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Abstract
The present work focuses on the determination of transient moldenvironment and metalmold heat transfer coefficients during
solidification. The method uses the expedient of comparing theoretical and experimental thermal profiles and can be applied both to pure
metals and metallic alloys. A solidification model based on the finite difference technique has been used to provide the theoretical results.
The experiments were carried out by positioning the thermocouples in both metal and mold. The comparison between experimental and
theoretical results is made by an automatic search of the best fitting among theoretical and experimental cooling curves simultaneously in
metal and in mold. This has permitted the evaluation of the variation of heat transfer coefficients along the solidification process in
unsteady state unidirectional heat flow of AlCu and SnPb alloys, as well as the analysis of the effects of the material and the thickness
of the mold and melt superheat. 2001 Elsevier Science B.V. All rights reserved.
Keywords: Interfacial heat transfer coefficients; Mathematical modeling; Chill mold casting; AlCu; SnPb
1. Introduction
The structural integrity of shaped castings is closely
related to their temperaturetime evolution during solidification. A number of analytical and numerical models were
developed in the last 2 decades to treat heat transfer during
solidification, and the consequent simulation of freezing
patterns in castings has provided many improvements in
foundry processes. The use of casting solidification simulation could do much to increase knowledge of the process,
however, some uncertainties must be eliminated before
such simulations can be widely accepted as realistic
descriptions of the process. The heat transfer at the metal
mold interface is one of these uncertainties, and reliable
experimental values of heat transfer coefficients are required for various metalmold combinations and superheats, as existing data is sparse. The way the heat flows
across the metal and mold surfaces directly affects the
evolution of solidification, and plays a notable role in
determining the freezing conditions within the metal,
mainly in foundry systems of high thermal diffusivity like
chill castings. Gravity or pressure die casting, continuous
casting, and squeeze casting are some of the processes
*Corresponding author.
E-mail address: amaurig@fem.unicamp.br (A. Garcia).
0925-8388 / 01 / $ see front matter 2001 Elsevier Science B.V. All rights reserved.
PII: S0925-8388( 01 )00904-5
(1)
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
175
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
176
O (T
n
F(h) 5
2
est 2 T exp )
(2)
i 51
where T est and T exp are, respectively, the estimated and the
experimentally measured temperatures at various thermocouples locations and times, and n is the iteration stage.
A suitable initial value of h i is assumed and with this
value, the temperature of each reference location in casting
and mold at the end of each time interval Dt is simulated
by using an explicit finite difference technique. The
correction in h i at each iteration step is made by a value
Dh i , and new temperatures are estimated [T est (h i 1 Dh i ) or
T est (h i 2 Dh i )]. With these values, sensitivity coefficients
(f ) are calculated for each iteration, given by
T est (h i 1 Dh i ) 2 T est (h i )
f 5 ]]]]]]]
Dh i
(3)
(4)
(5)
(6)
(7)
(8)
S D
fS T
2T
r c 2 L ? ] ] 5 k ]2
T t
x
(9)
fS
The term (L ? ] ) in Eq. (9) can be considered as a pseudo
T
specific heat and an apparent specific heat (c9) can be
defined, and this equation can be written as
Fig. 2. Flow chart for the determination of metalmold heat transfer
coefficients.
S D
T
2T
r c9] 5 k ]2
t
x
(10)
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
D S
n
T ni 11 2 T ni
T i21
2 2T ni 1 T ni11
r c9 ]]] 5 k ]]]]]]
Dt
Dx 2
(11)
n
n
T in11 2 T in
T i11
1 T i21
2 2T in
A T Dxr c9 ]]] 5 A T k ]]]]]]
Dt
Dx
(14)
Dx i21
R i21 5 ]]]
2k i21 A T
(15)
Dx i
R i 5 ]]
2k i A T
(16)
CTi
DS
DS
(17)
or
S D
Dt
Dt
T n11
5 ] ? T ni11 1 1 2 ]]
i
tQi
tQDi
h R 5 se (T EM 1 T 0 ) ? (T 2EM 1 T 20 )
(22)
S D
Dt
n
? T in 1 ] ? T i21
tDi
(23)
28
(24)
(25)
(26)
h
PR 5 ] ? c
k
(27)
CTi 5 A T Dx i ri c 9i 5Vri c 9i
177
3. Experimental
(18)
where
(19)
(20)
tQitDi
tQDi 5 ]]]
tQi 1 tDi
(21)
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
178
Table 1
Casting and chill materials used for experimentation and the corresponding thermophysical properties [1822] a
k S (W/ m K)
k L (W/ m K)
c S (J / kg K)
c L (J / kg K)
rS (kg / m 3 )
rL (kg / m 3 )
aS (m 2 / s)
aL (m 2 / s)
L (J / kg)
T F (8C)
T E (8C)
T L (8C)
e
K0
a
Al
Al
4.5%Cu
Al
15%Cu
Al
33%Cu
Steel
SAE
1010
Pb
Sn
39%Pb
Sn
20%Pb
Sn
10%Pb
Sn
5%Pb
Sn
Copper
222
92
1123
1086
2550
2380
7.75(310 25 )
3.36(310 25 )
385 000
660
193
85
1092
1059
2650
2480
6.67
3.24
381 900
660
548
645
179
80
1080
999
2910
2760
5.67
2.90
274 270
660
548
618
155
71
1070
895
3410
3240
4.25
2.45
350 000
660
548
46
34.7
29.7
129.8
138.2
11 340
10 678
2.37
2.04
26 205
327
54.7
31.7
186.2
212.9
8840
8400
3.35
1.79
47 560
232
183
59
32
200
231
8250
7860
3.58
1.76
52 580
232
183
202
63
33
209
243
7840
7480
3.84
1.81
56 140
232
183
216
64
33
221
259
7720
7380
3.91
1.82
57 120
232
183
220
67
33
221
259
7300
7000
4.15
1.82
60 710
232
372
0.17
0.17
0.0656
0.0656
0.0656
527
7860
0.8
419
8960
0.023
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
179
Fig. 4. Schematic representation of the experimental setup connected to the data acquisition and analysis system.
