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Sensitivity study of IHTC on solidification simulation for automotive casting

Abstract Interface heat transfer coefficient values between the mould/metal interfaces need to be precisely determined in order to accurately predict the thermal histories at different locations in automotive castings. Thermo-mechanical simulations are carried out for Al–Si alloy casting processes using a commercial code. The simulation results are verified with experimental data from the literature. Sensitivity studies show that the choice of the initial value of the interface heat transfer coefficient (IHTC) between chill/metal as well as the sand mould/metal interfaces has a marked effect on the cooling curves. In addition, having chosen an initial value of the IHTC, the analyses also show differences in the solidification rate of the casting alloy near the sand/metal and chill/metal interfaces, upon further cooling. The gap formation, which results in a change in IHTC from the initial value, does not affect the cooling curves in the vicinity of the sand/metal interface due to lower thermal conductivity of sand. However it is found to have a considerable effect in the chill/metal interfacial regions due to higher thermal conductivity of the chill. Based on these studies we recommend initial IHTC values of 3000 and 7000 W m–2 K–1 for sand/metal and chill (steel)/metal interfaces respectively, for application in casting simulations.