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Measurement of Kinetic Zone Temperature and Heat Transfer Coefficient in the Lost Foam Casting Process

[+] Author Affiliations
X. J. Liu, S. H. Bhavnani, R. A. Overfelt

Auburn University

Paper No. IMECE2004-59348, pp. 411-418; 8 pages
  • ASME 2004 International Mechanical Engineering Congress and Exposition
  • Heat Transfer, Volume 3
  • Anaheim, California, USA, November 13 – 19, 2004
  • Conference Sponsors: Heat Transfer Division
  • ISBN: 0-7918-4711-X | eISBN: 0-7918-4178-2, 0-7918-4179-0, 0-7918-4180-4
  • Copyright © 2004 by ASME


A thermometric technique has been developed to study the thermal characteristics of the foam-metal interaction in the lost foam casting process. A cylindrical foam pattern and heated steel block have been used to estimate the endothermic losses associated with the thermal degradation of the expanded polystyrene at the metal front. Thermocouple readings have been analyzed to determine the temperature of the kinetic zone between the advancing metal front and the receding foam pattern. The heat transfer coefficient between the metal front and the foam pattern has been calculated from the thermal data at the simulated metal front. The results confirmed that the endothermic degradation of the polystyrene pattern at the metal front introduced a steep thermal gradient in the metal and a consistently increasing heat flux. It is found that the heat transfer coefficient, initially 150 W/m2 ·K increases to 220 ~ 300 W/m2 ·K during the process. Foam density has marginal effect on the heat flux and heat transfer coefficient, whereas the increase of simulated metal front velocity enhances the heat transfer at the metal front. The kinetic zone temperature is measured to be in the range of 150 to 290°C with an average of 200°C and a gaseous gap size of 1 to 4 cm.

Copyright © 2004 by ASME



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