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<p>This study investigates the influence of five casting parameters and four die types (Gr1-Gr4) on the copper tubes produced by UPCAST process using a central composite design (CCD) of experiments. The results reveal that die selection is the most critical factor impacting casting quality and mechanical properties of copper tubes. The properties of graphite die strongly influence heat transfer and the mechanical integrity of copper tubes produced by the UPCAST process; however, the combined effects of die roughness, anisotropy, interplanar spacing, and thermophysical properties have not been quantitatively evaluated within a comprehensive experimental framework. In this study, the Gr3 die demonstrated superior performance, achieving the highest tensile strength (185-190&#xa0;MPa), the most favorable solidification front position, and the greatest reliability (Weibull modulus <i>λ</i> = 94). Internal roughness and thermal conductivity were identified as the main contributors to heat transfer efficiency and mechanical performance. In contrast, Gr1 and Gr2 exhibited higher sensitivity to process parameters, lower thermal conductivity, and reduced wear resistance, partly due to structural impurities and greater anisotropy. Overall, dies with optimal internal roughness, high isotropy, and suitable interplanar spacing—exemplified by Gr3—provide superior casting stability and product quality, offering a clear pathway for improving UPCAST process performance.</p>

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Effects of Graphite Die Characteristics on Heat Transfer and Mechanical Properties of Copper Tubes Produced in UPCAST Process

  • 期刊论文

  • 发表日期：

    2026年2月5日

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  • Arsalan Nazari,
  • Ramin Raiszadeh,
  • Diba Javidi,
  • Hamid Payandeh,
  • Mohammad Mehdi Khaleghian,
  • Mohsen Saffari Pour

摘要

This study investigates the influence of five casting parameters and four die types (Gr1-Gr4) on the copper tubes produced by UPCAST process using a central composite design (CCD) of experiments. The results reveal that die selection is the most critical factor impacting casting quality and mechanical properties of copper tubes. The properties of graphite die strongly influence heat transfer and the mechanical integrity of copper tubes produced by the UPCAST process; however, the combined effects of die roughness, anisotropy, interplanar spacing, and thermophysical properties have not been quantitatively evaluated within a comprehensive experimental framework. In this study, the Gr3 die demonstrated superior performance, achieving the highest tensile strength (185-190 MPa), the most favorable solidification front position, and the greatest reliability (Weibull modulus λ = 94). Internal roughness and thermal conductivity were identified as the main contributors to heat transfer efficiency and mechanical performance. In contrast, Gr1 and Gr2 exhibited higher sensitivity to process parameters, lower thermal conductivity, and reduced wear resistance, partly due to structural impurities and greater anisotropy. Overall, dies with optimal internal roughness, high isotropy, and suitable interplanar spacing—exemplified by Gr3—provide superior casting stability and product quality, offering a clear pathway for improving UPCAST process performance.