Freezing Range, Melt Quality, and Hot Tearing

in Al-Si Alloys
MUHAMMET ULUDAĞ, REMZI ÇETIN, and DERYA DISPINAR

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.

https://doi.org/10.1007/s11661-018-4512-8
Ó The Minerals, Metals & Materials Society and ASM International 2018

I. INTRODUCTION  Chill applications

 Grain refinement
HOT tearing is one of the most important defects in  Working with different alloys
aluminum alloys. It has been reported that the main  Using suitable mold design
reasons that cause hot tearing are the contraction in  Proper runner and sprue design (controlled filling)
mushy zone, restricted shrinkage, and lack of feed-
ing.[1,2] It is not easy to estimate this defect because of Eskin et al.[10] have extensively studied the character-
some complex events occurring simultaneously during isation of hot tearing phenomena and claimed that the
solidification. Although there are several studies on hot stage of separation between dendrites is crucial and
tearing,[3–8] yet, it cannot be fully explained.[1] The sensitive for the alloys that have a wide solidification
‘‘uncertainty’’ in the characteristic properties of hot range. Hot tearing formation was divided into four
tearing has been listed as follows: levels as described below:
 Occurs as messy in the form of branched cracks. i. Mass feeding where liquid and solid act freely.
 Main tearing and its extensions are observed to be ii. Interdendritic feeding where remaining liquid has to
intergranular. pass dendritic network. Network permeability is
 Defect surface has a dendritic morphology. still very large to prevent pore formation.
 Defect surface is usually packed with heavy oxides. iii. Interdendritic separation: as solid fraction is
 Generally located on hot spots where shrinkage increased, liquid is trapped in interstitial spaces or
takes place. immobilized because of surface tension. At this
 Not always seen under the same conditions. level, shrinkage occurs where solid network perme-
 Specific to certain alloys; not seen in all alloys. ability decreases and material shrinks.
iv. Solid feeding where only the liquid pockets remain
Campbell[9] recommend that this problem can be and the cast part has a significant strength on the
controlled by last level of solidification (fs > 0.9). Hot tearing can
occur at this level.
Eskin et al.[10] focused on the last two levels because
MUHAMMET ULUDAĞ is with the Metallurgical and Materials
interdendritic separation is quite sensitive to hot tearing
Engineering Department, Bursa Technical University, Bursa, Turkey; in alloys that have a large solidification range.
Contact e-mail: dr.uludagm@gmail.com REMZI ÇETIN is with the A study that measures hot tear length using a ‘‘U’’
Materials Engineering Department, KTO Karatay University, Konya, shape mold was used to investigate the effect of silicon
Turkey. DERYA DISPINAR is with the Metallurgical and Materials ratio on hot tearing in Al-Si alloys.[11] It was found that
Engineering Dept., Istanbul University, Istanbul, Turkey.
Manuscript submitted August 7, 2017. silicon can start to initiate hot tearing until 1.9 wt pct Si.
Article published online February 15, 2018 However, the hot tearing can be decreased by silicon

