dimensional thin-sample geometry. The oscillatory branch of growth solutions bifurcates subcritically from the main steady-state branch of solutions and exists over a finite range of large array spacings. In contrast, noise-induced sidebranching is associated with a smooth transition where the sidebranching amplitude increases exponentially with spacing up to nonlinear saturation due to the overlap of diffusion fields from neighboring cells, as observed experimentally. In the latter case where sidebranching is noise-induced, we find that increasing the externally imposed thermal gradient reduces the onset velocity and wavelength of sidebranching, as also observed experimentally. We show that this counterintuitive effect is due to tip blunting with increasing thermal gradient that promotes noise amplification in the tip region.

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We study spacing selection in directional solidification of Al-Cu alloys under transient growth conditions. New experimental results are presented which reveal that dendritic spacing versus solidification rate evolves in an almost step-wise fashion, consistent with previous theoretical predictions of Langer and co-workers. Phase field simulations of directional solidification with dynamical growth conditions approximating those in the experiments confirm this behavior. Changes in dendrite arm spacing is shown to be consistent with dendrite instabilities confined, initially, to sub-domains, rather than the entire system. This is due to the rapid variation in growth conditions, which prevent the system from adapting as a whole but, rather, in a succession of quasi-isolated domains.