3D morphology of the petal-like precipitates in Cu-Fe alloys: experimental study and phase field modelling

Precipitation hardening is a well-known phenomenon which is widely harnessed in alloy design strategy. In particular, the microstructural features such as shape, size, precipitate number density and volume fraction determine the mechanical behaviour of materials. During service, the morphology of precipitates sometimes achieves a complex 3D shape upon displaying branching and/or splitting patterns. Unfortunately, the detailed information about this intricate morphology cannot be retrieved through traditional experimental techniques based on 2D visualization. Here, we report the implementation of a 3D analysis technique combining Focused Ion Beam (FIB) and Scanning Electron Microscopy (SEM) tomography to visualize the atypical petal-like morphology of Fe-rich precipitates in a Cu-Fe alloy. Using Phase-Field modelling (PFM), we identify the mechanism responsible for the unusual morphologies of Fe-rich particles. Our work highlights the significance of 3D characterization of precipitates and provides a fascinating pathway for refining understanding of precipitation mechanisms in metals and alloys.