An important parameter affecting microstructure development during solidification is the amount of undercooling prior to nucleation. The undercooling potential of aluminum has been assessed by thermal analysis measurements on powder dispersions of the liquid metal. A number of variables have been identified which influence the undercooling of powder Al samples including powder coating, powder size, melt cooling rate, and melt superheat. Surface analysis by Auger electron spectroscopy indicates that changing the medium in which the powders are produced is an effective method of altering the coating chemistry. Factorial design analysis has been employed to quantify the potential of processing variables to increase the undercooling level obtainable in aluminum. The factorial analysis indicates that control of the powder coating through changing the medium in which the powders are produced is most effective in decreasing the nucleation temperature. Additionally, the finest powders produced in the medium which induces the least catalytic coating, when cooled at high rates,T = 500 °C/s, from low superheats,Ts = 710 °C, are found to achieve the deepest undercooling, ΔT = 175 °C. These studies provide the basis for further increases in undercooling and for future investigations into the solidification reactions which produce both stable and metastable structures in aluminum alloys.