The part of European project VIRCAST directed towards the modelling of hot tearing formation during direct chill casting of aluminium is summarised. The main goal has been to develop models by which hot tearing can be predicted and related to alloy composition and process conditions. A significant effort has been dedicated to measuring the hot tearing sensitivity in the direct chill casting process, and model validation. This co-ordinated action on hot tearing has represented an ideal combination of basic science and industrially relevant R&D. VIRCAST has provided a significantly deeper understanding of the mechanisms leading to hot tearing as well as new modelling tools of direct availability, applicability, and value for industry.
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