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Light-alloy castings often exhibit variability in the fracture sensitive properties such as ductility that does not necessarily correlate to the global average microstructural parameters such as dendrite cell size and porosity volume fraction in the three-dimensional microstructure. Nonetheless, in numerous such cases, the variability in the fracture sensitive properties does correlate to the variability in the local distributions of microstructural features and processing defects because the fracture path preferentially goes through the regions containing large concentrations of the defects and/or microstructural extrema. This paper presents the results of a detailed quantitative metallography and quantitative fractography based investigation of the relationships between microstructure and variability in uniaxial tensile ductility of the tensile test specimens drawn from very large size Al alloy automotive component castings fabricated using tilt-pour permanent-mold casting process. The percent tensile ductility e shows strong quantitative correlation with the area fraction of the porosity f in the corresponding fracture surfaces, which can be represented by the following power-law relationship, where e 0  and n are empirical constants.

Microstructural Origins of Variability in the Tensile Ductility of Tilt-Pour Permanent Mold Cast Al Alloy at a Warm Temperature