Heat flow at the casting/mold interface was assessed and studied during solidification of Al-Cu-Si (LM 21) alloy in preheated cast iron molds of two different thicknesses, coated with graphite and alumina based dressings. The casting and the mold were instrumented with thermocouples connected to a computer controlled temperature data acquisition system. The thermal history at nodal locations in the mold and casting obtained during experimentation was used to estimate the heat flux by solving the one-dimensional inverse heat conduction problem. The cooling rate and solidification time were measured using the computer-aided cooling curve analysis data. The estimated heat flux transients showed a peak due to the formation of a stable solid shell, which has a higher thermal conductivity compared with the liquid metal in contact with the mold wall prior to the occurrence of the peak. The high values of heat flux transients obtained with thin molds were attributed to mold distortion due to thermal stresses. For thin molds, assumption of Newtonian heating yielded reliable interfacial heat transfer coefficients as compared with one-dimensional inverse modeling. The time of occurrence of peak heat flux increased with a decrease in the mold wall thickness and increase in the casting thickness. © ASM International.

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dc.contributor.authorPrabhu, K.
dc.contributor.authorChowdary, B.
dc.contributor.authorVenkataraman, N.
dc.date.accessioned2026-02-05T11:00:17Z
dc.date.issuedCasting/mold thermal contact heat transfer during solidification of Al-Cu-Si alloy (LM 21) plates in thick and thin molds
dc.description.abstract2005
dc.identifier.citationJournal of Materials Engineering and Performance, 2005, 14, 5, pp. 604-609
dc.identifier.issn10599495
dc.identifier.urihttps://doi.org/10.1361/105994905X66015
dc.identifier.urihttps://idr.nitk.ac.in/handle/123456789/27912
dc.subjectCasting/mold interfaces
dc.subjectCooling curve analysis
dc.subjectInverse modeling
dc.subjectNewtonian heating
dc.subjectAlumina
dc.subjectCasting
dc.subjectComputer aided analysis
dc.subjectGraphite
dc.subjectHeat conduction
dc.subjectHeat flux
dc.subjectHeat transfer
dc.subjectLiquid metals
dc.subjectMolds
dc.subjectPlate metal
dc.subjectSolidification
dc.subjectAluminum alloys
dc.titleHeat flow at the casting/mold interface was assessed and studied during solidification of Al-Cu-Si (LM 21) alloy in preheated cast iron molds of two different thicknesses, coated with graphite and alumina based dressings. The casting and the mold were instrumented with thermocouples connected to a computer controlled temperature data acquisition system. The thermal history at nodal locations in the mold and casting obtained during experimentation was used to estimate the heat flux by solving the one-dimensional inverse heat conduction problem. The cooling rate and solidification time were measured using the computer-aided cooling curve analysis data. The estimated heat flux transients showed a peak due to the formation of a stable solid shell, which has a higher thermal conductivity compared with the liquid metal in contact with the mold wall prior to the occurrence of the peak. The high values of heat flux transients obtained with thin molds were attributed to mold distortion due to thermal stresses. For thin molds, assumption of Newtonian heating yielded reliable interfacial heat transfer coefficients as compared with one-dimensional inverse modeling. The time of occurrence of peak heat flux increased with a decrease in the mold wall thickness and increase in the casting thickness. © ASM International.

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