Segregation of the solidification structure of an immiscible alloy is related to the convection induced by the density differences of the components under gravity during solidification. Here, the solidification of the Al–Bi alloy in both opposing and parallel directions to the gravity force was investigated in situ using radiography and optical flow techniques. A quantitative analysis was performed on the flow, solute, and constitutional undercooling fields at the interface. During upward solidification, a flat solute-enriched layer was observed, with the melt flowing toward the center from both sides of the interface. During downward solidification, the solute-enriched layer was deformed, and solute plumes were observed, with the melt flowing toward the sides from the center of the interface. A high solute concentration gradient enhances the local flow and solute transport. The elongation of the plumes was attributed not only to the convective diffusion of the solute but also to the dispersion of droplet clusters. The forces acting on the droplets were calculated, and it was found that the resultant force on the droplets increased the area of the solute-enriched layer. Convection within the bulk melt and the motion of the droplets have synergistic effects on the flow pattern and solute distribution. Distinct microstructures were observed in opposite directions of solidification owing to the differences in constitutional undercooling and flow instability. This work offers insights into the quantitative measurement and understanding of the multi-physics fields during the solidification process.

Iridium, with its excellent high-temperature chemical inertness, is a preferred cladding material for radioisotope batteries. However, its inherent room-temperature brittleness severely restricts its application. In this research, pure Ir and six Ir-W solid solutions (Ir₃₁W₁ to Ir₂₆W₆) were modeled. The effects of W on the elastic properties, generalized stacking fault energy, and bonding properties of Ir solid solution alloys were investigated by first-principles simulation, aiming to find a way to overcome the intrinsic brittleness of Ir. With the W concentration increasing from 0 to 18.75 at %, the calculated Cauchy pressure (C₁₂–C₄₄) increases from −22 to 5 GPa, Pugh’s ratio (B/G) increases from 1.60 to 1.72, the intrinsic stacking fault energy reduces from 337.80 to 21.16 mJ/m², and the unstable stacking fault energy reduces from 636.90 to 547.39 mJ/m². According to these results, it is predicted that the addition of W improves the toughness of iridium alloys. The alloying of W weakens the covalency properties of the Ir-Ir bond (the ICOHP value increases from −0.8512 to −0.7923 eV). These phenomena result in a decrease in the energy barrier for grain slip.