1948—VOLUME 49A, MAY 2018 METALLURGICAL AND MATERIALS TRANSACTIONS A

additions after 1.9 wt pct. Pumphrey[12] studied hot displayed significantly less susceptibility to hot tearing.
tearing using six different alloys: Al-Si, Al-Cu, Al-Mg, It was claimed that grain size, microstructural features,
Al-Fe, Al-Mn, and Al-Zn. The alloys were prepared by and strain distributions at the junction between the
high-purity aluminum and high-purity master alloys. It horizontal casting bar and the downsprue have an
was found that at low additions, hot tearing is high; and important effect on the hot tearing formation.
at high additions, hot tearing is low. And it was claimed Cao and Kou[19] studied hot tearing in ternary
that chemical composition of alloys and overheating Mg-Al-Ca alloys by using CRC mold. To explain how
affect both grain structure and hot tearing. In Al-Si, hot tearing occurs in these alloys, the secondary phases,
Al-Mg, Al-Cu, and Al-Zn alloys, the hot tearing can be eutectic content, solidification path, and freezing range
decreased by columnar-to-equiaxed transition with were examined. It was found that the alloys that have
increased overheating.[12,13] the widest freezing range and the lowest eutectic content
Verö[11] investigated the effect of eutectic ratio on the are the most susceptible to hot tearing, while the alloys
hot tearing and it was found that hot tearing tendency that have opposite features are less susceptible to hot
can increase at low eutectic ratios. However, hot tearing tearing.
is decreased substantially at high eutectic ratios. Copper Lin et al.[20] carried out a study on hot tearing of
content in an alloy has an effect on hot tearing. The wrought aluminum alloys (AA1050, AA5182, and
copper content up to 7 wt pct is reported to be AA3104) by using CRC mold. Mechanisms of hot
dangerous for hot tearing but above this value, hot tearing were investigated via microstructural examina-
tearing tendency starts to decrease.[7] tion of hot tears. Hot tearing in AA1050 and AA5182
Pokorny et al.[14] investigated hot tearing in AZ91D alloys was characterized as interdendritic separation
alloy by using T-shape mold. The contraction of the during solidification. The results of this study showed
horizontal bar is restrained during solidification, and that hot tearing susceptibility (HTS) ranking of the
hot tearing occurs at the junction between the horizontal alloys was not explained by non-equilibrium freezing
bar and the vertical sprue. The study on the effect of range. It was claimed that hot tearing sensitivity is
mold temperatures from 140 °C to 380 °C showed that related to the average grain size of the castings. If the
the mold temperature has an important effect on hot grains size of a casting is above 200 lm, HTS of the
tearing susceptibility. The simulation results suggest that casting will be sensitive to grain refining. The most
the predicted damage is in agreement with the hot tears effective factor in reducing HTS in AA5182 alloy was
observed in the experimental castings, both in terms of related to the grain refining.
location and severity. Thus, there was a good correla- Pekguleryuz et al.[21] studied on developing castability
tion between experimental work and simulation. Bichler index for magnesium die casting alloys using CRC mold.
et al.[15] found the same effect on hot tearing of AZ91D A castability index was proposed based on alloy
and AE42 magnesium alloys. characteristics such as solid thermal conductivity,
Bichler and Ravindran[16] used T-shape mold for the non-equilibrium freezing range, and hot tear sensitivity.
hot tearing sensitivity of magnesium alloys. A numerical Hot tear sensitivity of AJ alloys has been determined
model was proposed to define hot tearing. It was and compared to other commercial magnesium die
claimed that hot tearing index reached a maximum at a casting alloys. It was found that AZ91D alloy has the
casting location coincident with the region of hot lowest hot tear sensitivity of 20 followed by AJ52 at 24,
tearing. However, the path of hot tear propagation which closely approximates to AZ91D. It was claimed
could not be identified using the numerical model. It was that hot tear and its rating (HTS) was able to predict the
also claimed that nucleation of microcracks occurs at a trend in diecastability of magnesium alloys.
stress concentration that is on the 90 deg corner of the Pekguleryuz et al.[13] also studied on hot tear suscep-
junction of the horizontal bar and the downsprue. tibility of aluminum-silicon binary alloys. CRC mold
Nasr Esfahani and Niroumand[17] carried out a study was used in the study. It was found that increasing
on the effect of casting temperature on hot tearing of silicon content has the ability to decrease the hot tear
A206 aluminum alloy using instrumented constrained susceptibility. Solidification shrinkage, non-equilibrium
T-shaped casting method. Casting apparatus was freezing range, dendrite arm spacing, and grain size
designed to measure contraction load in the casting affect hot tear severity directly. It was also found that
during solidification. It was found that hot tearing Al-0.5 pct Si alloy that has the largest non-equilibrium
susceptibility increases with increased casting tempera- freezing range, the highest solidification shrinkage, the
ture. This was associated with reduced cooling rate, largest dendrite arm spacing, the lowest amount of
increased solute segregation, and more localized hot eutectic phases and, hence, had the highest HTS.
spot formation at the T-junction area. It was claimed Kamguo Kamga et al.[22] studied hot tearing of
that grain size had affected the initiation of hot tears aluminum-copper B206 alloys with iron and silicon
that was increased with increasing casting temperature. additions using CRC mold to examine the combined
D’Elia et al.[18] also studied with T-shape mold to effect of these additions on hot tear resistance. It was
investigate hot tearing formation in B206 aluminum found that hot tearing formation was increased gradu-
alloy. It was found that titanum-boron grain refiner ally with iron content. This was attributed to the
additions resulted in a significant decrease in grain size conditions that led to the formation of the b(FeCu)
and a transformation from dendritic to globular mor- phases while silicon had an opposite effect. The hot
phology. These globular grains were less prone to the tearing sensitivity of the alloys was characterized with a
formation of hot tears and thus, the grain-refined alloys new index that shows a very good correlation with the