(28)
(29)
2
180
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
Fig. 6. Typical experimental temperature responses in steel molds at two locations: external wall temperature and at 3 mm from metalchill interface: (A)
6 mm mold thick and (B) 60 mm mold thick.
Fig. 7. Typical experimental temperature responses in cooper molds at two locations: external wall temperature and at 3 mm from metalchill interface:
(A) 6 mm mold thick and (B) 60 mm mold thick.
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
181
Fig. 8. Calculated moldenvironment heat transfer coefficients h a : (A) steel molds with different thicknesses, (B) copper molds with different
thicknesses.
182
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
Fig. 9. Typical experimental temperature responses at two locations in casting and chill: in casting at 20 mm from the metalmold interface and in chill at
3 mm from this interface: (A) Sn 10 wt.% Pb, (B) pure Sn both solidified in a 60 mm thick steel chill and a superheat DT 5 0.1 T L (10% of liquidus or
melting temperatures).
heat transfer coefficient. Anyway, a more complex experimental set-up and a numerical technique dealing with
convection heat transfer would be necessary for an accur-
Fig. 10. Typical experimental temperature responses at two locations in casting and chill: in casting at 20 mm from the metalmold interface and in chill at
3 mm from this interface: (A) Al 4.5 wt.% Cu, (B) pure Al both solidified in a 60 mm thick steel chill and a superheat DT 5 0.1 T L (A) and DT 5 0.2 T L (B).
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
183
Fig. 11. Evolution the metalmold interfacial heat transfer coefficients as a function of alloy composition: SnPb system, 60 mm thick steel chill and a
superheat DT 5 0.1 T L .
Fig. 12. Evolution the metalmold interfacial heat transfer coefficients as a function of alloy composition: AlCu system, 60 mm thick steel chill and a
superheat DT 5 0.1 T L (10% of liquidus or melting temperatures).
184
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
Fig. 13. Evolution of the metalmold heat transfer coefficients as a function of chill thickness: Sn 10 wt.% Pb alloy, steel chill and a superheat DT 5 0.1
TL.
Fig. 14. Evolution of the metalmold heat transfer coefficients as a function of chill thickness: Sn 10 wt.% Pb alloy, cooper chill and a superheat DT 5 0.1
TL.
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
185
Fig. 15. Evolution of the metalmold heat transfer coefficients as a function of superheat: Sn 10 wt.% Pb alloy, 60 mm thick steel chill.
Fig. 16. Evolution of the metalmold heat transfer coefficients as a function of superheat: Al, 60 mm thick steel chill.
C. A. Santos et al. / Journal of Alloys and Compounds 319 (2001) 174 186
186
fluidity of molten alloys increase with increasing superheat, favoring the wetting of the chill by the melt [23,24].
Some results reported in the literature indicate that the
surface of solidified shell becomes smoother as the superheat increases for the same chill microgeometry, thus
increasing the interfacial contact [3]. The influence of
superheat is not so significant for the Sn 10 wt.% Pb alloy.
In fact some differences can be observed only for values
higher than 408C (Fig. 15). This is not the case for Al,
where fluidity plays a more significant role. The initial
value of h i rises from about 1500 to 6000 W/ m 2 K if the
superheat is increased from 10% of the melting point (T f )
to 20% of T f (Fig. 16).
The h i profiles increased with increasing thermal diffusivity of the chill material and with decreasing
thickness of the chill.
Acknowledgements
The authors would like to acknowledge financial support
provided by FAPESP (The Scientific Research Foundation
Paulo, Brazil) and CNPq (The Brazilian
of the State of Sao
Research Council).
References
5. Conclusions
Experiments were conducted to analyze the evolution of
moldenvironment (h a ) and metalmold (h i ) heat transfer
coefficients during solidification of SnPb and AlCu
alloys in vertical steel and copper chills. The following
conclusions can be drawn
The transient interfacial heat transfer coefficients (h i
and h a ) have been successfully characterized by using
an approach based on measured temperatures along
casting and chill, and analytical calculations (h a ) and
numerical simulations provided by a heat flow model
(h i ).
The moldenvironment heat transfer coefficient have
been expressed as a power function of time, given by
the general form
h a 5 Cm (t)0.15
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[11]
[12]
[13]
2
[14]
[15]
[16]
[17]
[18]
[19]
h i 5 Ci (t)2n
[20]
[21]
[22]
[23]
[24]