A correlation to describe interfacial heat transfer during solidification simulation and its use in the optimal feeding design of castings

Abstract

It is known from experimental data that for pure aluminum castings manufactured via the gravity die casting process, the interfacial heat-transfer coefficient can vary in the range 500 to 16,000 W/m 2 K. These coefficients are of significant importance for the numerical simulation of the solidification process. The experimentally determined variation of interfacial heat-transfer coefficients with respect to time has been recalculated to highlight the variation with respect to casting temperature at the interface. This variation was observed to be of an exponential nature. Also, the pattern of variation was found to be similar in all the experimental results. It has been found that all these patterns of interfacial heat-transfer coefficient variation can be matched by a unique equation that has been proposed as a correlation to model the metal-mold interfacial heat transfer. The benefit of this correlation is in its ability to approximate the combined effects of geometry variation, insulation, chills, die coatings, air gap formation, etc. during the numerical simulation and its use in the optimal design of heat transfer at the metal-mold interface.

Application of an optimization method and experiment in inverse determination of interfacial heat transfer coefficients in the blade casting process

“…Lewis and Ransing [21] Santos et al [18] This study Comparisons between the experimental temperature and the predicted temperature in other locations are shown in Fig. 14.…”

“…The other two models proposed by Santos et al [18] and Lewis and Ransing [21] are also tested to calculate the IHTC, and the optimization results are given in Table 3. The corresponding temperature calculated at thermocouple 1 is shown in Fig.…”

Computation of casting solidification feed-paths using gradient vector method with various boundary conditions

“…The IHTC value can be modelled as a function of casting temperature at metal-mould interface [20] or as a function of air gap formation at the interface [21,22]. Lewis and Ransing [23] proposed a correlation and presented that variation in IHTC with respect to interface temperature is exponential in nature. Prasanna kumar and Kamath [24] showed that heat flux at interface depends upon casting geometry.…”

Numerical modeling of heat transfer through casting–mould with 3D/1D patched transient heat transfer model

“…Then the air gap width is related to interfacial heat transfer coefficient by a 'user defined' equation. Later, Lewis et al proposed a correlation [10][11][12] to adjust the interfacial heat transfer coefficient with respect to casting interface temperature. Researchers have been numerically and experimentally studied the effect of gap on heat transfer for different alloys [13][14][15][16].…”