The solidification history of individual thermal spray particles has been the subject of many experimental and theoretical studies. Yet it is customary to assume that solidification occurs at the equilibrium temperature, and that heat propagates according to Fourier's Law. To account for a finite thermal diffusion speed, a hyperbolic heat conduction equation is usually adopted to analyze heat transfer. However, under certain circumstances, this equation can violate the second law of thermodynamics, and so others have modified the original hyperbolic equation via theories of extended irreversible thermodynamics. In this work, we study non-equilibrium effects of rapid solidification of a pure metal particle, and compare the so-called parabolic, hyperbolic and modified hyperbolic equations for heat transfer. to predict the interface undercooling due to thermal effects and velocity as a function of time, for different relaxation times. Results indicate that differences are limited to the early part of the solidification process, when undercooling is most significant, the interface velocity is highest, and non-equilibrium effects are most evident. As solidification progresses, the non-equilibrium effects wane and solidification can then be properly modeled as an equilibrium process. (C) 2008 Elsevier Ltd. All rights reserved.