Combined modular measuring device for casting aluminum alloy casting heat exchange coefficient and data rapid acquisition method

Abstract

The application discloses a combined modular determination device for casting aluminum alloy casting heat exchange coefficient and a data rapid acquisition method, which can simultaneously acquire multiple heat exchange coefficients of cavity and core materials, and through the combined modularization of used materials, each to-be-tested material is separated by an adiabatic layer and is combined with stable structure through shape design. The modular structure comprises different size metal type / non-metal type modules and chilling modules. Each module can be replaced according to the used materials of the cavity and the core. The application can integrate multiple casting environments, and can be conveniently adjusted according to the corresponding environment, and simultaneously acquire the heat exchange coefficients under multiple environments, thereby shortening the determination time of the heat exchange coefficients and improving the work efficiency.

Description

Technical Field

[0001] This invention belongs to the field of aluminum alloy casting process design, specifically a method for obtaining the heat transfer coefficient required for aluminum alloy casting process design, particularly a method for obtaining reliable heat transfer coefficients under various casting conditions. Specifically, it is a modular method for rapidly obtaining heat transfer coefficients within a solidification temperature range for aluminum alloy casting. Background Technology

[0002] Cast aluminum alloys, such as aluminum (Al)-silicon (Si), aluminum (Al)-copper (Cu), and aluminum (Al)-zinc (Zn), are the most widely used type of aluminum alloy, favored for their excellent properties. Furthermore, with current processing techniques, these alloys can be endowed with good strength, toughness, and plasticity, enabling them to withstand large loads without brittle fracture, making them an indispensable material in modern manufacturing.

[0003] In casting processes, the heat transfer coefficient is a crucial parameter that profoundly impacts the quality, performance, and production efficiency of castings. The heat transfer coefficient defines a material's ability to conduct heat; specifically, it represents the relationship between the amount of heat passing through a unit area per unit time and the temperature difference. During casting, a higher heat transfer coefficient accelerates metal cooling, allowing castings to solidify more quickly. Increased cooling rates not only shorten production cycles but also improve the microstructure of castings, enhancing their strength and hardness. However, high heat transfer coefficients can also lead to casting defects related to cooling rate. Mold design must also fully consider the heat transfer coefficient. The material, shape, and thickness of the mold all affect heat transfer efficiency. Designers must select appropriate materials and structures to ensure effective heat conduction, preventing mold damage due to overheating or casting defects caused by uneven cooling. Uneven cooling rates can easily lead to defects such as cracks and shrinkage cavities. By properly managing the heat transfer coefficient, more uniform cooling can be achieved, reducing the probability of defects and thus improving the quality and reliability of castings. A reasonable casting heat transfer coefficient can improve the reliability of conclusions from numerical simulations and finite element simulations of the casting process. This allows for more efficient identification of optimal pouring temperature, cooling time, and mold design parameters, thereby increasing production efficiency, reducing energy consumption, and achieving greater economic benefits. Especially in the production of high-performance castings, effectively managing and optimizing the heat transfer coefficient by selecting appropriate mold materials and matching them with reasonable cooling conditions is key to improving product quality and production efficiency in the casting industry.

[0004] Casting is an extremely complex process system. Based on the raw materials used, it can be divided into metal mold casting, sand casting, etc., and based on the process flow, it can be divided into gravity casting, pressure casting, centrifugal casting, etc. Adding to this the recently developed composite casting process, which uses different raw materials and requires different process controls, the requirements for process simulation and optimization, and the setting of heat transfer coefficients during design, become even more stringent. For example, patent CN203409212 discloses a device for measuring the heat transfer coefficient between ingot and cooling water in a semi-continuous aluminum alloy casting process; patent CN109856183 discloses a method and device for determining the solid-liquid interface heat transfer coefficient in differential pressure metal mold casting; and CN112464398 discloses a method for establishing a four-dimensional interface heat transfer coefficient model for the casting process. These methods provide corresponding heat transfer coefficient measurement methods for specific casting environments. However, modern casting processes are diverse and environmental structures are complex. Therefore, developing a rapid method for measuring casting heat transfer coefficients in various environments is necessary to improve the practicality and production efficiency of casting processes. Summary of the Invention

