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In the present study, trace Ca (0\u20131.0 wt.%) was added to improve the resistance of AZ91 alloy to hot tearing. The hot tearing susceptivity (HTS) of alloys was experimentally measured by a constraint rod casting method. The results indicate that the HTS presents a \u03bd-shaped tendency with the increase in Ca content, and reaches its minimum value in AZ91\u20130.1Ca alloy. Ca is well dissolved into \u03b1-Mg matrix and Mg17Al12 phase at an addition not exceeding 0.1 wt.%. The solid-solution behavior of Ca increases eutectic content and its corresponding liquid film thickness, improves the strength of dendrites at high temperature, and thereby promotes the hot tearing resistance of the alloy. Al2Ca phases appear and aggregate at dendrite boundaries with further increases in Ca above 0.1 wt.%. The coarsened Al2Ca phase hinders the feeding channel and causes stress concentration during the solidification shrinkage, thereby deteriorating the hot tearing resistance of the alloy. These findings were further verified by fracture morphology observations and microscopic strain analysis near the fracture surface based on kernel average misorientation (KAM).<\/jats:p>","DOI":"10.3390\/ma16103886","type":"journal-article","created":{"date-parts":[[2023,5,23]],"date-time":"2023-05-23T02:02:27Z","timestamp":1684807347000},"page":"3886","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":8,"title":["Improvement of Hot Tearing Resistance of AZ91 Alloy with the Addition of Trace Ca"],"prefix":"10.3390","volume":"16","author":[{"given":"Hongchen","family":"Xiang","sequence":"first","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University of Technology, No. 69, Hongguang Road, Banan District, Chongqing 400054, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-0707-8025","authenticated-orcid":false,"given":"Wenjun","family":"Liu","sequence":"additional","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University of Technology, No. 69, Hongguang Road, Banan District, Chongqing 400054, China"},{"name":"Chongqing Tsingshan Industrial, No. 88, Qingshan North Road, Bishan District, Chongqing 402761, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Qiang","family":"Wang","sequence":"additional","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University of Technology, No. 69, Hongguang Road, Banan District, Chongqing 400054, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Bin","family":"Jiang","sequence":"additional","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University, No. 174, Shazheng Street, Shapingba District, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Jiangfeng","family":"Song","sequence":"additional","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University, No. 174, Shazheng Street, Shapingba District, Chongqing 400044, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Hang","family":"Wu","sequence":"additional","affiliation":[{"name":"Chongqing Tsingshan Industrial, No. 88, Qingshan North Road, Bishan District, Chongqing 402761, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Nan","family":"Feng","sequence":"additional","affiliation":[{"name":"Chongqing Tsingshan Industrial, No. 88, Qingshan North Road, Bishan District, Chongqing 402761, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-9750-6259","authenticated-orcid":false,"given":"Linjiang","family":"Chai","sequence":"additional","affiliation":[{"name":"College of Materials Science and Engineering, Chongqing University of Technology, No. 69, Hongguang Road, Banan District, Chongqing 400054, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2023,5,22]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"15","DOI":"10.1016\/j.jma.2022.12.015","article-title":"Development and application of magnesium alloy parts for automotive OEMs: A review","volume":"11","author":"Liu","year":"2023","journal-title":"J. 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A"}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/16\/10\/3886\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,10]],"date-time":"2025-10-10T19:40:11Z","timestamp":1760125211000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/16\/10\/3886"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2023,5,22]]},"references-count":48,"journal-issue":{"issue":"10","published-online":{"date-parts":[[2023,5]]}},"alternative-id":["ma16103886"],"URL":"https:\/\/doi.org\/10.3390\/ma16103886","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2023,5,22]]}}}