Abstract
Magnesium alloy AE42 has long been recognized as a superior high temperature magnesium alloy for aerospace and automotive components. The elevated temperature strength of this alloy is attributed to the Mg-Alx-REy intermetallics on the grain boundaries preventing grain boundary sliding. However, these intermetallics also hinder interdendritic liquid feeding during casting solidification and contribute to the alloy's high susceptibility to hot tearing.In this research, the conditions associated with the onset of hot tearing in the AE42 alloy were identified. Thermal analysis suggested that a casting with a hot tear experienced long vulnerable interval, when interdendritic feeding was minimal and the alloy was susceptible to hot tearing. Microscopic analysis revealed the presence of interdendritic shrinkage pores with Al-RE intermetallics at hot-tear nucleation sites. Further, the elastic residual strain measured by neutron diffraction indicates that tensile strain resulting from contraction of the casting during solidification was responsible for opening and propagation of hot tears in the AE42 alloy.
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