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During the solidification of hypoeutectic Al–7% Si alloy, density differences develop in the melt due to variations in concentration and temperature. On Earth, melt flow can occur due to gravity, which then affects the solidification process. The microgravity environment strongly eliminates convection in the melt and allows investigation of the solidification process in purely diffusive circumstances. In this study, four solidification experiments were performed on grain-refined and non-grain-refined Al–7 wt% Si alloy on-board the International Space Station (ISS) in the Materials Science Lab (MSL) to study the effect of solidification parameters (solid/liquid front velocity (v) and temperature gradient (G)) on the grain structure and dendritic microstructure. The grain structure has been analyzed in detail in some earlier studies. The aim of this work was to carry out detailed analysis of the macrosegregation caused by the diffusion of Si from the initial mushy zone during the homogenization step and the subsequent solidification phase of the experiments as well as the correlated distribution of eutectic along the solidification direction. The secondary dendrite arm spacing (SDAS) for different process conditions was also studied. For these two issues, microgravity experimental results were compared to simulation results. The macrosegregation was calculated by the finite difference method. Because the steady-state solidification conditions were never reached, the solidification process was characterized by the average front velocity and temperature gradient. Considering the actual liquidus temperature (TL) caused by macrosegregation, the SDAS was calculated as a function of the average processing parameters and the actual liquidus temperature with the classical Kirkwood’s equation. As a result, good agreement was obtained between the calculated and measured SDAS.

Influence of Solidification Parameters on the Amount of Eutectic and Secondary Arm Spacing of Al–7wt% Si Alloy Solidified under Microgravity