METALLURGICAL AND MATERIALS TRANSACTIONS A VOLUME 49A, MAY 2018—1949

 Table I. Chemical Composition (in Wt Pct) of the Alloys Used in the Study

Alloys Si Fe Cu Mn Mg Zn Ti Al
A356 6.80 0.19 0.003 0.001 0.30 0.011 0.108 rem.
A413 11.77 0.19 0.006 0.001 0.005 0.016 0.006 rem.
A380.1 8.14 0.64 3.12 0.44 0.22 0.49 0.02 rem.

Fig. 1—Dimensions of the molds used in the study. (a) CRC, (b) T, (c) RPT mold.

Fig. 2—Cast parts and sample locations for pore analysis.

Katgerman’s[23] hot tearing index (HCS). In this index, On the other hand, grain refinement can decrease hot
the temperature where inadequate feeding started had to tearing in alloy 206 significantly and hot tearing can be
be determined. eliminated if the alloy has a fine globular microstructure.
Li et al.[24] studied the characterization of hot tearing On the other hand, there are several studies that
in Al cast alloys by using an instrument which allows evaluate hot tearing formation by using various criteria.
measuring the contraction force/displacement and tem- Some of those studies focused on the effect of
perature during solidification. It was claimed that the stress,[27–33] some focused on strain[9,31,34,35] and others
test results were repeatable and reliable. Hot tearing was used strain rate.[6,36,37] Most famous ones are the studies
alloy dependent. A356 alloy has high resistance to hot of Clyne and Davies,[38] Feurer,[39] and Katgerman[23] on
tearing, while M206 has the tendency to tear under the extracting a criterion for hot tearing. The aim of these
same conditions. Interdendritic cracking was evident in criteria is based on estimating hot tearing tendency in
M206. Filled cracks were seen around the transition alloys prior to casting. The common feature of these
area. The flow of interdendritic liquid plays an impor- criteria is the ‘‘circa’’ estimation because there was never
tant role in filling the incipient cracks. It was found that a perfect correlation between the estimators and exper-
at 561 °C and at fraction solid of 0.89, solid network imental findings. However, they were still good enough
starts in A356 alloy while it starts at 601 °C and at to explain hot tearing formation.
fraction solid of 0.80 in M206 alloy. Also, Li et al.[25,26] Bifilms are the casting defects that are formed due to the
reported another study where the severity of hot tearing entrainment of the surface oxide film into the liquid
and linear contraction was found to decrease signifi- aluminum.[1] The folded oxide surfaces have zero bonding
cantly when mold temperature was increased. Increasing and air gap in between them. Thus, it acts as a crack in the
pouring temperature resulted in more severe hot tearing. liquid. During solidification, they may unravel and open up

1950—VOLUME 49A, MAY 2018 METALLURGICAL AND MATERIALS TRANSACTIONS A

Fig. 3—Microstructure images of the alloys. (a) 356, (b) 413, (c) 380.

