A predictive model for the evolution of the thermal conductance at the casting–die interfaces in high pressure die casting

An analytical model is proposed to predict the time varying thermal conductance at the casting–die interface during solidification of light alloys during High pressure Die Casting. Details of the topography of the interface between the casting and the die are included in the model through the inclusion of solid surface roughness parameters and the mean trapped air layer at the interface. The transitory phase of the interfacial thermal conductance has been related to the degradation of contact as solidification progresses through the casting thickness. The modelled time varying thermal conductance showed very good agreement with experimentally determined values for different alloy compositions and casting geometries. The analysis shows that the parameters that govern the thermal conductance are different for the first stage of contact compared to the second stage of contact when the alloy begins to solidify.

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