Simulation-Driven Insights into Heat Transfer during Copper Mold Casting of Magnesium-Based Bulk Metallic Glasses

Magnesium-based bulk metallic glasses (BMGs) present fabrication challenges due to their low glass-forming ability and high critical cooling rate. Copper mold casting, with its high thermal conductivity, is the most viable method for producing Mg-based BMGs, though amorphous diameters typically remain under 10 mm, limiting practical applications. This study uses FLOW-3D CAST simulations to analyze heat transfer and solidification behavior in two copper mold designs. The simulations evaluate flow uniformity, thermal dissipation, and cooling rate distribution, aiming to correlate cooling rate with achievable BMG diameter. The results provide design guidance for casting larger amorphous Mg components.