[0005] Objective of the Invention: To address the shortcomings of existing technologies, the objective of this invention is to provide a modular device and rapid data acquisition method for measuring the heat transfer coefficient of cast aluminum alloys. By simultaneously obtaining solidification temperature curves within solidification temperature ranges under multiple environments and utilizing a universal heat transfer coefficient back-calculation module, multiple heat transfer coefficients can be acquired simultaneously. This invention differs from heat transfer coefficient measurement methods tailored to specific casting process environments; instead, it is a modular device integrating multiple casting environments and allowing for flexible adjustments based on the specific environment, simultaneously obtaining heat transfer coefficients under various conditions. Furthermore, the integration of environments shortens the measurement time for heat transfer coefficients and improves work efficiency.

[0006] Technical solution: A modular combination measuring device for measuring the heat transfer coefficient of cast aluminum alloys, comprising four parts: a metal / non-metal module I, a metal / non-metal module II of another size, a support contact module and a quenching module, with the remainder being the casting cavity;

[0007] Each module is determined according to the casting environment. Each module can be replaced according to the materials used in the cavity and core. The module is not a homogeneous whole, but is composed of a combination of multiple materials. The module can be divided into several areas according to the materials used, and the areas are separated by an insulation layer.

[0008] The insulation layer is made of heat-insulating zirconia or alumina foam ceramic material, with a single layer thickness of 5%-10% of the module thickness. The insulation layer is I-shaped and is combined with each part of the test material using high-temperature adhesive to ensure stable bonding between the parts and prevent melt leakage.

[0009] Each module contains a temperature sensor, and wired or wireless sensors can be used to obtain temperature curves depending on the actual situation. The cooling module is made of a single material and can be equipped with 1-2 temperature sensors.

[0010] A method for rapidly acquiring data based on the modular combined measuring device for measuring the heat transfer coefficient of cast aluminum alloys includes the following steps:

[0011] Step 1: Arrange the temperature sensors of the measuring device according to their positions. Specifically, the temperature sensors should be evenly distributed in the thickness direction and in the middle of the width direction of each area to be measured. The number of thermocouples can also be adjusted according to the actual situation, but the spacing should be uniform.

[0012] Step 2: Based on the number of temperature sensors in Step 1, collect temperature data using a general-purpose temperature acquisition instrument;

[0013] Step 3: Conduct casting experiment: Select the aluminum alloy required for production, melt it and pour it into the cavity of the temperature measuring device to prepare for temperature data collection;

[0014] Step 4: Based on the data collected in Step 3, plot the solidification temperature curve and calculate the heat transfer coefficient using the back-calculation module provided by the commercial software.

[0015] Step 5: Using the solidification temperature curve from Step 4, and employing commercial casting simulation software, based on the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively, and the heat transfer coefficient is calculated.

[0016] Step 6: Verify the back-calculation results from Step 5 with the experimental data. If they are inconsistent, adjust the parameters of the empirical formula or adjust the numerical calculation process.

[0017] As an optimization: simultaneously obtaining solidification temperature curves within solidification temperature ranges under multiple environments allows for the simultaneous acquisition of multiple heat transfer coefficients.

[0018] As an optimization: During the testing process, each material under test is separated by an insulation layer.

[0019] As an optimization: a modular design is adopted to integrate multiple casting environments, which can be flexibly adjusted according to the corresponding environment, and heat transfer coefficients under multiple environments can be obtained.

[0020] As an optimization: a modular approach is adopted, and high-temperature adhesive is used to combine each part of the test material.