Fig. 5—Qualities (bifilm index) of the castings before and after

Fig. 4—Cross section of RPT samples before and after degassing. degassing.

to cause porosity.[40] This process of unraveling depends on These definitions cannot explain hot tearing formation
the size, shape, and type of the oxide. Therefore, existing of completely. Yet, this is the reason why the term ‘‘circa’’
bifilms in the solidified cast part will lead to deterioration of was used above, because the approximations and analyt-
many properties. There are several works in the litera- ical approaches do not 100 pct justify experimental
ture[10,41–44] that characterize these findings, many of which findings. Regarding these uncertainties in the list above,
show the decrease in mechanical properties. Dispinar[45–50] a new approach was proposed which consisted of a new
has worked on the quantification of bifilms (i.e., melt index that contained liquid metal cleanliness that was
cleanliness) and proposed an index called bifilm index. This never considered before. Thus, three different alloys with
index is measured by Reduced Pressure Test (RPT). A different freezing ranges were investigated in order to
sample is solidified under 100 mbar vacuum to enhance the characterize the hot tearing tendency.
unraveling of bifilms and the cross section of the sample is
subjected to image analysis to measure the number and size
of porosity. The sum of the maximum length of pores is II. EXPERIMENTAL DETAILS
calculated to give a numerical indication of melt quality.
Three different alloys that have different solidification
Since all pores are initiated by bifilms, consequently, the
ranges were used in this study. A356 and A413 alloys
higher the bifilm index would mean lower the melt
were provided from Eti Aluminyum, Turkey and A380.1
cleanliness.
alloy was provided by Cevher Döküm, Turkey. The
When all the literature work on hot tearing is
chemical compositions of these alloys are given in
investigated, it can be seen that there are three charac-
Table I.
teristics of this defect:
Hot tearing test was carried out using two different
i hot tearing does not occur under all casting die molds: CRC and T shape. Reduced pressure test
conditions, (RPT) was used to quantify casting quality.[51] The
ii hot tearing is not seen in all alloys, dimension of the hot tearing molds and RPT mold is
iii hot tearing occurs randomly and indiscriminately given in Figure 1.

METALLURGICAL AND MATERIALS TRANSACTIONS A VOLUME 49A, MAY 2018—1951

Fig. 6—Pore formation mechanism in the presence of bifilms with regard to the solidification mode. (a) A356: light gray: dendrites, dashed:
Al-Si eutectic. (b) A413: Al and Si phases (eutectic). (c) A380.1: light gray: dendrites, dashed: Al-Si eutectic, black: CuAl2 eutectic.

All alloys were melted in coated SiC crucible by using three times under two conditions: before and after
an electrical furnace. Casting temperatures of A356 and degassing. Degassing was carried out for 20 minutes
A380.1 alloys were 740 °C, and A413 alloy was poured with Ar by a graphite nozzle. Casting quality was
at 670 °C. RPT samples were collected before pouring calculated by means of bifilm index from RPT samples.
alloys into hot tearing molds. Castings were carried out An image analysis software (SigmaScan) was used for

1952—VOLUME 49A, MAY 2018 METALLURGICAL AND MATERIALS TRANSACTIONS A

Fig. 7—T zones of the T-shape castings.

Fig. 8—(a) Pore numbers from T zones for no degassing condition, (b) pore numbers from T zones for degassed condition, (c) total pore lengths
from T zones for no degassing condition, and (d) total pore lengths from T zones for degassed condition.

METALLURGICAL AND MATERIALS TRANSACTIONS A VOLUME 49A, MAY 2018—1953

Fig. 9—(a) Magmasoft mold filling results showing the turbulence in A2 and A4 region. (b) Magmasoft stress results of three alloys.

quantification of pore size, shape and dimension. III. RESULTS AND DISCUSSION
MagmaSoft was used to examine the stress and strain
during the solidification of the alloys. A356 alloy has dendritic and eutectic microstructure.
Pore number and total pore length were calculated for In this alloy, a-(Al) is solidified first and a-(Al)+Si
T mold and spherical zone of CRC mold as shown in eutectic forms second. a-(Al) dendrites can be columnar
Figure 2. Areas of pore calculations were marked as A1, and eutectic is formed between the dendrite arms. For
A2, A3, and A4 on T zone. For CRC mold, areas of A413, Al+Si eutectic morphology is the only phase since
pore calculations were called as A1, A2, A3, and A4 the composition is at 12 Si wt pct which is the eutectic
from bottom to top as shown in Figure 2. composition. This eutectic phase transformation occurs

