High-precision solidification simulation by estimating heat transfer coefficients through data assimilation

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Solidification analysis is important for accurately predicting casting processes. A high-precision casting simulation requires accurate data of the physical properties of materials and heat transfer parameters. In particular, the heat transfer coefficient is a major parameter influencing the casting simulation results. Because the heat transfer coefficient is not uniquely determined by the material, it is typically estimated by trial and error, which requires considerable time for accurate estimations. Therefore, we developed a method to quickly estimate the heat transfer coefficient in a casting process by combining data assimilation and solidification simulations. With this method, the time-dependent heat transfer coefficient can be estimated in an appropriate and easy manner. To reproduce the 3D temperature distribution in a casting with high accuracy, we developed a method to estimate multiple heat transfer coefficients simultaneously by combining data assimilation and 3D solidification simulation. Al–5 mass% Si alloy was cast into a sand mold with a casting size of 30 mm × 30 mm × 100 mm, and the temperature was measured at five points in the casting to obtain a cooling curve. Two cooling curves corresponding to locations of 5 mm from the casting wall were used to estimate the two heat transfer coefficients on the side and bottom surfaces, which were simultaneously estimated by data assimilation. The results confirmed that all the five cooling curves could be reproduced with a high accuracy and that high-precision casting simulation was possible.