Unveiling the origin of severe hot cracking susceptibility in Al-Li alloys

Abstract

This work reports a new mechanism for the severe hot cracking susceptibility (HCS) of cast Al-Li alloys. In contrast to the narrow vulnerable solidification temperature range increasing cracking resistance, alloys with high Li content or solute content, which are supposed to show lower HCS, instead exhibit anomalously high HCS. Results reveal that this phenomenon arises from a variety of Li-rich inclusions distributed in the interdendritic paths, including Li2O, LiAlO2, Li2CO3 and LiH. These particles can form spontaneously with O2, CO2 and H2O during solidification, deteriorating the interfacial bonding capacity. Meanwhile, the occupation of refilling channels for residual liquid increases the potential risk of microcrack initiation. These unfavorable factors promote the rapid propagation of cracks from the casting surface inward, which eventually leads to catastrophic fractures.