Hot Cracking Behaviors of Mg-Zn-Er Alloys with Different Er Contents

The hot cracking behaviors of Mg-5Zn-xEr (x = 0.83, 1.25, 2.5, 5 wt.%) alloys are investigated by optimized hot cracking experimental apparatus, optical microscope, and scanning electron microscope, such as contraction behaviors, feeding behaviors, and permeability characteristics. It is found that the solid phase fraction at hot crack initiation and within the freezing range both increased with increasing Er contents up to 2.5 wt.% and then decreased at 5 wt.% Er content. The Mg-5Zn-5Er alloy exhibits the lowest solid phase fraction (87.4%) and a reduced freezing range (74.2 °C), which leads to more effective liquid feeding in the latter stages of solidification. Combined with the grain size, the permeability of the mushy zone, and fracture morphology, the overall permeability is optimal in the Mg-5Zn-5Er alloy, which is beneficial for feeding the cavities and micro-pores. Meanwhile, a large amount of W phase precipitated by the eutectic reaction (L→α-Mg + W phase), which facilitates healing of the incurred cracking. Conversely, the Mg-5Zn-2.5Er alloy shows inferior feeding ability due to the lowest solid phase fraction (98.3%), wide freezing range (199.5 °C), and lowest permeability. Therefore, the Mg-5Zn-2.5Er alloy exhibits maximal hot cracking susceptibility, and the Mg-5Zn-5Er alloy exhibits minimal hot cracking susceptibility. This work provides guidance for improving the hot cracking resistance of cast Mg-Zn-Er alloy and enables an understanding of the hot cracking behaviors of Mg-Zn-RE alloys.