Inverse analysis of mould-casting interfacial heat transfer towards improved castings

The correct information about the interfacial heat transfer coefficient (IHTC) at the mould-casting interface is of utmost importance for the better castings. The quality of caste materials is essentially dependent on the rate of heat transfer across the mould-casting interface during solidification and cooling of the casting materials. The uniform heat transfer across the casting and mould would lead to reduce casting defects. The aim of the present investigation is to carry out the inverse heat transfer analysis on the interface of mold and casting. The effect of pouring temperature, mould material and the properties of the cast metal were investigated by evaluating interfacial heat flux and interfacial heat transfer coefficient (IHTC) using transient temperatures inside the mould and casting. During the experiments, transient temperatures inside the mould and casting are recorded by very precise thermocouples. From the results, both interfacial heat flux and interfacial heat transfer coefficient are found to be dependent on pouring temperature keeping all other parameters constant. At same pouring temperature, interfacial heat flux is found to be independent of casting material while IHTC is found to be dependent on the properties of casting material. Peak value of IHTC is found to be much higher in case of zinc metal casting as compared to aluminium metal casting. Novel and experimental based analytical interpretation of the results are provided. The results might be useful for metal forming industries to develop improved castings at lower costs. © 2021