Prediction of heat transfer and microstructure in high-pressure die-cast A383 aluminum alloy

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dc.contributor Brewer, Luke
dc.contributor Wang, Ruigang
dc.contributor Mulani, Sameer
dc.contributor Monroe, Charles A.
dc.contributor.advisor Nastac, Laurentiu Karkkainen, Mikko 2020-01-16T15:03:33Z 2020-01-16T15:03:33Z 2019
dc.identifier.other u0015_0000001_0003388
dc.identifier.other Karkkainen_alatus_0004D_13880
dc.description Electronic Thesis or Dissertation
dc.description.abstract Predicting the microstructure of the as-cast HPDC (high-pressure die cast) product is valuable, because micro-scale features often determine its mechanical properties. To predict the microstructure, the effect of processing parameters such as pressure and cooling rates must be known. The object of this study is to create state-of-the-art models for predicting heat transfer in the HPDC process, and apply those models to predict the evolution of one feature of the microstructure: the size of polyhedral α-Fe intermetallic phase. In the study, we develop a new empirical correlation for the Nusselt number in water cooling channels. This can be used to validate heat transfer coefficients for water cooling channels in commercial software to assist in modelling heat transfer in the HPDC process. Additionally, we develop a model for impact pressure in HPDC, which augments the state-of-the-art Hamasaiid model for peak IHTC (interfacial heat transfer coefficient) in HPDC, and relaxes some of their empirical assumptions. We integrate the IHTC model as a custom boundary condition in FLUENT 18.1 using SCM and UDF-files. Finally, we predict the size of polyhedral Fe-rich intermetallics using commercial casting simulation NOVAFLOW&SOLID for cooling rates and classical solidification theory for intermetallic size, and validate the results using optical micrograph size measurements.
dc.format.extent 147 p.
dc.format.medium electronic
dc.format.mimetype application/pdf
dc.language English
dc.language.iso en_US
dc.publisher University of Alabama Libraries
dc.relation.ispartof The University of Alabama Electronic Theses and Dissertations
dc.relation.ispartof The University of Alabama Libraries Digital Collections
dc.relation.haspart Supplementary materials include mathematica notebook file
dc.relation.hasversion born digital
dc.rights All rights reserved by the author unless otherwise indicated.
dc.subject.other Materials Science
dc.subject.other Computational physics
dc.subject.other Engineering
dc.title Prediction of heat transfer and microstructure in high-pressure die-cast A383 aluminum alloy
dc.type thesis
dc.type text University of Alabama. Department of Metallurgical and Materials Engineering Metallurgical/Materials Engineering The University of Alabama doctoral Ph.D.

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