Abstract
In the case of casting processes with permanent molds, there is still a relatively pronounced lack of knowledge regarding the locally prevailing heat transfer between casts and mold. This in turn results in an insufficient knowledge of the microstructure and the associated material properties in the areas of the casting component close to the surface. Therefore, this work deals with the design and evaluation of a test tool with an integrated sensor system for temperature measurements, which was applied to obtain a time-dependent heat transfer coefficient (HTC) during casting solidification. For this purpose, the setup, design and computational approach are described first. Special attention is paid to the qualification of the multi-depth sensor and the calculation method. For the calculations, an inverse estimation method (nonlinear sequential function) was used to obtain the HTC profiles from the collected data. The developed sensor technology was used in a test mold to verify the usability of the sensor technology and the plausibility of the obtained calculation results under real casting conditions and associated temperature loads. Both the experimental temperature profiles and the HTC profiles showed that, in the evaluated casting series, the peak values determined were close to each other and reached values between 6000 W/(m2·K) and 8000 W/(m2·K) during solidification.
Highlights
In terms of high production and material efficiency, die casting processes are very suitable manufacturing processes for the mass production of components with a high geometric complexity.This is true for industrial sectors in which the challenge of reducing component weight while at the same time achieving very good quality and high strength of the parts is becoming increasingly important
In order to achieve the overall goal of a valid determination of the heat transfer coefficient, the
The casting tests with the designed test tool were carried out at the institute. This made it possible, in a first step, to validate the effective function of the entire test set-up before the measuring sensor technology was transferred to the real casting process
Summary
In terms of high production and material efficiency, die casting processes are very suitable manufacturing processes for the mass production of components with a high geometric complexity. This is true for industrial sectors in which the challenge of reducing component weight while at the same time achieving very good quality and high strength of the parts is becoming increasingly important. Many efforts have been made [2,3,4,5] to integrate advanced sensor technologies into the permanent mold casting process. In addition to a better understanding of the process behavior, advanced sensor technology has enabled us to monitor and control various casting parameters
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