Heat-Transfer Coefficient and In-Cavity Pressure at the Casting-Die Interface during High-Pressure Die Casting of the Magnesium Alloy AZ91D

Hamasaiid, Anwar; Dour, Gilles; Dargusch, Matthew S.; Loulou, Tahar; Davidson, Cameron; Savage, Gary

doi:10.1007/s11661-007-9452-7

Cited by 38 publications

(38 citation statements)

References 21 publications

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“…According to Dour et al [16] , a higher velocity always leads to a higher heat flux. This trend was also observed by Guo et al [20] and Hamasaiid et al [8] . They explained that this effect is mainly caused by the in-cavity pressure arising from the high speed melt impact on the die surface.…”

Section: φ60supporting

confidence: 85%

“…Equation (8) shows that the decreasing rate of h has an exponential relationship with the increasing rate of f at rapid decreasing stage of h. Furthermore, this quantitative analysis indicates that the molten metal solidification state and the interface heat transfer behavior are interdependent with each other.…”

Section: It Is Supposedmentioning

confidence: 81%

“…the interfacial heat transfer behavior at the metal-die interface, which can be characterized by an interfacial heat flux (q) and an interfacial heat transfer coefficient (h) [3,8,9] . Especially, after the emergence of new numerical approaches associated with inverse heat conduction problems, the interfacial heat transfer coefficient has been shown as a function of casting pressure, injection velocity and initial die temperature [10][11][12][13] .…”

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confidence: 99%

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Interfacial heat transfer behavior at metal/die in finger-plated casting during high pressure die casting process

Yu¹,

Liu²,

Cao³

et al. 2017

China Foundry

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H igh pressure die casting (HPDC) is extensively used for mass production, due to the high productive efficiency of a desired component in a rapid solidification speed [1,2] . When HPDC molten alloy is injected into a relatively cold cavity of a die, the solidification rate is highly dependent on the interfacial heat transfer behavior in both the die and the molten alloy [3] , and subsequently influences the microstructure and the consequent mechanical properties of the final product [4][5][6][7] . In other words, a proper high cooling rate could favor the formation of fine microstructure in produced castings. Otherwise, too rapid a cooling rate could cause the premature solidification of the molten metal before the filling completion.Many studies have been carried out to investigate Abstract: Heat transfer at the metal-die interface has a great influence on the solidification process and casting structure. As thin-wall components are extensively produced by high pressure die casting process (HPDC), the B390 alloy finger-plate casting was cast against an H13 steel die on a cold-chamber HPDC machine. The interfacial heat transfer behavior at different positions of the die was carefully studied using an inverse approach based on the temperature measurements inside the die. Furthermore, the filling process and the solidification rate in different finger-plates were also given to explain the distribution of interfacial heat flux (q) and interfacial heat transfer . Due to this high velocity, the interfacial heat flux at the end of T 1 could firstly reach a highest value 7.92 MW•m -2 among the ends of T n (n=2,3,4,5). In addition, the q max and h max values of T 2 , T 4 and T 5 finger-plates increase with the increasing thickness of the finger plate. Finally, at the rapid decreasing stage of interfacial heat transfer coefficient (h), the decreasing rate of h has an exponential relationship with the increasing rate of solid fraction (f).Key words: high pressure die casting (HPDC); interfacial heat transfer behavior; metal/die interface; solidification speed; solid fraction CLC numbers: TG146.1

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Section: φ60supporting

confidence: 85%

Section: It Is Supposedmentioning

confidence: 81%

mentioning

confidence: 99%

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Interfacial heat transfer behavior at metal/die in finger-plated casting during high pressure die casting process

Yu¹,

Liu²,

Cao³

et al. 2017

China Foundry

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“…In some cases, the peak values for the heat transfer vary by almost an order of magnitude. 25,26 These major differences in the heat transfer coefficient are also noticed in Reference 14. The metal/die interfacial heat transfer coefficient was assumed to be a constant value of 20,000 W/(m 2 K), thus taking into account an order that can be found in numerous publications.…”

Section: Thermal Propertiessupporting

confidence: 58%

An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach

Müller

Rothe

et al. 2018

Inter Metalcast

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High-pressure die casting dies are produced in most cases by conventional subtractive manufacturing processes. In this case, a massive design of the die usually ensures high stability during the casting process. However, at the same time, it leads to low flexibility in casting production and high material costs. The basic approach in the present work is to reduce the conventional subtractive production process of a die casting die in favor of a flexible, modular design, where only a few contour elements of the die have to be replaced for achieving different castings. In order to pave the way for this design principle, basic thermal and structural properties of a lightweight design die casting die were analyzed. The finite element calculations carried out showed that the modular lightweight die casting die consumes considerably less energy for preheating and during operation. Due to the reduced stiffness and material, however, calculated deformations and stresses in the die are considerably higher during the casting process. Although the initial calculation results look very promising, further knowledge must be gained in order to ensure the future success of modular lightweight die casting dies.

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“…Hamasaiid et al [21] have investigated injection first and second phase velocities. When the injection velocity is increased, heat flux values are increased at both runner and body areas.…”

Section: Resultsmentioning

confidence: 99%

Experimental and Numerical Determination of Casting-Mold Interfacial Heat Transfer Coefficient in the High Pressure Die Casting of A-360 Aluminum Alloy

Koru

Serçe

2016

Acta Phys. Pol. A

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Although die casting is a near net shape manufacturing process, it mainly involves a thermal process. Therefore, in order to produce high quality parts, it is important to determine casting-mold interfacial heat transfer coefficient and heat flux. In this paper the effects of different injection parameters (second phase velocity, injection pressure, pouring and die temperature) on heat flux and interfacial heat transfer coefficient were investigated experimentally and numerically. Experiments were performed in cylindrical geometry using a cast aluminum alloy A360 against H13 steel mold. Selected injection parameters were 1.7-2.5 m/s for second phase velocity, 100-200 bar for third phase pressure, 983-1053 K for pouring temperature and 373, 433, 493, 553 K for the die temperature. These parameters were used for both non-vacuum and vacuum conditions in the cavity of the mold. The effects of the application under vacuum conditions were also studied. Temperatures were measured as functions of time, using 18 thermocouples, which were mounted at different depths of casting and mold material. Measured and calculated temperature values are found compatible. Interfacial heat transfer coefficient h and heat flux q depending on the experimentally measured temperature values were calculated with finite difference method using explicit technique in C# programming language. In addition to experiments, Flow-3D software simulations were performed using the same parameters. Interfacial heat transfer coefficient and heat flux results obtained from Flow-3D are also presented in the study. Interfacial heat transfer coefficient has decreased as a result of increasing of temperature of mold and pouring. In addition, interfacial heat transfer coefficient values have increased slightly with the increase of injection speed and pressure. It was observed that the values of interfacial heat transfer coefficient and heat flux have also increased when vacuum was applied inside the cavity of the mold. When all injection parameters are considered, it is seen that the interfacial heat transfer coefficient varies between 92-117 kW/m 2 K.

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Heat-Transfer Coefficient and In-Cavity Pressure at the Casting-Die Interface during High-Pressure Die Casting of the Magnesium Alloy AZ91D

Cited by 38 publications

References 21 publications

Interfacial heat transfer behavior at metal/die in finger-plated casting during high pressure die casting process

Interfacial heat transfer behavior at metal/die in finger-plated casting during high pressure die casting process

An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach

Experimental and Numerical Determination of Casting-Mold Interfacial Heat Transfer Coefficient in the High Pressure Die Casting of A-360 Aluminum Alloy

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