Heat transfer during the solidification of an Al-Cu-Si alloy (LM4) and commercial pure tin in single steel, graphite, and graphite-lined metallic (composite) molds was investigated. Experiments were carried out at three different superheats. In the case of composite molds, the effect of the thickness of the graphite lining and the outer wall on heat transfer was studied. Temperatures at known locations inside the mold and casting were used to solve the Fourier heat conduction equation inversely to yield the casting/mold interfacial heat flux transients. Increased melt superheats and higher thermal conductivity of the mold material led to an increase in the peak heat flux at the metal/mold interface. Factorial experiments indicated that the mold material had a significant effect on the peak heat flux at the 5% level of significance. The ratio of graphite lining to outer steel wall and superheat had a significant effect on the peak heat flux in significance range varying between 5 and 25%. A heat flux model was proposed to estimate the maximum heat flux transients at different superheat levels of 25 to 75°C for any metal/mold combinations having a thermal diffusivity ratio (?<inf>R</inf>) varying between 0.25 and 6.96. The heat flow models could be used to estimate interfacial heat flux transients from the thermophysical properties of the mold and cast materials and the melt superheat. Metallographic analysis indicated finer microstructures for castings poured at increased melt superheats and cast in high-thermal diffusivity molds.

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dc.contributor.authorPrabhu, K.
dc.contributor.authorSuresha, K.M.
dc.date.accessioned2026-02-05T11:00:18Z
dc.date.issuedEffect of superheat, mold, and casting materials on the metal/mold interfacial heat transfer during solidification in graphite-lined permanent molds
dc.description.abstract2004
dc.identifier.citationJournal of Materials Engineering and Performance, 2004, 13, 5, pp. 619-626
dc.identifier.issn10599495
dc.identifier.urihttps://doi.org/10.1361/10599490420647
dc.identifier.urihttps://idr.nitk.ac.in/handle/123456789/27936
dc.subjectAluminum alloys
dc.subjectComposite materials
dc.subjectHeat flux
dc.subjectHeat transfer
dc.subjectHeating
dc.subjectMetallographic microstructure
dc.subjectMetallography
dc.subjectMolds
dc.subjectPermanent mold casting
dc.subjectThermal diffusion
dc.subjectComposite molds
dc.subjectGraphite lining
dc.subjectInterfacial heat flux
dc.subjectGraphite
dc.titleHeat transfer during the solidification of an Al-Cu-Si alloy (LM4) and commercial pure tin in single steel, graphite, and graphite-lined metallic (composite) molds was investigated. Experiments were carried out at three different superheats. In the case of composite molds, the effect of the thickness of the graphite lining and the outer wall on heat transfer was studied. Temperatures at known locations inside the mold and casting were used to solve the Fourier heat conduction equation inversely to yield the casting/mold interfacial heat flux transients. Increased melt superheats and higher thermal conductivity of the mold material led to an increase in the peak heat flux at the metal/mold interface. Factorial experiments indicated that the mold material had a significant effect on the peak heat flux at the 5% level of significance. The ratio of graphite lining to outer steel wall and superheat had a significant effect on the peak heat flux in significance range varying between 5 and 25%. A heat flux model was proposed to estimate the maximum heat flux transients at different superheat levels of 25 to 75°C for any metal/mold combinations having a thermal diffusivity ratio (?<inf>R</inf>) varying between 0.25 and 6.96. The heat flow models could be used to estimate interfacial heat flux transients from the thermophysical properties of the mold and cast materials and the melt superheat. Metallographic analysis indicated finer microstructures for castings poured at increased melt superheats and cast in high-thermal diffusivity molds.

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