Modeling of Metal-Mold Interface Resistance in the AI-ll.5 wt% Si Alloy Casting Process

In this investigation, a computational model has been developed, including heat transfer andthe effects of the resistance of a metal-mold interface and pressure, for simulation of thesolidification process. simulation of the interface resistance is based on the zero thicknesselement (zte), utilizing the finite element method (fem). solid boundary conditions, includingcontact resistances, have been modified by a pressure gradient in each of the zte. the pressuregradient has been modeled, based on experimental data. in order to verify the computationalresults, an ai-ii.s wt% si alloy was poured into a permanent mold and the temperature ofthe interface was measured by a data acquisition system. then, the effect of metalo-staticpressure on overall heat transfer in the interface resistance was modeled. comparison betweenthe experimental and simulation results during the solidification process shows a good consistency,which confirms the accuracy of the model for the effects of interface resistance on solidificationtime.