Interfacial heat transfer of squeeze casting of wrought aluminum alloy 5083 with variation in wall thicknesses

The squeeze casting technique, combining the advantage of die casting and forging process, is becoming one of the fast growing and efficient methods for production of near-net to net shape of aluminum alloys. Wrought aluminum alloys with their high strength properties have achieved widespread use in the automotive industry. In this study, a five-step squeeze casting experiment using aluminum wrought alloy 5083 has been designed and conducted. The temperature profiles inside the die and casting were measured. The metal/die interfacial heat transfer coefficient (IHTC) by using a computer program based on the inverse method was calculated and studied. The results showed that the IHTC of the thicker section had a higher peak value than the thinner one in which a firm contact might be formed at the metal/die interface as the section became thicker, which facilitated the transfer of the applied hydraulic pressure to the metal/die interface. The IHTC value increased immediately after the mold cavity was filled by the liquid metal, and decreased as the solidification process proceeded. The regression analysis indicated that an empirical equation, relating IHTCs to the wall thickness of the casting could be established based on a logarithmic function.