We have to try casting high tin content aluminium -tin alloy in simple static mold casting to save cost. But it was very often having gotten parts with cracks. Can anyone summarise the current state-art of the technique and provide a possible solution?
In my point of view the crack is happend due to:
Large difference in the thermal expansion, Tin segregation and shrinkage stress. Then the solution must be as follow:
1, control cooling rate carefully
2, Preheat the mold
3, Use alloy with additional modifiers
To clarify number 1: Avoid rapid cooling that increases thermal gradients and stress.
If the melt is damaged, i.e. is full of bifilms, hot tears are inevitable in these alloys because of tensile stresses generated due to solidification contraction
Slow cooling and adding some additional elements to modify the property may help to reduce cracking of the Al-Sn alloy.
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