[0021] Beneficial Effects: This invention assembles a test module based on the materials used in the mold cavity, core, and chiller. Each test material is separated by insulating foam ceramic, avoiding temperature errors caused by heat conduction between materials. Simultaneously, it collects solidification temperature curves within various solidification temperature ranges under different environments and uses a universal heat transfer coefficient back-calculation module to obtain the heat transfer coefficients for multiple materials and environments. This invention differs from heat transfer coefficient measurement methods specific to particular casting process environments; instead, it is a modular, integrated approach that combines multiple casting environments and can be flexibly adjusted according to the corresponding environment, simultaneously obtaining heat transfer coefficients under various conditions. Furthermore, the integrated environment shortens the heat transfer coefficient measurement time and improves work efficiency. This invention does not involve the emission of waste gas or wastewater and will not pollute the environment. Attached Figure Description

[0022] Figure 1 These are schematic diagrams (a) and cross-sectional views (b and c) of the measuring device of the present invention; metal / non-metal module I (1 and 2); another size metal / non-metal module II (3 and 4); support contact module (5); cooling module (6).

[0023] Figure 2 Schematic diagram of insulation layer arrangement in Example 1;

[0024] Figure 3 Thermocouple layout diagram in Example 1, (a) side view, (b) front view;

[0025] Figure 4 Example 1: Data and Fitting Results (dotted lines represent fitting results);

[0026] Figure 5 Example 3: Data and Fitting Results (dotted lines represent fitting results);

[0027] Figure 6 Example 5: Data and fitting results graph (dotted lines represent fitting results). Detailed Implementation

[0028] The technical solutions in the embodiments of the present invention will be clearly and completely described below, so that those skilled in the art can better understand the advantages and features of the present invention, thereby making a clearer definition of the scope of protection of the present invention. The embodiments described in this invention are only some embodiments of the present invention, not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention. Example

[0029] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0030] Step (1) Design the device according to the all-metal gravity casting process: The device size is 480 mm × 480 mm × 360 mm. Figure 1 The metal modules 1 and 2 in section a measure 240 mm × 220 mm × 50 mm and consist of three parts: ductile iron QT500, ductile iron QT450, and 45 steel. The insulation layer is made of 4 mm thick insulating zirconia foam ceramic, machined into an I-shape, and combined with the various test materials using high-temperature adhesive. Figure 1 In module II of type a, insulation zirconia foam ceramic with a thickness of 15 mm is used in modules 3 and 4. Figure 1 The fifth support contact module in section a is made of heat-insulating zirconia foam ceramic. Figure 1 In section a, the quenching module 6 is made of ductile iron QT500, and the rest is a casting cavity;

[0031] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0032] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0033] Step (4) Casting experiment: Select the A356 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data.

[0034] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0035] Step (6) uses the solidification temperature curve from Step 5, and utilizes commercial casting simulation software and the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 (Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively) to calculate the heat transfer coefficient;

[0036] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0037] Example 2

[0038] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0039] Step (1) Design the device according to the all-metal gravity casting process: The device size is 480 mm × 480 mm × 360 mm. Figure 1 The metal modules 1 and 2 in section a measure 240 mm × 220 mm × 50 mm and consist of three parts: H13 steel, T8 steel, and 55 steel. The insulation layer is made of 4 mm thick insulating zirconia foam ceramic, machined into an I-shape, and assembled with the various test materials using high-temperature adhesive. Figure 1 In module II of type a, insulation zirconia foam ceramic with a thickness of 15 mm is used in modules 3 and 4. Figure 1 The fifth support contact module in section a is made of heat-insulating zirconia foam ceramic. Figure 1 In section a, the quenching module 6 is made of ductile iron QT500, and the rest is a casting cavity;

[0040] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0041] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0042] Step (4) Casting experiment: Select the A380 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data.

