Resolidification of a mushy-zone and directional solidification: a method for efficient alloy development demonstrated using the example of Cu–Ga–Sn

An experimental method for alloy development that allows to systematically scan multicomponent alloy systems is presented using the Cu–Ga–Sn system as an example. Rods with homogeneous concentration distribution of different initial compositions are annealed in a steep temperature gradient with temperatures in the range from above liquidus to below solidus temperature. During resolidification of the initially formed mushy-zone, a continuously varying composition over the length of the rods develops. Further concentration gradients of the alloying elements are generated during subsequent directional solidification. The graded samples are evaluated for different properties. Vickers hardness as a function of composition was measured along the length of the samples to get first information on the mechanical behavior of bulk samples. The melting range of selected compositions (cylindrical disks of 1 mm thickness cut out of the rods) was determined by differential scanning calorimetry and compared to liquidus temperatures extrapolated from the binary systems with a fitting method and the Calphad method. With the procedure introduced here, it is possible to determine several alloy properties over an extended composition range of a multicomponent system with significantly reduced experimental effort.