Effect of Si on Castability of Al-Cu-Si Alloys

This study was conducted to investigate the effect of Si addition (1, 2, 3, and 5 wt. %) on the microstructure and castability of hypoeutectic Al-4.5Cu-Si alloys. According to the results, Si addition increased the average size and volume fraction of eutectic Si platelets in the microstructure. Adding Si also improved the fluidity and decreased the porosity content of the alloy, and enhanced its resistance against hot tearing. According to the constrained rod test results, the hot tearing sensitivity index (HTS) of the alloys containing 1, 3, and 5 wt. % Si, was decreased by 48, 78, and 88%, respectively. In agreement with hot tearing testing results, the extensive existence of dendrites and shrinkage micropores on the hot torn surface of the alloy without Si implies on its low potential in feeding the solidification shrinkages and healing hot cracks. Adding Si decreased the amount of shrinkage micropores on the hot torn surface and due to improving the fluidity as well as increasing the amount of Al-Cu-Si ternary eutectic at the last stage of solidification, improved the feeding characteristics of alloy. Therefore, the amount of free dendrite arms was significantly decreased on the fracture surface. However, adding 5 wt. % Si increased the amount of eutectic Si on the hot torn surface giving rises to a more brittle fracture mode.