Producibility of the planar-flow process depends on the dynamics and stability of a group of three-phase and two-phase configurations. The stability and control of these are crucial in strip-casting (or melt-spinning), impact-forming, die-casting, spray-foaming, and extrusion, among others; that is, in virtually any casting process where integrity of bulk properties and surface quality are paramount. The objectives of this research are: (1) to understand the fluid mechanics of air entertainment at the upstream meniscus; (2) to develop implications of certain compatibility relations that constrain the downstream injunction; (3) to identify the physics responsible for an observed transition from smooth to rough texture with applied pressure; and (4) to capture the feedback influence of fluid flow on the morphological stability of the solidification front. The ultimate goals are to understand the influence of processing on microstructure: the number, size and orientation of grains; to control surface quality and to widen the process operability window; and, to better control the phase-change, process stability and thereby quality of the ribbon, foil and sheet produced. Improvements on the engineering side are expected to go hand-in-hand with scientific advances.
