Effect of Interfacial Heat Transfer on the Solidification Behaviour of Numerically Simulated High-Pressure Die Casting Process

The effect of time-dependent interfacial heat transfer coefficient () within the shot sleeve and die cavity of high pressure die casting process (HPDC) has been simulated to systematically study the solidification occurring during filling. Two different-profiles have been considered with peak values of 7 kW/m 2 K and 12 kW/m 2 K for the shot sleeve, and 18 kW/m 2 K and 26 kW/m 2 K for the runner, gate, and die cavity based on the values reported in the literature. In addition, two types of gate designs were considered for plate type castings to analyze their solidification behaviour and filling velocity. Solidification typically occurs along the bottom wall of the shot sleeve, from the mid-region toward the mould-side region along the direction of pouring. At the end of filling, the solid fraction () inside the shot sleeve increases from 10 to 18% with increasing peak value for-profiles. Similarly, the solidification around the gate regions progresses rapidly above 0.4 and reduces the fluid velocity at the gate entry for profile with higher peak values. Despite the lack of consensus on the selection of value (peak value and range), this study highlights the influence profiles and gating design on solidification during filling and discusses its implications on the quality of HPDC parts.