Thermomechanical Characterization of AA5182, AA6111, AA3104 Aluminum Alloys y the Direct Chill Surface Simulator

Hot tearing is a complex defect in aluminium castings which is produced during solidification when a certain amount of liquid phase remains and weakens tensile resistance of the alloy. In direct chill casting of aluminium alloys, hot tears initiate at the surface of sheet ingots just after the primary cooling zone, where the microstructure is particularly vulnerable. In order to study the hot tearing susceptibility of these alloys, and the effect of grain refiners on their thermo-mechanical behavior , tensile tests were carried out in the semi-solid state ( ~95% solid) and at low strain rates using an apparatus called DCSS, for Direct Chill Surface Simulator. This apparatus, originally developed at Alcan Arvida R&D Centre (ARDC), is an instrumented rig test reproducing the conditions prevailing during the primary cooling stage of the DC casting process. The mechanical behavior of solidifying shells and the hot tear formation under applied tensile loads were measured and the occurrence of hot tearing was observed. Temperature in different locations of the casting, applied load and surface strain were monitored during the tensile tests conducted on aluminum alloys AA5182, AA6111 and AA3104. The microstructure of the tested samples was examined using the optical microscope to evaluate their columnar or equiaxed aspect and their effect on the mechanical response of the alloy. A special emphasis has been given to the evaluation of fractions solid existing in the castings at the start of the tensile tests, taking into account the local temperature, thermal gradient and cooling rates experienced. It was found that excessive grain refiner additions decreased the strength of solidifying shells because of the increased level of porosity induced by easier nucleation of new phases (gas included). It was also observed that cooling rates increased with the level of grain refiner, a phenomenon that was associated to the higher number of contact points obtained with small equiaxed grains. Finally, the concept of a stress based criterion for hot tearing was reinforced by the strengths obtained on not grain refined AA5182 and AA6111 showing similar fraction solid near the surface, but significantly different grain sizes.