[0043] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0044] Step (6) uses the solidification temperature curve from Step 5, and utilizes commercial casting simulation software and the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 (Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively) to calculate the heat transfer coefficient;

[0045] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0046] Example 3

[0047] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0048] Step (1) Design the device according to the all-metal gravity casting process: The device size is 240 mm × 240 mm × 360 mm. Figure 1The metal modules 1 and 2 in section a measure 160 mm × 160 mm × 30 mm and consist of three parts: ductile iron QT500, ductile iron QT450, and 45 steel. The insulation layer is made of 3 mm thick insulating zirconia foam ceramic, machined into an I-shape, and combined with the various test materials using high-temperature adhesive. Figure 1 In module II of type a, insulation zirconia foam ceramic with a thickness of 15 mm is used in modules 3 and 4. Figure 1 The fifth support contact module in section a is made of heat-insulating zirconia foam ceramic. Figure 1 In section a, the quenching module 6 is made of ductile iron QT500, and the rest is a casting cavity;

[0049] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0050] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0051] Step (4) Casting experiment: Select the A356.1 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data;

[0052] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0053] Step (6) uses the solidification temperature curve from Step 5, and utilizes commercial casting simulation software and the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 (Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively) to calculate the heat transfer coefficient;

[0054] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0055] Example 4

[0056] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0057] Step (1) Design the device according to the all-metal gravity casting process: The device size is 240 mm × 240 mm × 360 mm. Figure 1The metal modules 1 and 2 in section a measure 160 mm × 160 mm × 30 mm and consist of three parts: T2 copper, TC4 titanium alloy, and 316 stainless steel. The insulation layer is made of 3 mm thick insulating zirconia foam ceramic, machined into an I-shape, and assembled with the various test materials using high-temperature adhesive. Figure 1 In module II of type a, insulation zirconia foam ceramic with a thickness of 15 mm is used in modules 3 and 4. Figure 1 The fifth support contact module in section a is a QT500 enclosure with internal circulating cooling water. The internal cavity dimensions are 240 mm × 240 mm × 4 mm. The cooling water is pumped in from one side and circulated into the cooling water tank through the other side. Figure 1 In section a, the quenching module 6 is T2, and the rest are casting cavities;

[0058] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0059] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0060] Step (4) Casting experiment: Select the A356 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data.

[0061] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0062] Step (6) uses the solidification temperature curve from Step 5, and utilizes commercial casting simulation software and the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 (Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively) to calculate the heat transfer coefficient;

[0063] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0064] Example 5

[0065] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0066] Step (1) Design the device according to the all-metal gravity casting process: The device size is 240 mm × 240 mm × 360 mm. Figure 1The metal modules 1 and 2 in section a measure 160 mm × 160 mm × 30 mm and consist of three parts: ductile iron QT500, ductile iron QT450, and 45 steel. The insulation layer is made of 3 mm thick insulating zirconia foam ceramic, machined into an I-shape, and combined with the various test materials using high-temperature adhesive. Figure 1 In module II of type a, insulation zirconia foam ceramic with a thickness of 15 mm is used in modules 3 and 4. Figure 1 The fifth support contact module in section a is a QT500 enclosure with internal circulating cooling water. The internal cavity dimensions are 240 mm × 240 mm × 4 mm. The cooling water is pumped in from one side and circulated into the cooling water tank through the other side. Figure 1 In section a, the quenching module 6 is QT500, and the rest are cast cavities;

[0067] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0068] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0069] Step (4) Casting experiment: Select the ZL205 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device, and prepare to collect temperature data.

[0070] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0071] Step (6) uses the solidification temperature curve from Step 5, and utilizes commercial casting simulation software and the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 (Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively) to calculate the heat transfer coefficient;

[0072] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0073] Example 6

[0074] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0075] Step (1) Design the device according to the all-metal gravity casting process: The device size is 240 mm × 240 mm × 360 mm. Figure 1The metal modules 1 and 2 in section a measure 160 mm × 160 mm × 30 mm and consist of three parts: H13 steel, T8 steel, and 55 steel. The insulation layer is made of 3 mm thick insulating zirconia foam ceramic, machined into an I-shape, and assembled with the various test materials using high-temperature adhesive. Figure 1 In module II of type a, insulation zirconia foam ceramic with a thickness of 15 mm is used in modules 3 and 4. Figure 1 The fifth support contact module in section a is a QT500 enclosure with internal circulating cooling water. The internal cavity dimensions are 240 mm × 240 mm × 4 mm. The cooling water is pumped in from one side and circulated into the cooling water tank through the other side. Figure 1 In section a, the quenching module 6 is QT500, and the rest are cast cavities;

[0076] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0077] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0078] Step (4) Casting experiment: Select the ZL411 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data.

