Date of Award

2012

Degree Type

Dissertation

Degree Name

Ph.D.

Department

Mechanical, Automotive, and Materials Engineering

First Advisor

Hu, Henry (Mechanical, Automotive, and Materials Engineering)

Keywords

Engineering.

Rights

CC BY-NC-ND 4.0

Abstract

This study developed a solution algorithm based on the function specification method to solve the inverse heat conduction equations. By this solution, the casting-die interfacial heat transfer coefficients(IHTC) in light metal squeeze castings were determined accurately and the pressurized solidification was simulated precisely. This goal was accomplished in the four stages. First, a model was developed to simulate fluid flow in forced convection and heat transfer in pressurized solidification of a cylindrical simple shape squeeze casting. Pressure-dependent heat transfer coefficients (HTC) and non-equilibrium solidification temperatures were determined by experimental measurements. With the measured HTC and temperatures under the different pressures, the temperature distributions and the cooling behaviours of squeeze cast were simulated. In the second stage, a different wall-thickness 5-step casting mould was designed, and squeeze casting of magnesium alloy AM60 was performed under an applied pressure 30, 60 and 90 MPa in a hydraulic press. With measured temperatures, heat fluxes and IHTCs were evaluated using the polynomial curve fitting method and numerical inverse method. The accuracy of these curves was analyzed by the direct modeling calculation. The results indicated that heat flux and IHTCs determined by the inverse method were more accurately than those from the extrapolated fitting method. In the third stage, the inverse method was applied to an aluminum alloy A443 and magnesium alloy AM60. As the applied hydraulic pressure increased, the IHTC peak value of each step was increased accordingly. Compared to the thin steps at the upper cavity, the relatively thick steps attained higher peak IHTCs and heat fluxes values due to high local pressures and high melt temperature. The empirical equations relating IHTC to the local pressures and solidification temperature at the casting surface were derived and summarized. Finally, the IHTC values calculated by inverse method were applied to simulate the solidification process of the 5-step casting model. The results showed that the numerical calculated temperatures were in well agreement with experimental ones. It is adequately demonstrated that the inverse method is a feasible and effective tool for determination of the IHTC.

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