Objective: Obtain new process data for advancing the state of the art of computer simulation
software used in High Pressure Die Casting Processes (HPDC).

Background: HPDC processes are designed based on process analysis using computer
simulation software for heat transfer, solidification, and fluid dynamics. The accuracy of
software simulation results depends on physical phenomena considered and process
parameters related to the liquid metal, lubricant application, and die cooling.

Lubricant Application: The cooling effect of lubricant on the die and its insulating effect
during casting solidification, are investigated using heat flux sensors.

Mold filling and Entrapped air: In-situ process data for software development is very limited,
as the mold filling time is less than 0.05s. Experiments will be conducted to illustrate mold filling,
air entrapment during mold filling and porosity distribution.

Open-die experiments: Obtain flow pattern, break-up pattern, droplet size, and velocity
distributions as liquid exits the gate into the runner.

Industrial support
GM
Ford Motor Co.
DaimlerChryler
Ford Motor Co.
Supplier consortium

Collaborators
Dr. Saito, Dr. Kuwana, Dr. Ali, University of Kentucky, Lexington

---

Acknowledgements U.S. Department of Energy, Assistant Secretary for Energy Efficiency and
Renewable Energy, Office of FreedomCAR and Vehicle Technologies, as part of the
Automotive Lightweighting Materials Program.