Heat Transfer Analysis during External Chilling of Composite Material Castings through Experimental and Finite Element (FE) Modelling


In controlled solidification, one of the important factors that affects heat transfer from the solidifying casting is the resistance offered at the casting/chill interface. In the present investigation, heat transfer analysis during solidification of Al-12%Si (LM 13) alloy is carried out by collecting temperature history of the solidifying casting. The temperature distribution during solidification in the present investigation is obtained using ANSYS multiphysics software and further for comparison. The temperature profiles are also obtained by FE (Finite Element) modelling using the same software. By using a temperature data logger and lab view based software, the temperature data is acquired and processed at every second. The cooling curves obtained are analysed to know the effect of chilling on solidification behaviour of Al-12%Si alloy castings. Finally, it is concluded from the above research that the cooling curves and temperature distribution obtained by FE analysis do not so closely converge with the experimental data due to modelling limitations.

Share and Cite:

J. Hemanth, "Heat Transfer Analysis during External Chilling of Composite Material Castings through Experimental and Finite Element (FE) Modelling," Modeling and Numerical Simulation of Material Science, Vol. 4 No. 1, 2014, pp. 1-7. doi: 10.4236/mnsms.2014.41001.

Conflicts of Interest

The authors declare no conflicts of interest.


[1] J. Hemanth, “Fracture Behaviour of Cryogenically Solidified Al-Alloy Reinforced with Nano ZrO2MMCs,” International Journal of Microstructure and Materials Properties (IJMMP), Vol. 7, No. 4, 2012, pp. 68-77.
[2] J. Hemanth, “Microstructure, Mechanical Properties and Wear Behaviour of Metallic, Non-Metallic and Deep Cryogenically Chilled ASTM a216 WCB Steel,” Journal of Alloys and Compounds, Elsevier Science, Vol. 506, 2010, pp. 645-652.
[3] J. Hemanth, “Development and Wear Behaviour of Al/ Al2SiO5/C Chilled Hybrid Metal Matrix Composites by Both Experimental and Finite Element Method,” SAE International, Ohio, 2011.
[4] J. Hemanth, “Abrasive and Slurry Wear Behaviour of Chilled Aluminium Alloy (A356) Reinforced with Used Silica (SiO2p) MMCs,” Composites Part B, Elsevier Science, Vol. 42, No. 7, 2011, pp. 1826-1833.
[5] J. Hemanth, “Cryo Effect during Solidification on the Tribological Behaviour of Al-Alloy/GlassSiO2 MMCs,” Journal of Composite Materials, Vol. 43, No. 6, 2009, pp. 675-688.
[6] P. K. Rohatgi, et al., “Heat Transfer Characteristics of Mould Materials,” Journal of Materials Science, Vol. 29, No. 20, 1994, pp. 5357-5366. http://dx.doi.org/10.1007/BF01171548
[7] G. S. Hanumanth and G. A. Irons, “Solidification Behaviour of Aluminium Alloy Die Castings,” Metallurgical and Materials Transactions B, Vol. 27, No. 4, 1996, pp. 663-671. http://dx.doi.org/10.1007/BF02915665
[8] S. L. Soo, “Multiphase Fluid Dynamics,” Science Press, Beijing, 1990.
[9] G. S. Hanumanth, G. A. Irons and S. Lafreniere, “Effect of Chill Metal Interface during Solidification of Aluminium Alloys,” Metallurgical and Materials Transactions B, Vol. 23, No. 6, 1992, pp. 753-763. http://dx.doi.org/10.1007/BF02656454
[10] C. Beckermann and C. Y. Wang, “Annual Review of Heat Transfer,” In: C. L. Tien, Ed., Begell House, New York, 1995, pp. 98-115.
[11] A. Scott, “Cooling Curve Analysis of Chilled Aluminium 12% Si Alloys,” M.S. Thesis, Virginia Polytechnic Institute and State University, Blacksburg, 1996.
[12] K. N. Seetharamu and Sadhana, “Solidification Behaviour of Aluminiumalloy Composite by Die Casting Method,” Journal of Composites, Vol. 26, 2009, pp. 103-120.
[13] R. W. Lewis and R. S. Ransingh, “Solidification Analysis through Cooling Curves for Aluminium Alloy Reinforced with SiO2 Composites,” Metallurgical and Materials Transactions, Vol. 29B, 1988, pp. 435-444.
[14] K. S. Kannan, et al., “Effect of Heat Transfer on during Solidification of Steel Castings,” Indian Journal of Technology, Vol. 28, 1990, pp. 460-474.
[15] L. B?ckerud and B. Chalmers, “Effect of Convection Heat Transfer during Solidification of Aluminium Alloy Castings,” Transactions of the Metallurgical Society of AIME, Vol. 245, No. 2, 1969, pp. 309-318.
[16] L.-S. Chao and W.-C. Du, “Effect of Air Gap Formation in Chills Ruing Solidification of Copper Alloy Castings,” Proc. Natl. Sci. Counc. ROC (A), Vol. 23, No. 5, 1999, pp. 622-629.
[17] J. Tamminen, “Heat Transfer Analysis between Chill and Metal Interface,” Ph.D. Thesis, University of Stockholm, Stockholm, 2010.
[18] H. Morrogh and W. J. Williams, “Convective Heat Transfer Analysis during Solidification of Steel Alloys,” Journal of Iron and Steel Institute, Vol. 12, 1999, pp. 375-378.
[19] A. Nathan, “Correction of Transient Solid-Embedded Thermocouple Data with Application to Inverse Heat Conduction,” Ph.D. Thesis, Mississippi State University, Mississippi, 2011.
[20] ANSYS Software Company, “Manual of ANSYS-10 Multi-Physics Tutorials on Phase Change Problems,” 2011.
[21] C. A. Long, “Essential Heat transfer,” Addition Wesley Longman Publications, Boston, 2001.
[22] R. Asthana, “Finite Element Analysis of Solidification Behaviour of Metals,” Journal of Materials Science, Vol. 15, No. 11, 1998, pp. 213-255.
[23] J. Hashim, L. Looney and M. S. J. Hashmi, “Finite Element Modelling of Heat Transfer Analysis during Solidification of Aluminium Alloy Castings,” Journal of Material Processing Technology, Vol. 123, No. 2, 2002, pp. 251-257. http://dx.doi.org/10.1016/S0924-0136(02)00098-5
[24] Z. Markovie and B. Rasuo, “Finite Element and Finite Difference Method of Analysing Hear Transfer during Solidification,” International Conference on Computational Mechanics (CM04), Belgrade, November 2004, pp. 26-34.
[25] T. Goel and M. Rowan, “Film Coefficient of Heat Transfer for Aluminium Alloy Chilled Castings,” Material Science Letters, Elsevier Science, Vol 25, 2010, pp. 81-89.
[26] M. Hughes and K. L. Warren, “ANSYS Code for Euler’s Backward Integration Method for Solution to Heat Transfer during Solidification Problems,” Journal of Advanced Heat Transfer, Vol. 17, No. 2, 2011, pp. 34-47.
[27] S. Sawato, J. L. Guy and L. H. Philips, “Temperature Gradients during Solidification—A Numerical Approach,” Journal of AIME, Vol. 24, No. 9, 2010, pp. 56-67.

Copyright © 2024 by authors and Scientific Research Publishing Inc.

Creative Commons License

This work and the related PDF file are licensed under a Creative Commons Attribution 4.0 International License.