Study on interfacial heat transfer coefficient at metal/die interface during high pressure die casting process of AZ91D alloy

The high pressure die casting (HPDC) process is one of the fastest growing and most efficient methods for the production of complex shape castings of magnesium and aluminum alloys in today's manufacturing industry. In this study, a high pressure die casting experiment using AZ91D magnesium alloy was conducted, and the temperature profiles inside the die were measured. By using a computer program based on solving the inverse heat problem, the metal/die interfacial heat transfer coefficient (IHTC) was calculated and studied. The results show that the IHTC between the metal and die increases right after the liquid metal is brought into the cavity by the plunger, and decreases as the solidification process of the liquid metal proceeds until the liquid metal is completely solidified, when the IHTC tends to be stable. The interfacial heat transfer coefficient shows different characteristics under different casting wall thicknesses and varies with the change of solidification behavior.

Regularization Method to the Parameter Identification of Interfacial Heat Transfer Coefficient and Properties during Casting Solidification

The accurate material physical properties, initial and boundary conditions are indispensable to the numerical simulation in the casting process, and they are related to the simulation accuracy directly. The inverse heat conduction method can be used to identify the mentioned above parameters based on the temperature measurement data. This paper presented a new inverse method according to Tikhonov regularization theory. A regularization functional was established and the regularization parameter was deduced, the Newton-Raphson iteration method was used to solve the equations. One detailed case was solved to identify the thermal conductivity and specific heat of sand mold and interfacial heat transfer coefficient (IHTC) at the meantime. This indicates that the regularization method is very efficient in decreasing the sensitivity to the temperature measurement data, overcoming the ill-posedness of the inverse heat conduction problem (IHCP) and improving the stability and accuracy of the results. As a general inverse method, it can be used to identify not only the material physical properties but also the initial and boundary conditions' parameters.

Determination of interfacial heat transfer coefficient and its application in high pressure die casting process

In this paper,the research progress of the interfacial heat transfer in high pressure die casting(HPDC)is reviewed.Results including determination of the interfacial heat transfer coefficient(IHTC),influence of casting thickness,process parameters and casting alloys on the IHTC are summarized and discussed.A thermal boundary condition model was developed based on the two correlations:(a)IHTC and casting solid fraction and(b)IHTC peak value and initial die surface temperature.The boundary model was then applied during the determination of the temperature field in HPDC and excellent agreement was found.

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

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.

Regularized determination of interfacial heat transfer coefficient during ZL102 solidification process

The interfacial heat transfer coefficient(IHTC)between the casting and the mould is essential to the numerical simulation as one of boundary conditions.A new inverse method was presented according to the Tikhonov regularization theory.A regularized functional was established and the regularization parameter was deduced.The functional was solved to determine the interfacial heat transfer coefficient by using the sensitivity coefficient and Newton-Raphson iteration method.The temperature measurement experiment was done to ZL102 sand mold casting,and the appropriate mathematical model of the IHTC was established.Moreover, the regularization method was used to determinate the IHTC.The results indicate that the regularization method is very efficient in overcoming the ill-posedness of the inverse heat conduction problem(IHCP),and ensuring the accuracy and stability of the solutions.

Optimal Experiment Design for the Identification of the Interfacial Heat Transfer Coefficient in Sand Casting

The interfacial heat transfer coefficient(IHTC)is one of the main input parameters required by casting simulation software.It plays an important role in the accurate modeling of the solidification process.However,its value is not easily identifiable by means of experimental methods requiring temperature measurements during the solidification process itself.For these reasons,an optimal experiment design was performed in this study to determine the optimal position for the temperature measurement and the optimal thickness of the rectangular cast iron part.This parameter was identified using an inverse technique.In particular,two different algorithms were used:Levenberg Marquard(LM)and Monte Carlo(MC).A numerical model of the solidification process was associated with the optimization algorithm.The temperature was measured at different positions from the mould/metal interface at d=0 mm(mould/metal interface),30 mm,60 mm and 90 mm.the thicknesses of the cast part were:L1=40 mm,60 mm and 80 mm.A comparative study on the IHTC identification was then carried out by varying the initial value of the IHTC between 500 Wm^(-2)K^(-1) and 1050 Wm^(-2)K^(-1).Results showed that the MC algorithm used for estimating the IHTC gives the best results,and the optimal position was at d=30 mm,the position closest to the mould/metal interface,for the lowest thickness L1=40 mm.