[0079] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0080] Step (6) uses the solidification temperature curve from Step 5, and utilizes commercial casting simulation software and the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 (Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively) to calculate the heat transfer coefficient;

[0081] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0082] Example 7

[0083] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0084] Step (1) Design the device according to the all-metal gravity casting process: The device size is 480 mm × 480 mm × 360 mm. Figure 1The metal modules 1 and 2 in section a measure 240 mm × 220 mm × 50 mm and consist of three parts: ductile iron QT500, ductile iron QT450, and 45 steel. The insulation layer is made of 4 mm thick insulating zirconia foam ceramic, machined into an I-shape, and combined with the various test materials using high-temperature adhesive. Figure 1 Modules 3 and 4 in section II are not partitioned and use ductile iron QT500 with a thickness of 15 mm. Figure 1 The fifth support contact module in section a is made of heat-insulating zirconia foam ceramic. Figure 1 In module a, the quenching module 6 is made of alumina foam ceramic, while the rest are cast cavities;

[0085] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0086] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0087] Step (4) Casting experiment: Select the A356 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data.

[0088] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0089] Step (6) Use the solidification temperature curve from step 5, and use commercial casting simulation software and the convection model to calculate the Nusselt number Nu based on the model to calculate the heat transfer coefficient.

[0090] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0091] Example 8

[0092] A modular combination device and method for rapidly acquiring data on the heat transfer coefficient of cast aluminum alloys include the following steps:

[0093] Step (1) Design the device according to the all-metal gravity casting process: The device size is 240 mm × 240 mm × 360 mm. Figure 1 The metal modules 1 and 2 in section a measure 160 mm × 160 mm × 50 mm and consist of three parts: H13 steel, T8 steel, and 55 steel. The insulation layer is made of 4 mm thick insulating zirconia foam ceramic, machined into an I-shape, and combined with the test materials using high-temperature adhesive. Figure 1In module a, modules 3 and 4 are not partitioned and use T2 copper with a thickness of 50 mm. Figure 1 The 5-support contact module in section a is made of alumina foam ceramic. Figure 1 In section a, the quenching module 6 is made of T2 copper, and the rest is a cast cavity;

[0094] Step (2) Module I according to Figure 3 Arrange type K thermocouples;

[0095] Step (3) Based on the number of thermocouples in Step 2, use a general-purpose temperature acquisition instrument to collect temperature data;

[0096] Step (4) Casting experiment: Select the A380 aluminum alloy required for production, melt and pour it into the cavity of the temperature measuring device to prepare for collecting temperature data.

[0097] Step (5) Based on the data collected in step 4, plot the solidification temperature curve and calculate the heat transfer coefficient using the back calculation module provided by commercial software.

[0098] Step (6) Use the solidification temperature curve from step 5, and use commercial casting simulation software and the convection model to calculate the Nusselt number Nu based on the model to calculate the heat transfer coefficient.

[0099] Step (7) can further verify the back-calculation results in step 6 with the experimental data. If they are inconsistent, adjust the empirical formula parameters or adjust the numerical calculation process.

