Effect of Returnable Material in Batch on Hot Tearing Tendency of AlSi9Cu3 Alloy

The main reason for the use of returnable material, or recycled alloys, is a cost reduction while maintaining the final properties of the casting. The casting resulting quality is directly related to the correct ratio of commercial grade alloy and alloy made by remelting the returnable material in the batch. The casting quality is also affected by the purity of the secondary raw materials used, the shape complexity and the use of the casting itself. The presented article focuses on the effect of increasing the returnable material content in the batch on the hot tearing susceptibility of AlSi9Cu3 alloy. Hot tears are a complex phenomenon that combines metallurgical and thermo-mechanical interactions of the cast metal. Hot tearing susceptibility was evaluated on the basis of quantitative (HTS-hot tearing susceptibility index) and qualitative evaluation. The negative effect of returnable material in the batch was already manifested at a 20% content in the batch. The critical proportion of the returnable alloy in the batch can be stated as 50%. The alloy with a 50% returnable material content manifested insufficient results of the HTS index and qualitative evaluation, which means increased sensitivity to tearing. The negative effect of returnable material and the increased sensitivity were also confirmed in the evaluation of the fracture surface and hot tear profile. The microstructure of alloys with 50% and higher proportion of returnable material was characterized by a higher amount of iron phases (mainly Al₅FeSi), whose sharp ends acted as critical regions of hot tearing and subsequent hot tear propagation, which had a major impact on the increase in hot tearing susceptibility.