1954—VOLUME 49A, MAY 2018 METALLURGICAL AND MATERIALS TRANSACTIONS A

Fig. 10—Schematic images for bifilm formation (a) for no hot tearing, (b) for hot tearing.

at a single temperature where two solids phases are of the alloys used in the study are given in Figure 3.
formed simultaneously. The feedability is more favorable Differences among the microstructures can be easily seen
in A413 alloy than A356 alloy. On the other hand, on these images. As seen in Figure 3(a), A356 consists of
A380.1 alloy also has 8 wt pct Si and 3 wt pct Cu. The dendrites and eutectic phase. In Figure 3(b), the
microstructural transition occurs as follows: a-(Al) microstructure of A413 consists of Al-Si eutectic and
dendrite, a-(Al)+Si eutectic, and a-(Al)+Cu+Si eutec- dendrites due to the change in the undercooling condi-
tic. Therefore, during the solidification process, after tions in the presence of grain refiners. In Figure 3(b), the
Al-Si eutectic phase, there stills remains a liquid phase three phases aforementioned can be easily seen. These
that transforms to Al-Cu eutectic. The microstructures are the typical morphologies for those alloys.

METALLURGICAL AND MATERIALS TRANSACTIONS A VOLUME 49A, MAY 2018—1955

Fig. 11—A1-A4 region cross section that show bifilms and pores.

Bifilms determine the quality of casting bifilms. While there are small and numerous bifilms in
parts.[1,40,45,46,49] It was known that bifilms can be A356, there are bigger and outnumbered bifilms in A413
determined by using reduced pressure test.[45,46,51] This alloy. On the other hand, A380.1 alloy has bifilms that
test can help bifilms to enlarge 10 times due to 100 mbar are larger than A356 but smaller than A413. Addition-
vacuum during solidification. These can be visually ally, bifilm number of A380.1 is between A356 and
examined when cross sections of RPT samples are A413. Bifilms are surface oxides that are folded and
considered. Representative images of RPT samples submerged into the melt mainly due to turbulence. As
before and after degassing are shown in Figure 4. As Campbell[1] has shown, the microstructural changes
can be seen, all of the three alloys have a certain amount during solidification determine whether the bifilms can
of bifilms before degassing. Consequently, after degas- unravel or not. Faster and rapid solidification hinders
sing, bifilms were significantly removed from the melt. the growth and unraveling of bifilms. Slower cooling
Bifilm index values were calculated from RPT images and the growth of large dendrites can easily push the
to determine casting quality and the results are given in bifilms to become unraveled. Therefore, in A356, after
Figure 5. Bifilm index[51] is the sum of the total length of the formation of a-Al, the only way bifilm can open is
pores on the cross section of the reduced pressure test right before the eutectic phase formation. Once the
samples. The differences between melt conditions can be remaining liquid between the dendrites is transformed
easily seen. These differences show that the degassing into eutectic (rapid solidification), there will no longer
process was very effective. Scatter of bifilm index in the be pore formation. As seen in Figure 4, this is why there
melt before degassing is an indication of how the melt is is numerous number of pores in A356 that is distributed
contaminated with various sizes of bifilms.[52–61] It can along the cross section. A similar scenario applies to
be seen that the worst quality melt was A380.1 with a A380.1. On the other hand, with the same mechanism,
bifilm index of 150 mm. However, after degassing, the since there is only a eutectic phase in A413, as long as
lowest bifilm index value (i.e., highest-quality melt) was bifilms open up before the liquid–solid transformation
also obtained in the same alloy which was 5 mm. A356 occurs, they can be observed as pores. This mechanism
and A413 alloys have almost the same bifilm index value is schematically shown in Figure 6 for three different
(20 mm) for both melt conditions. solidification modes.
It is important to note that each alloy has different The hot tearing formation was examined first by using
pore morphology due the different characteristics of T-shape mold. T zone of the T-shape mold has a hot
solidification which is mainly based on the behavior of spot. Images of T zones for all castings are given in

1956—VOLUME 49A, MAY 2018 METALLURGICAL AND MATERIALS TRANSACTIONS A

Fig. 12—Casting parts from CRC mold (a) 356, (b) 413, (c) 380.1.

