Experimental study on the heat transfer behavior and contact pressure at the casting-mold interface in squeeze casting of aluminum alloy

Wang, Feifan; Ma, Qiang; Meng, W. J.; Zhou, Han

doi:10.1016/j.ijheatmasstransfer.2017.05.051

Cited by 50 publications

(18 citation statements)

References 33 publications

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“…As mentioned in our previous work [16] , for the process in which the heat flux at the casting-die interface increased dramatically, in order to accurately determine the IHTC, the nearest distance between the temperature measurement point and the casting-die interface must be smaller than 1 mm. As a result, a special temperature sensor unit was designed.…”

Section: Experiments Proceduresmentioning

confidence: 99%

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Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

Wang

et al. 2017

China Foundry

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Male, born in 1968, Ph.D., Associate Professor. His research interests mainly focus on high integrity and near net shape casting technology for lightweight metal alloys, aluminum and magnesium alloys squeeze casting process and its macro and microscopic modeling, multi-scale and multi-discipline modeling and computation of solidification and casting processes. L ightweight components have vital importance due to weight reduction in vehicles because of high strength-to-weight ratio. The utilization of these, whose materials are mainly aluminum and magnesium alloys, in the automotive industry has therefore significantly increased in the past few years [1] . However, the mechanical properties of these components are often deteriorated by defects such as shrinkage and gas pores due to inappropriate casting technologies [2][3][4] .Thus, it is very important to find an appropriate casting technology. Squeeze casting (SC) is a promising near net-shape processing technique, where the molten metal solidifies under a relatively high external pressure, and the fabricated components are normally free of shrinkage and gas pores [5] . In the squeeze casting process, process parameters Abstract: As an advanced near-net shape technology, squeeze casting is an excellent method for producing high integrity castings. Numerical simulation is a very effective method to optimize squeeze casting process, and the interfacial heat transfer coefficient (IHTC) is an important boundary condition in numerical simulation. Therefore, the study of the IHTC is of great significance. In the present study, experiments were conducted and a "plate shape" aluminum alloy casting was cast in H13 steel die. In order to obtain accurate temperature readings inside the die, a special temperature sensor units (TSU) was designed. Six 1 mm wide and 1 mm deep grooves were machined in the sensor unit for the placement of the thermocouples whose tips were welded to the end wall. Each groove was machined to terminate at a particular distance (1, 3, and 6 mm) from the front end of the sensor unit. Based on the temperature measurements inside the die, the interfacial heat transfer coefficient (IHTC) at the metal-die interface was determined by applying an inverse approach. The acquired data were processed by a low pass filtering method based on Fast Fourier Transform (FFT). The feature of the IHTC at the metal-die interface was discussed.

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Section: Experiments Proceduresmentioning

confidence: 99%

“…The heat flux at the casting-die interface at each time-step is obtained by solving the inverse thermal problem [16] . The method introduced by Beck [17] focused on minimizing the following function:…”

Section: Mathematical Modeling Of Ihtcmentioning

confidence: 99%

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

Wang

et al. 2017

China Foundry

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“…As a result, the porosity in a squeeze‐cast component is almost eliminated . Furthermore, due to the elimination of the air gap at the liquid–mold interface by the applied high pressure, the heat transfer across die surfaces is enhanced, increasing solidification and cooling rates . Thus, fine microstructures with reduced porosity are achieved, obtaining castings with superior mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

et al. 2018

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An innovative Low Pressure Die Casting (LPDC) process has been developed for aluminum cast components based on the application of an extra pressure during the solidification process. The new process, named "Low Pressure Squeeze Casting" (LPSC) has been proved to be able to increase the solidification rate, refining the microstructure of the casting, and reducing its shrinkage porosity. Furthermore, the cycle time is also reduced, increasing the productivity of the process. Two demonstrators from the automotive and wind power industries have been produced to validate the process in a relevant industrial environment.

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“…1 Die casting is one of the most efficient forming methods used for aluminum components. 2 A mold affects not only the productivity but also the die-casting performance, such as surface finishing and microstructure refinement. So, many researchers focus on improving the mold quality and prolonging the service life of a mold.…”

Section: Introductionmentioning

confidence: 99%

Erosion of mold-steel surface oxidation and nitriding layers due to a die-casting aluminum alloy

Cao¹,

Liu²,

Shen³

et al. 2018

Mater. Tehnol.

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The resistance to erosion due to A356 aluminum-alloy melt of H11 die steel treated with two different surface-treatment technologies (oxidation treatment and nitriding treatment) was investigated by employing a hot-dip-aluminum (immersion) experiment. The microstructure, chemical constituents, phase compositions, heat-flux variation and activation energy were analyzed, using a scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD) and differential scanning calorimetry (DSC). Compared to the nitrided samples, the oxidized samples have a smaller erosion area and a lower mass loss. Moreover, the nitrided samples require lower Gibbs free energy to react with the aluminum-alloy melt. Compared to the samples with the oxidation treatment, the activation energy of the reaction between the nitrided samples and aluminum alloy is smaller. These results indicate that the H11 die steel surface-treated with oxidation tends to exhibit a better erosion resistance to aluminum-alloy melt than the steel surface-treated with nitriding.

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Experimental study on the heat transfer behavior and contact pressure at the casting-mold interface in squeeze casting of aluminum alloy

Cited by 50 publications

References 33 publications

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

Erosion of mold-steel surface oxidation and nitriding layers due to a die-casting aluminum alloy

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