Spatial interfacial heat transfer and surface characteristics during gravity casting of A356 alloy

As one of the key boundary conditions during casting solidification process, the interfacial heat transfer coefficient (IHTC) affects the temperature variation and distribution. Based on the improved nonlinear estimation method (NEM), thermal measurements near both bottom and lateral metal-mold interfaces throughout A356 gravity casting process were carried out and applied to solving the inverse heat conduction problem (IHCP). Finite element method (FEM) is employed for modeling transient thermal fields implementing a developed NEM interface program to quantify transient IHTCs. It is found that IHTCs at the lateral interface become stable after the volumetric shrinkage of casting while those of the bottom interface reach the steady period once a surface layer has solidified. The stable value of bottom IHTCs is 750 W/(m^2·℃), which is approximately 3 times that at the lateral interface. Further analysis of the interplay between spatial IHTCs and observed surface morphology reveals that spatial heat transfer across casting-mold interfaces is the direct result of different interface evolution during solidification process.

Equivalent heat transfer coefficient at casting/Cu mould interface and temperature field simulation

Using the inverse algorithm of heat transfer and the nonlinear estimation method, matching calculated values with measured ones, the interfacial heat transfer coefficient at casting/Cu mould interface was determined.The results show that the interfacial heat transfer coefficient at Al/Cu interface changes in a range of 4.0×10 3 1.0×10 5 W·m -2 ·K -1 and its average value is in a range of 5.0×10 37.0×10 3 W·m -2 ·K -1 .

Heat Transfer between Casting and Die during High Pressure Die Casting Process of AM50 Alloy-Modeling and Experimental Results

A method based on die casting experiments and mathematic modeling is presented for the determination of the heat flow density （HFD） and interfacial heat transfer coefficient （IHTC） during the high pressure die casting （HPDC） process.Experiments were carried out using step shape casting and a commercial magnesium alloy,AM50.Temperature profiles were measured and recorded using thermocouples embedded inside the die. Based on these temperature readings,the HFD and IHTC were successfully determined and the calculation results show that the HFD and IHTC at the metal-die interface increases sharply right after the fast phase injection process until approaching their maximum values,after which their values decrease to a much lower level until the dies are opened.Different patterns of heat transfer behavior were found between the die and the casting at different thicknesses.The thinner the casting was,the more quickly the HFD and IHTC reached their steady states.Also,the values for both the HFD and IHTC values were different between die and casting at different thicknesses.

铝车轮铸造模具水冷界面换热系数反算求解

铝车轮低压铸造过程中,模具温度场是影响铝液凝固的重要因素。水冷作为铸造模具的主要冷却方式,对模具温度场的影响机理仍不明晰,有待深入研究。本文以铝车轮铸造模具的边模水冷模块为研究对象,设计水冷降温实验并采集水冷过程中的模具温度数据。通过ProCAST及ANSYS分析冷却水流动状态,以实测温度数据为基础进行软件反求解,基于Beck非线性估算法,建立界面换热数值模型。通过对比分析两种界面换热系数求解方式,并正向求解以验证两种求解方式的准确性,以期为铝车轮低压铸造模拟验证提供数据支撑,有望获取冷却水与模具的真实换热系数,并揭示其传热行为和换热机理。

