Hot tear susceptibility of Al-Mg-Si-Fe alloys with varying iron contents

Hot tear susceptibility in cast Al-0.52Si-0.34Mg-xFe 6060 aluminum alloys was investigated using a hot tearing test apparatus to simulate hot tearing in DC casting. The test apparatus has two cast bars, one that is used to measure the load response and one which is fixed at both ends to restrain thermal contraction so that hot tearing can be observed and rated where it occurred. The iron (Fe) content, ranging from 0.02 to 0.5 wt pct, was seen to have a major influence on the load response during solidification and the tear rating of these alloys. The findings are discussed in terms of Rappaz-Drezet-Gremaud (RDG) model sensitivity analysis and related to the effect of Fe content on the morphology and prevalence of the ß-Al5FeSi and a-AlFeSi intermetallic phases and their influence on the coherency and coalescence of the microstructure.