Figure 7. It can be seen that A380.1 alloy is the only one As described in detail in experimental work, pore
that has hot tearing for both melt conditions. All cast number and total pore length were calculated from T
parts of this alloy have either hot tearing or crack in all zones. The results of pore measurements are given in
conditions. A surface sink can be seen in the cast part Figure 8. The maximum pore formation was found in
with crack or tear. Campbell[1,62] had shown that in the A4 part of T zone in all alloys and all conditions. This
absence of bifilms, liquid/solid contraction stresses are zone has the hot spot. This location is also a point where
so strong that it can lead to surface sink. On the other turbulence occurs as seen in trace element results of
hand, A356 alloy does not have any hot tearing MagmaSoft shown in Figure 9. Therefore, these results
formation but has a surface sink in all conditions. reflect how the pore formation occurs in test samples not
However, A413 alloy has neither hot tearing nor surface just due to bifilms that are coming from the melt but due
sink. There are two different features to separate these to the turbulence that generates new bifilms on the
three alloys from each other. One is solidification T-junction during filling of the mold. The stress and
morphology and another one is solidification range. strain generated during solidification of these alloys

METALLURGICAL AND MATERIALS TRANSACTIONS A VOLUME 49A, MAY 2018—1957

Fig. 13—(a) Pore numbers of cast parts from CRC mold for no degassing condition, (b) Pore numbers of cast parts from CRC mold for
degassed condition, (c) total pore of cast parts from CRC mold for no degassing condition, and (d) total pore of cast parts from CRC mold for
degassed condition.

have been simulated by Magma and the results are given iv. The orientation of bifilms should be vertical to the
in Figure 9(b). These stress and strain will aid in the direction of shrinkage in order to trigger hot
unraveling of the bifilms. tearing. If it is horizontal, hot tearing cannot occur.
With regard to pore analysis shown in Figure 8, it was
found in the present study that the relationship between It can be understood that orientation of bifilms is the
bifilms and hot tearing depends on distribution, number, most important factor to hot tearing formation
size, and orientation of bifilms. For hot tearing defect to (Figure 10). An example of actual cast parts is given in
occur, four conditions given below should take place at Figure 11. When there are too many bifilms in T zone,
the same time. This phenomenon is schematically given two different possibilities are accounted for. If A4 part
in Figure 10. of T zone has bifilms more than A2 part of T zone, hot
tearing can occur. However, if A4 and A2 parts of T
i. Distribution of bifilms should be intensified on A4 zone have almost the same amount of bifilms, hot
part in the hot spot. tearing cannot occur, because the number of bifilms that
ii. Number of bifilms should either be too high or too causes porosity will balance stress distribution of solid-
low. If it is the lowest, its size should be the greatest. ification (that is the liquid/solid contraction). In this
If highest, it should be heterogeneously distributed case, stress that is enough to tear alloy cannot take
between hot spot and T-junction regions. place. On the other hand, bifilms might be accumulated
iii. Size of bifilms should be large enough to trigger hot on A2 parts of T zone and so, the hot tearing cannot
tearing occur because of the insufficient number of bifilms on

1958—VOLUME 49A, MAY 2018 METALLURGICAL AND MATERIALS TRANSACTIONS A

Fig. 14—SEM images for pore formation (a) A356 and (b) A380.1 alloys and for hot torn region (c, d) A380.1 alloy.