铜及黄铜与模具钢界面稳态接触换热行为的研究

接触换热系数直接决定金属热加工过程的温度分布,进而影响零件的微观组织及使役性能。本文采用自主开发的稳态接触换热设备和测量系统,系统研究了纯铜及H62黄铜与H13模具钢在接触面温度为200~600℃、压力为1.56~12.56 MPa下的接触换热行为。结果表明,载荷加载的历程对接触换热系数有较大影响,相比于从低载荷加载到目标压力时,从高载荷卸载到同一目标压力测得的接触换热系数更高;在相同加载历程下,接触换热系数随着界面温差的升高而增加,且界面温度高于400℃时接触换热系数增速变快;接触换热系数与压力呈幂指数关系增长,随着压力的增大,接触换热系数增长逐渐变得缓慢;在相同条件下,黄铜/H13传热时的温度梯度更大,导致黄铜/H13的接触换热系数更大。

镍基单晶涡轮叶片定向凝固过程温度场数值模拟研究进展

作为先进航空发动机不可缺少的核心部件之一,镍基单晶涡轮叶片(简称单晶叶片)的空心结构尺寸精度、合金元素的分布均匀性和表面及内腔冶金质量等要求极为苛刻。研究发现,定向凝固过程中温度梯度的控制直接影响单晶叶片性能和质量,能否持续获得稳定热流成为定向凝固技术的关键。随着计算机技术的不断进步,数值模拟已经成为单晶叶片定向凝固研究的重要手段之一。首先,对单晶叶片制备技术进行了介绍,分析了定向凝固过程中的传热方式。其次,总结了数值模拟界面换热系数边界条件的优化方法,重点介绍了Beck非线性估算法和有限差分法在界面换热系数求解中的应用,证明了两种方法均可以对铸件/型壳间的界面换热系数进行求解,有效提升了温度场模拟的准确性。最后,对定向凝固过程温度场数值模拟的研究进展进行了追踪,总结归纳出了工艺参数对温度场的影响规律。基于对镍基单晶涡轮叶片定向凝固过程温度场数值模拟研究进展的分析,提出了定向凝固工艺优化方向以及相关技术后续的发展趋势,以促进单晶涡轮叶片的高质量研发。

铝合金在接触固溶处理工艺中的界面传热系数

采用有限元模拟和反演优化(IO)方法测定7075铝合金在不同压力、表面粗糙度和温度下接触固溶处理过程中的界面传热系数(IHTC)值,并分析这些因素对IHTC的影响。结果表明:随着压力的增加,IHTC值先增加,然后保持稳定;IHTC值随表面粗糙度的增大而减小;随着板温的升高,瞬时IHTC值先增大后减小。基于压力、表面粗糙度和温度的综合影响规律,建立多因素影响的IHTC理论模型。使用此模型能较好地预测不同条件下合金的瞬时IHTC值。

熔模铸造ZL114A铝合金凝固过程界面换热系数研究

为获得ZL114A铝合金在凝固过程中温度场的分布规律,根据实际工况设计了测温实验方案,利用热电偶和热成像仪得到了金属及其型壳在凝固过程中温度场的变化曲线,并根据实际测得的温度曲线借助ProCAST模拟软件中的反算模块对铸件与型壳间的界面换热系数进行了反求,得到了更加符合实际的界面换热系数。随后对其进行验证,用该界面换热系数所模拟求得的金属液温度曲线与实测值最大温差为10℃,型壳温度曲线与实测值最大温差为15℃,该方法及结果为铝合金熔模精铸模拟界面换热系数的设置提供了参考依据。

基于L-M算法的铝合金铸造过程界面换热系数的反问题模型

铝合金铸造过程铸件-铸模之间的界面换热系数的变化非常复杂,且预测非常困难。本文基于L-M(Levenberg-Marquardt)算法建立了铝合金铸造过程传热反问题模型,通过反问题分析获得铝合金铸造过程中铸件-铸模界面换热系数。通过将铸件-铸模界面换热系数反演值与标准值进行比较,验证传热反问题模型的准确性。在此基础上,分析了铸模上测点位置(与铸件-铸模界面距离、相邻测点间距)和温度测量误差对铸件-铸模界面换热系数反演值的影响规律,并给出了最优的测点布置方案和温度测量误差要求。通过铝合金铸造实验,用该反问题模型能求解出铝合金凝固过程中的铸件-铸模界面换热系数。

