Effects of Fe, Si, Cu, and TiB₂ Grain Refiner Amounts on the Hot Tearing Susceptibility of 5083, 6061, and 7075 Aluminum Ingots

Aluminum alloys 5083, 6061, and 7075 are prone to hot tearing under direct-chill casting conditions; the defects that form during solidification of those alloys are highly sensitive to variation in the alloying elements, with these elements commonly being Si, Fe, Cu, and Ti. This study investigates the influence of the morphology, content, and size of intermetallic compounds on the hot tearing behavior of the 5083, 6061, and 7075 aluminum alloys by combining a constrained rod casting technique, phase diagram calculation, and multiscale microstructural characterizations. The fishbone-shaped α-Al₁₅(Fe,Mn)₃Si₂ in 5083 can serve as a path for crack nucleation and growth, and an increase in Si content results in Mg₂Si assuming fishbone morphology, thereby increasing hot tearing susceptibility. The amount of plate-like β-Al₅FeSi is the primary factor controlling the hot tearing susceptibility of 6061. For 7075, increasing the Cu content can greatly enhance the remaining liquid fraction, feeding, and hot tearing susceptibility. For all three alloys, TiB₂ grain refiner minimizes hot tearing. This study elucidates the influences of the amounts of Fe, Si, Cu, and TiB₂ grain refiner on hot tearing susceptibility. The findings can help establish compositional control standards for the 5083, 6061, and 7075 aluminum alloy series, particularly when the recycling rate must be increased.