Optimizing hot tearing susceptibility of Al-5.5Zn-2.4 Mg-1.3Cu alloys by grain refinement, increasing mold and casting temperature

• Hot tearing susceptibility and mechanical properties of cast Al-Zn-Mg-Cu alloys were investigated in combination for the first time. • present a device for quantitatively determining Hot tearing susceptibility. • provides direct evidence of the relationship between grain size and solidification shrinkage stress and displacement. • Several methods of reducing hot tearing sensitivity were explored through experimental validation. The Al-Zn-Mg-Cu alloy is widely used in automotive lightweighting and other applications due to its excellent mechanical properties. However, when this alloy is cast using metal molds, it exhibits high hot tearing susceptibility (HTS), increasing the risk of use. Volumetric shrinkage due to density differences during the transition from liquid to solid metal produces shrinkage stresses. At the same time, lacks feeding of the remaining liquid phase in the late solidification stage can also lead to hot tearing. The purpose of this paper is to present a device for quantitatively determining and optimizing HTS. The relationship between solidification shrinkage displacement and stress was tested in a quantitative way using a Self-designed T-tester equipped with stress and displacement sensors. The test results show that the reduction of grain size shifts the solidification shrinkage of the alloy and reduces the solidification shrinkage stress, which avoids hot tearing caused by higher solidification shrinkage stress and local stress inhomogeneity. Secondly, the grain size reduction increases the number of feeding channels in the solidification vulnerable stage, and more liquid phase is available for crack healing. In addition, the influence of casting process parameters on the HTS was studied.