Microstructure Adjustment of Spherical Micro-samples for High-Throughput Analysis Using a Drop-on-Demand Droplet Generator

High-throughput methods for the development of structural materials require samples which are comparable in geometric dimensions and microstructure. Molten metal droplet generators produce thousands of droplets and microspheres from specific alloys with very good reproducibility. In this study, droplet generation experiments were conducted with two alloys and their microstructure was analyzed regarding secondary dendrite arm spacing (SDAS) in order to determine cooling rates during solidification. A droplet cooling model was developed, and predictions showed good agreement with the experimental data. Finally, a sensitivity study was conducted using the validated model to identify critical process parameters which have great impact on the resulting microstructure and need to be well-controlled to achieve the desired reproducibility in microstructure.