Understanding of the influence of process parameters on the heat transfer behavior at the metal/die interface in high pressure die casting process

The current paper focuses on the influence of the process parameters on the peak values of the interfacial heat transfer coefficient (IHTC) at metal/die interface during high pressure die casting (HPDC) process. A “step shape” casting and AM50 alloy were used during the experiment. The IHTC was determined by solving the inverse thermal problem based on the measured temperature inside the die. Results show that the initial die surface temperature (IDST, T _DI) has a dominant influence while the casting pressure and fast shot velocity have a secondary influence on the IHTC peak values. By curve fitting, it was found that the IHTC peak value (h _max) changes as a function of the IDST in a manner of h _max =e ^α T _DI ^γ . Such relationship between the IHTC peak value and the IDST can also be found when the casting alloy is ADC12, indicating that this phenomenon is a common characteristic in the HPDC process. Supported by the National Natural Science Foundation of China (Grant No. 50675114), National Basic Research Program of China (“973”) (Grant Nos. 2006CB605208-2, 2005CB724105)