Freezing Range, Melt Quality, and Hot Tearing in Al-Si Alloys

In this study, three different aluminum-silicon alloys (A356, A413, and A380) that have different solidification morphology and solidification ranges were examined with an aim to evaluate the hot tearing susceptibility. T-shape mold and Constrained Rod Casting (CRC) mold were used for the characterization. Reduced Pressure Test (RPT) was used to quantify the casting quality by measuring bifilm index. It was found that bifilm index and solidification range have an important role on the hot tearing formation. As it is known, bifilms can cause porosity and in this case, it was shown that porosity formed by bifilms decreased hot tearing tendency. As the freezing range of alloy increases, bifilms find the time to unravel that reduces hot tearing. However, for eutectic alloy (A413), due to zero freezing range, regardless of bifilm content, hot tearing was never observed. A380.1 alloy had the highest tendency for hot tearing due to having the highest freezing range among the alloys investigated in this work

Effect of Degassing and Grain Refinement on Hot Tearing Tendency in Al8Si3Cu Alloy

The effect of melt quality on hot tearing susceptibility of Al8Si3Cu alloy was examined under six different conditions, by using a traditional T-shaped mold. Grain refinement was carried out by two different modifiers: AlTi5B1 and Al3B. For each test, samples were cast before and after degassing of melt. Therefore, a new hot tearing tendency index was developed by both bifilm calculations and porosity that occurred in the middle of T-zone of casting parts. Results indicated that hot tearing of cast aluminum alloys was a complex phenomenon, and bifilms play a major role, especially by compensating for shrinkage and consequently contributing to the inconsistencies in results