冷冻砂型对铸铁合金凝固行为及组织性能影响规律研究

采用冷冻砂型铸造铸铁合金,界面换热系数是反映冷冻砂型与铸铁合金换热程度的重要参数,对于分析铸铁合金组织性能具有重要意义。研究测定了合金的界面接触温度随时间的变化规律,在此基础上分析了界面换热特征,获得了界面换热系数随初始界面温度变化的函数式,同时分析了冷冻砂型中铸件凝固的铸态微观组织及力学性能。结果表明:界面换热系数随着冷冻砂型初始温度的增加而降低,随含水率的减少而升高。当含水率为6%(质量分数,下同)时,在-35℃、-30℃、-25℃初始冷冻温度条件下,铸型铸件界面换热系数峰值分别是195663W/(m^(2)·K)、147933W/(m^(2)·K)、120836W/(m^(2)·K);当含水率为5%时,在-35℃、-30℃、-25℃初始冷冻温度条件下,铸型铸件界面换热系数峰值分别是209257W/(m^(2)·K)、176878W/(m^(2)·K)、134472W/(m^(2)·K)。相同含水率下初始冷冻温度越低,珠光体晶粒越细,石墨化程度越高,抗拉强度也越高。

单晶叶片铸造过程中界面换热系数的确定

为有效提高铸造数值模拟的准确性,以单晶空心涡轮叶片为典型件,设计试验方案,采用钨铼热电偶进行温度场数据采集工作。通过实测温度场、数值模拟温度场与界面换热系数反向求解相结合的方法,得出界面间换热系数随时间变化的经验公式。通过逆运算,得到较为精确的涡轮叶片铸造过程界面换热值。结果表明,铸造过程数值模拟精度得到了有效提高。

自由降膜表面波流动和传热特性的研究

要对垂直自由降膜表面波建立了数学模型及计算方法，在雷诺数Ｒｅ为８８０、等温壁面条件下，根据实验测定的薄膜厚度随时间变化的规律，经坐标转换，在运动坐标系下，采用有限差分法求解动量方程和连续性方程，得到了定常温度下层流降膜内的速度分布和压力分布；并在恒壁面热流密度条件下，结合能量方程，求得并分析了换热系数和表面波之间的关系。

铝合金熔模精密铸造界面换热系数测量

熔模精密铸造对于铸件近净成形具有重要意义,但目前鲜见对其铸件-铸型界面换热系数的相关研究。本试验在一维传热模型中采用非线性估算法对工业纯铝在熔模铸造过程中与型壳的换热行为进行了研究,分析结果表明:在凝固前期,铸件与型壳之间的热流密度基本不变,而界面换热系数随两者温差减小而增大;凝固中期,界面换热系数随着整体固相分数增加而线性下降;凝固后期,界面换热系数下降变得十分缓慢。将在一维模型中反求得到的界面换热系数应用到三维铸件模型中,得到的模拟温度与实测温度基本吻合,证明通过一维模型与非线性估算法求取的界面换热系数比较准确,有望在铝合金精密铸造温度模拟中得到应用。

热成形工艺中界面换热系数求解方法对比分析

根据高强度钢热成形特点,通过圆台模具实验,分别利用热平衡法、Beck非线性估算法以及基于优化的有限元仿真法(FEM优化法)求解热成形用22MnB5钢在模具淬火下的实时界面换热系数(IHTC),并对3种求解方法的结果和适用性进行比较和仿真验证。研究结果表明:Beck非线性估算法、热平衡法与FEM优化法3种方法求解IHTC的平均误差率分别为3.7%,7.5%和10.3%左右,Beck非线性估算法最准确;同时,得出马氏体相变的发生会对样件与模具间的IHTC有正的增益效果,压强与IHTC间存在着近似幂函数关系。