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• W145362489 abstract "Abstract Casting is a process where components are produced by pouring molten metal into moulds or dies which is then allowed to solidify. A variety of casting techniques are used in industry, but this thesis focuses on aluminium casting using a type of permanent mould casting called Gravity Die Casting (GDC). Casting is a process which is largely dictated by thermal conditions. Thermal conditions dictate solidification rate, which partly determines the microstructure and affects the mechanical properties of a component. Casting parameters such as melt temperature, initial die temperature, and die coating can also affect how heat is removed from a casting. The rate of heat removal is expressed as heat flux (q) (MWm-2). The rate of heat removal from a casting and through a die is known as interfacial heat flux, and is calculated at the metal/mould boundary. Heat transfer at the metal/mould boundary can also be described by the interfacial Heat Transfer Coefficient (HTC) (Wm-2K-1). In general if the HTC is large then solidification will be rapid. The HTC is a very important parameter in casting simulation programs, which are often used to optimise casting processes and die design. For most simulation programs the HTC is required, however, the HTC generally has to be estimated for the particular casting condition being simulated. Current state-of-the-art modelling packages, such as Magmasoft, have the ability to use variable HTCs in computations, but this information is rarely available. The variable HTC plots presented in this thesis provide a valuable database for more accurate modelling the solidification of gravity die cast aluminium-silicon alloys. Aluminum gravity die castings were produced using an experimental gravity die casting rig installed with a Heat Transfer Coefficient gauge. Al-7Si-0.3Mg aluminium alloy was used for all castings and two different die coatings were used. A ceramic die coating primarily consisting of titanium dioxide particles in a water suspension, and a graphite die coating were applied to the die using a spray gun with adjustable spray pressure. Two sets of castings were produced with the die set at variable thicknesses of 15 mm, 20 mm and 25 mm, one with the die coated in the ceramic coating and the other with the graphite coating. Castings were produced with the ceramic coating applied at different spray pressures of 2 bar, 4 bar and 6 bar. Heat flux and HTCs were calculated and plotted against time for all castings. The castings of various thicknesses had maximum HTCs in the range of 1.4 to 1.5 kWm-2K-1 for castings from the graphite coated die, and 1.3 to 1.4 kWm-2K-1 for castings from the ceramic coated die. Heat transfer data for castings from the die coated with ceramic coating applied at spray pressures of 2 bar, 4 bar and 6 bar were also plotted and analysed. It was found that the castings from the die coated at 4 bar had the highest HTC of 1.3 kWm-2K-1, with the 2 bar and 6 bar castings only reaching maximum HTCs of approximately 1.0 kWm-2K-1 and 1.1 kWm-2K-1, respectively. Microstructures from castings were also analysed with dendrite cell sizes and eutectic volume fraction measurements taken. This information was then compared to the HTC data and solidification times in order to establish links between heat transfer, maximum HTC and the resultant microstructures. Significant variations in the HTC are likely to occur as results of normal processes in commercial foundries. This thesis provides an idea of how much the absolute value of the HTC varies with changes in some typical parameters. From this knowledge a robust casting process can be designed to tolerate these typical changes in the HTC." @default.
• W145362489 created "2016-06-24" @default.
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• W145362489 date "2010-09-01" @default.
• W145362489 modified "2023-09-27" @default.
• W145362489 title "The Effects of Varying Die Coating and Casting Volume on Heat Transfer in Aluminium Gravity Die Casting" @default.
• W145362489 hasPublicationYear "2010" @default.
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