Modeling of metalo-static pressure on the metal–mould interface thermal resistance in the casting process

In this investigation, a computational model has been developed for simulation of low melting point alloys solidification process. The proposed model is capable of considering the effects of resistance of metal–mould interface and metalo-static pressure during solidification, jointly. The simulation of interface resistance has been achieved on the Zero Thickness Element (ZTE), utilizing the Finite Element Method. The solid boundary conditions, including contact resistances, have been modified by pressure gradient in each ZTE. The effect of pressure gradient has been modeled based on the experimental data, and an innovative model was developed. In order to verify the computational results, an Al–Si 11.5% alloy was poured into a permanent mould and the temperature of the interface was measured by data acquisition system for alternative metalo-static pressures. Then, the effect of metalo-static pressure was modeled as in the case of an overall heat transfer coefficient at the metal–mould interface. A comparison between the experimental and the simulation results during solidification process showed a good consistency, which confirms the accuracy of the present model for estimating the solidification time.