Modeling of Metal-Mold Interface Resistance in the Al-11.5 wt% Si Alloy Casting Process

Abstract

In this investigation, a computational model has been developed, including heat transfer and the e ects of the resistance of a metal-mold interface and pressure, for simulation of the solidi cation process. Simulation of the interface resistance is based on the Zero Thickness Element (ZTE), utilizing the Finite Element Method (FEM). Solid boundary conditions, including contact resistances, have been modi ed by a pressure gradient in each of the ZTE. The pressure gradient has been modeled, based on experimental data. In order to verify the computational results, an Al-11.5 wt% Si alloy was poured into a permanent mold and the temperature of the interface was measured by a data acquisition system. Then, the e ect of metalo-static pressure on overall heat transfer in the interface resistance was modeled. Comparison between the experimental and simulation results during the solidi cation process shows a good consistency, which con rms the accuracy of the model for the e ects of interface resistance on solidi cation time.