[0100] This invention constructs a test module based on the materials used in the mold cavity, core, and chiller. Each test material is separated by insulating foam ceramic, avoiding temperature errors caused by heat conduction between materials. Simultaneously, it collects solidification temperature curves within various solidification temperature ranges under different environments and uses a general heat transfer coefficient back-calculation module to obtain the heat transfer coefficients for multiple materials and environments. This invention differs from heat transfer coefficient measurement methods specific to particular casting process environments; instead, it is a modular, integrated approach that combines multiple casting environments and can be flexibly adjusted according to the corresponding environment, simultaneously obtaining heat transfer coefficients under various conditions. Furthermore, the integrated environment shortens the heat transfer coefficient measurement time and improves work efficiency. This invention does not involve the emission of waste gas or wastewater and will not pollute the environment.

[0101] It should be noted that the embodiments described in this invention are only used to illustrate the technical solutions of this invention, and are not intended to limit the scope of protection of this invention. Although this invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this invention without departing from the essence and scope of the technical solutions of this invention.

Claims

1. A method for rapid data acquisition using a modular combined measuring device for the heat transfer coefficient of cast aluminum alloys, characterized in that: The modular combination measuring device for measuring the heat transfer coefficient of cast aluminum alloy comprises four parts: a metal / non-metal module I, a metal / non-metal module II of another size, a support contact module, and a quenching module, with the remainder being the casting cavity; Each module is determined according to the casting environment. Each module can be replaced according to the materials used in the cavity and core. The module is not a homogeneous whole, but is composed of a combination of multiple materials. The module can be divided into several areas according to the materials used, and the areas are separated by an insulation layer. The insulation layer is made of heat-insulating zirconia or alumina foam ceramic material, with a single layer thickness of 5%-10% of the module thickness. The insulation layer is I-shaped and is combined with each part of the test material using high-temperature adhesive to ensure stable bonding between the parts and prevent melt leakage. Each module contains a temperature sensor, and wired or wireless sensors can be used to obtain the temperature curve as needed. The cooling module is made of a single material and can be equipped with 1-2 temperature sensors. The method for rapid data acquisition of the modular combined measuring device for measuring the heat transfer coefficient of cast aluminum alloys includes the following steps: Step 1: Arrange the temperature sensors of the measuring device according to their positions. Specifically, the temperature sensors should be evenly distributed in the thickness direction and in the middle of the width direction of each area to be measured. The number of thermocouples can also be adjusted according to the actual situation, but the spacing should be uniform. Step 2: Based on the number of temperature sensors in Step 1, collect temperature data using a general-purpose temperature acquisition instrument; Step 3: Conduct casting experiment: Select the aluminum alloy required for production, melt it and pour it into the cavity of the temperature measuring device to prepare for temperature data collection; Step 4: Based on the data collected in Step 3, plot the solidification temperature curve and calculate the heat transfer coefficient using the back-calculation module provided by the commercial software. Step 5: Using the solidification temperature curve from Step 4, and employing commercial casting simulation software, based on the convection model and its corresponding empirical formula Nu=0.023×Re 0.8 Pr 0.4 Nu, Re, and Pr are the Nusselt number, Reynolds number, and Prandtl number, respectively, and the heat transfer coefficient is calculated. Step 6: Verify the back-calculation results from Step 5 with the experimental data. If they are inconsistent, adjust the parameters of the empirical formula or adjust the numerical calculation process.

2. The method for rapid data acquisition of the modular combined measuring device for the heat transfer coefficient of cast aluminum alloys according to claim 1, characterized in that: Simultaneously, solidification temperature curves within solidification temperature ranges under various environments can be obtained, enabling the acquisition of multiple heat transfer coefficients at the same time.

3. The method for rapid data acquisition of the modular combined measuring device for the heat transfer coefficient of cast aluminum alloys according to claim 1, characterized in that: It adopts a modular design, integrates multiple casting environments, and can be flexibly adjusted according to the corresponding environment, while obtaining heat transfer coefficients under various environments.

4. The method for rapid data acquisition of the modular combined measuring device for the heat transfer coefficient of cast aluminum alloys according to claim 1, characterized in that: A modular approach is adopted, and high-temperature adhesive is used to combine each part of the test material.

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