present and how the feedability is effective. It can be

realized that if there is enough number of opened bifilms
in T zone, surface sink does not take place. However, if
there is no or insufficient bifilms in T zone, surface sink
can be seen on the surface. These comments about
surface sink and pore formation were explained in detail
in Reference 1. This work has also shown that this
theoretical approach was experimentally proven.
CRC mold was also used in this study to investigate
hot tearing formation. Cast parts of all alloys and all
conditions for CRC mold are given in Figure 12. It was
found that the results of CRC molds are quite similar to
the results of T-shape mold. While there was no hot
tearing in A356 and A413 alloy castings, there was
various severity of hot tearing in A380.1 alloy castings.
CRC mold has four different arms that have different
lengths and spherical parts on the end of the arms. It
was observed that surface sink occurred on the spherical
parts in A356 and A380.1 alloys, but it did not occur in
A413 alloy. This is due to the solidification morphology
and solidification range. Measurements of pore forma-
tion from CRC mold were done and the results are given
Fig. 15—Effect of freezing range and bifilm index on hot tearing. in Figure 13. As described in experimental details,
spherical parts of the arms of CRC casting parts were
A4. The last and the most important factor is the cut vertically. One of these two parts was examined to
existence of large and vertically located bifilms along the calculate pore formation. It can be seen on the results
hot spot region. If bifilms are large in size and few but that the minimum pore formation is in castings of A356
vertical to the stress direction of shrinkage, hot tearing alloy, and the maximum pore formation is in castings of
can occur easily. However, if they exist in large size and A380.1 alloy. An evidence for this role is shown in the
small amount but horizontal to the direction of shrink- SEM images in Figures 14(a) and (b). Oxides are clearly
age, it is very difficult to trigger hot tearing. On the other seen on the cross section of the hot torn parts in
hand, surface sink is related with how many bifilms are Figures 14(c) and (d). A356 has lower solidification

METALLURGICAL AND MATERIALS TRANSACTIONS A VOLUME 49A, MAY 2018—1959

range than A380.1 alloy and columnar morphology. ACKNOWLEDGMENTS
During the solidification, bifilms cannot be opened
between the dendrite arms. However, A380.1 alloy has a Special thanks to Murat Akcin from MagmaSoft,
high solidification range and two different eutectic Istanbul, Turkey for the simulations. This work has
morphology form in the microstructure. The structure been supported by the Scientific Research Projects
of A380.1 alloy on the SEM image is more equiaxed and Coordination Unit of Selcuk University (Project Num-
smaller than A356 alloy. During the solidification, the ber: 13101026). Muhammet Uludağ was a Ph.D. stu-
last region of liquid to solidify will aid in the unraveling dent at Selcuk University, during the publication
of bifilms. Opened bifilms are the most dangerous process, and he started working at Bursa Technical
defects for not only hot tearing but also several other University. Author would like to thank to TUBITAK
properties of a cast part. (Turkey) for its support.
It is important to note that for the first time in
literature, the concept of melt quality was introduced for
hot tearing phenomena in cast Al-Si alloys. It was found
that there is a strong relationship among freezing
(solidification) range, bifilm index, and hot tearing REFERENCES
susceptibility. The result of this relationship is shown 1. J. Campbell: Complete Casting Handbook: Metal Casting Processes,
in Figure 15. It shows that hot tearing formation Metallurgy, Techniques and Design. Butterworth-Heinemann,
depends on the freezing range and bifilm index. Hot Oxford, 2015.
2. D. Eskin and L. Katgerman: Metall. Mater. Trans. A, 2007,
tearing can occur at larger freezing range depending on vol. 38A, pp. 1511–19.
the bifilm index value. With increased bifilm index (i.e., 3. C.H. Cáceres and B.I. Selling: Mater. Sci. Eng., A, 1996, vol. 220
low-quality melt), hot tearing decreases regardless of (1–2), pp. 109–16.
high freezing range. The extrapolation of results shows 4. T. Clyne, M. Wolf, and W. Kurz: Metall. Trans. B, 1982, vol. 13B,
that (Figure 15), freezing ranges above 55 °C and bifilm pp. 259–66.
5. M. M’Hamdi, A. Mo, and H.G. Fjær: Metall. Mater. Trans. A,
index above 120 mm result in no hot tear. On the other 2006, vol. 37A, pp. 3069–83.
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