Characterization and fracture behavior of bismuth–tin thermal fuse alloy wires produced by the Ohno continuous casting process

Bismuth–tin binary alloys containing high bismuth concentrations of 40 to 77% were continuously cast into wires of approximately 2 mm in diameter with casting speeds between 15 and 150 mm min−1 using the Ohno Continuous Casting (OCC) process. The microstructure was examined and tensile tests were performed for wires cast at various speeds. It was found that for slowly cast wires containing large primary bismuth dendrites, bismuth fracture occurring along the (111) plane exerted a key role in wire fracture, while microstructures with refined bismuth dendrites exhibited a mixture of bismuth cracks and inter-phase decohesion, allowing the accommodation of larger strain before wire fracture. For wires with microstructures containing primary tin dendrites, inter-phase decohesion played a key role in wire fracture.