Paper Titles
Neural Network-Based Machine Learning Model for Spatiotemporal Prediction of Temperature and Fraction Solid in Low-Pressure Sand Casting
p.1
Assessment of Natural Gas-Hydrogen Fuel Blends for Industrial Melting Furnaces in Secondary Aluminium Production
p.11
Potential and Advantages of Vertical Strip Casting for Production of High-Strength Aluminum-Magnesium Alloys
p.21
RSM-Based Approach to Optimize the Gating System in High Pressure Die Casting
p.33
Effect of Interfacial Heat Transfer on the Solidification Behaviour of Numerically Simulated High-Pressure Die Casting Process
p.45
Additive Manufacturing for Advanced and Functional Tooling of Dies Used in High-Pressure Die Casting Processes
p.57
Digital Manufacturing of One-Off Replacement Components Using Reverse Engineering and Rapid Low-Pressure Sand Casting: Dimensional Evaluation and Key Challenges
p.75
Exploiting Artificial Neural Networks for Digital Twins in Sand Casting
p.85
Cleaner Melt Transfer of Recycled Aluminium Alloys: Simulation-Guided Launder Baffle Design for Aerospace-Grade Structural Castings
p.95

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

Article Preview
View Pdf By email

Abstract:

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/m2K and 12 kW/m2K for the shot sleeve, and 18 kW/m2K and 26 kW/m2K 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.

You have full access to the following eBook
Advanced Metal Casting Read eBook

Info:

Periodical:

Materials Science Forum (Volume 1188)

Pages:

45-55

Online since:

April 2026

Authors:

Nagasivamuni Balasubramani*, Mohamed El Mansori

Keywords:

Filling Velocity, High-Pressure Die Casting, Numerical Simulation, Solidification

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

Share:

* - Corresponding Author

References

[1] F. Bonollo, N. Gramegna, G. Timelli, High-Pressure Die-Casting: Contradictions and Challenges, JOM 67 (2015) 901–908.

DOI: 10.1007/s11837-015-1333-8

Google Scholar

[2] Y. Zhang, E. Lordan, K. Dou, S. Wang, Z. Fan, Influence of porosity characteristics on the variability in mechanical properties of high pressure die casting (HPDC) AlSi7MgMn alloys, J. Manuf. Process. 56 (2020) 500–509.

DOI: 10.1016/j.jmapro.2020.04.071

Google Scholar

[3] A.R. Adamane, L. Arnberg, E. Fiorese, G. Timelli, F. Bonollo, Influence of Injection Parameters on the Porosity and Tensile Properties of High-Pressure Die Cast Al-Si Alloys: A Review, Inter. Metalcast. 9 (2015) 43–53.

DOI: 10.1007/BF03355601

Google Scholar

[4] S. Otarawanna, H.I. Laukli, C.M. Gourlay, A.K. Dahle, Feeding Mechanisms in High-Pressure Die Castings, Metall. Mater. Trans. A 41 (2010) 1836–1846.

DOI: 10.1007/s11661-010-0222-6

Google Scholar

[5] S. Otarawanna, C.M. Gourlay, H.I. Laukli, A.K. Dahle, Microstructure Formation in AlSi4MgMn and AlMg5Si2Mn High-Pressure Die Castings, Metall. Mater. Trans. A 40 (2009) 1645–1659.

DOI: 10.1007/s11661-009-9841-1

Google Scholar

[6] D. Blondheim, A. Monroe, Macro Porosity Formation: A Study in High Pressure Die Casting, Inter. Metalcast. 16 (2022) 330–341.

DOI: 10.1007/s40962-021-00602-x

Google Scholar

[7] X.P. Niu, K.K. Tong, B.H. Hu, I. Pinwill, Cavity pressure sensor study of the gate freezing behaviour in aluminium high pressure die casting, Int. J. Cast Met. Res.11 (1998) 105–112.

DOI: 10.1080/13640461.1998.11819264

Google Scholar

[8] K. Dou, Y. Zhang, E. Lordan, A. Jacot, Z. Fan, Understanding the Initial Solidification Behavior for Al–Si Alloy in Cold Chamber High-Pressure Die Casting (CC-HPDC) Process Combining Experimental and Modeling Approach, Metall. Mater. Trans. A 53 (2022) 3110–3124.

DOI: 10.1007/s11661-022-06731-0

Google Scholar

[9] K. Dou, E. Lordan, Y.J. Zhang, A. Jacot, Z.Y. Fan, A complete computer aided engineering (CAE) modelling and optimization of high pressure die casting (HPDC) process, J. Manuf. Process. 60 (2020) 435–446.

