The problem of graphite crystallization and growth in cast iron has recently received increased attention. As most of the literature data describe analysis of room temperature graphite, there is a legitimate concern that the crystallization of graphite is obscured by subsequent recrystallization and growth in solid state. To avoid confusion in the interpretation of room temperature graphite morphology, the authors used Field Emission Gun Scanning Electron Microscopy on deep-etched interrupted solidification (quenched) specimens to reveal the morphology of graphite at the very beginning of solidification, when the graphite is in contact with the liquid. Information from related phenomena, such as crystallization of hexagonal structure snowflakes and metamorphic graphite, as well as of diamond cubic structure silicon crystals in aluminum alloys is incorporated in the analysis. Research discussing graphite produced through gas-solid and solid-solid transformations is also examined. Because the faceted growth of graphite is the result of diffusion-limited crystal growth in the presence of anisotropic surface energy and anisotropic attachment kinetics, a variety of solidification morphologies are found. The basic building blocks of the graphite aggregates are hexagonal faceted graphite platelets generated through the growth of graphene layers. As solidification advances, the platelets thicken through 2-D nucleation or spiral dislocation growth. Depending on bulk composition, local supersaturation and undercooling, the platelets aggregate through a variety of mechanisms including foliated/tiled-roof crystals and dendrites, curved-circumferential, cone-helix, helical (macro-spiral), and polyhedral columnar or conical (pyramidal) sectors growth.
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