Simulation and implementation of a Jet Cooling system

High Pressure Die Casting (HPDC) is a fundamental manufacturing process for the high-volume production of lightweight alloy components characterized by complex geometries and high dimensional precision. This thesis aims to optimize this process, with a particular focus on the critical role of Jet Cooling, which is implemented and analyzed through numerical simulation. The research begins with an in-depth analysis of the aluminum die-casting process, focusing on typical defects, particularly shrinkage porosity. The main objective is the qualitative evaluation of the Interfacial Heat Transfer Coefficient (IHTC) between the molten metal and the die, with a specific focus on the core pin where the Jet Cooling is applied. The accurate definition of these IHTC values is essential for increasing the precision of simulations and improving defect prediction. Initially, simplified models were developed to represent only the core pin in- tegrated with the Jet Cooling system and the surrounding affected volume. To support this, the system’s operating conditions were defined and a Hot Disk analy- sis was conducted to determine the thermophysical properties of the alloy. Once outputs consistent with real-world operating conditions were obtained, the IHTC values were implemented in the casting simulation of a real industrial component. Finally, the simulation results were validated through X-ray inspection, com- paring the quality of the part with and without the application of Jet Cooling to quantify the system’s benefits in defect reduction. The IHTC values and simulation methodologies identified in this study represent a significant contribution to the future optimization of the HPDC process.