DOI: 10.1016/j.jmapro.2020.10.062

Google Scholar

[10] M.S. Dargusch, A. Hamasaiid, G. Dour, N. Balasubramani, D.H. StJohn, The Influence of In-Cavity Pressure on Heat Transfer and Porosity Formation During High-Pressure Die Casting of A380 Alloy, JOM 72 (2020) 3798–3805.

DOI: 10.1007/s11837-020-04341-y

Google Scholar

[11] N. Balasubramani, A. Ktari, M. El Mansori, Numerical simulation of solidification within the shot sleeve of high-pressure die casting and the prediction of secondary dendrite arm spacing for externally solidified crystals, Materialia 42 (2025) 102479.

DOI: 10.1016/j.mtla.2025.102479

Google Scholar

[12] M. Koru, O. Serçe, Experimental and Theoretical Investigation of Heat Transfer in Vacuum Assisted High Pressure Die Casting (HPDC) Process, Inter. Metalcast. 18 (2024) 3013–3027.

DOI: 10.1007/s40962-023-01217-0

Google Scholar

[13] W. Yu, S. Liang, Y. Cao, X. Li, Z. Guo, S. Xiong, Interfacial heat transfer behavior at metal/die in finger-plated casting during high pressure die casting process, China Foundry 14 (2017) 258–264.

DOI: 10.1007/s41230-017-6066-6

Google Scholar

[14] P. Sharifi, J. Jamali, K. Sadayappan, J.T. Wood, Grain Size Distribution and Interfacial Heat Transfer Coefficient during Solidification of Magnesium Alloys Using High Pressure Die Casting Process, J. Mater. Sci. Technol. 34 (2018) 324–334.

DOI: 10.1016/j.jmst.2016.09.004

Google Scholar

[15] W. Yu, Y. Cao, Z. Guo, S. Xiong, Development and application of inverse heat transfer model between liquid metal and shot sleeve in high pressure die casting process under non-shooting condition, China Foundry 13 (2016) 269–275.

DOI: 10.1007/s41230-016-5137-4

Google Scholar

[16] E. Lordan, K. Dou, Y. Zhang, C. Tzileroglou, A. Jacot, P. Blake, Z. Fan, Turbulent breakup of non-metallic inclusions and equiaxed crystals during solidification of a hypoeutectic Al-Si alloy, Materialia 17 (2021) 101114.

DOI: 10.1016/j.mtla.2021.101114

Google Scholar

[17] J. Santos, A.E.W. Jarfors, A.K. Dahle, Filling, Feeding and Defect Formation of Thick-Walled AlSi7Mg0.3 Semi-Solid Castings, SSP 256 (2016) 222–227.

DOI: 10.4028/www.scientific.net/SSP.256.222

Google Scholar

[18] H. Tokunaga, Y. Motoyama, T. Okane, Particle Method Simulation for Formation and Flow of Cold Flakes in High-Pressure Die Casting, Inter. Metalcast. 13 (2019) 897–904.

DOI: 10.1007/s40962-019-00306-3

Google Scholar

[19] D.R. Gunasegaram, B.R. Finnin, F.B. Polivka, Melt flow velocity in high pressure die casting: Its effect on microstructure and mechanical properties in an Al–Si alloy, Mater. Sci. Technol. 23 (2007) 847–856.

DOI: 10.1179/174328407X176992

Google Scholar

[20] X.P. Niu, K.K. Tong, B.H. Hu, I. Pinwill, Cavity pressure sensor study of the gate freezing behaviour in aluminium high pressure die casting, Int. J. Cast Met. Res. 11 (1998) 105–112.

DOI: 10.1080/13640461.1998.11819264

Google Scholar

[21] A.K. Dahle, T. Sumitomo, S. Instone, Relationship between tensile and shear strengths of the mushy zone in solidifying aluminum alloys, Metall. Mater. Trans A 34 (2003) 105–113.

DOI: 10.1007/s11661-003-0212-z

Google Scholar

[22] D.R. Gunasegaram, M. Givord, R.G. O'Donnell, B.R. Finnin, Improvements engineered in UTS and elongation of aluminum alloy high pressure die castings through the alteration of runner geometry and plunger velocity, Mater. Sci. Eng. A 559 (2013) 276–286.

DOI: 10.1016/j.msea.2012.08.098

Google Scholar