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Multi-Phase Flow and Heat Transfer Processes in Thermal Engineering and...
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Multi-Phase Flow and Heat Transfer Processes in Thermal Engineering and Technology

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Energy Systems".

Deadline for manuscript submissions: 31 October 2026 | Viewed by 1733

Special Issue Editor

Prof. Dr. Ziad Saghir

E-Mail Website
Guest Editor
Department of Mechanical and Industrial Engineering, Toronto Metropolitan University, Toronto, ON M5B 2K3, Canada
Interests: computational fluid dynamics; material science; flow in porous media; biomedical engineering; thermofluid; phase change materials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue aims to cover a wide range of research in the fields of thermal engineering and technology, which may include heat and mass transfer and fluid flow, new energy materials, waste-to-energy conversion, energy storage technologies, energy management, and thermal engineering in environmental sustainability. Contributions can be experimental, numerical, or both.

The 16th International Conference on Thermal Engineering (ICTEA, www.ictea.ca) is to be held in Bucharest, Romania, 18–20 June 2025. This conference covers significant topics related to this Special Issue. Papers attracting the most interest at the conference, or those that provide novel contributions, will be selected for publication in this Special Issue of Processes. These papers will be peer-reviewed to validate their research results, developments, and applications.

Prof. Dr. Ziad Saghir
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • thermal engineering
  • heat transfer
  • multi-phase flow
  • energy conversion
  • environmental engineering

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (3 papers)

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Research

18 pages, 2743 KB  
Article
Axial Solidification Experiments to Mimic Net-Shaped Castings of Aluminum Alloys—Interfacial Heat-Transfer Coefficient and Thermal Diffusivity
by Ravi Peri, Ahmed M. Teamah, Xiaochun Zeng, Mohamed S. Hamed and Sumanth Shankar
Processes 2026, 14(1), 128; https://doi.org/10.3390/pr14010128 - 30 Dec 2025
Viewed by 250
Abstract
Net-shaped casting processes in the automotive industry have proved to be difficult to simulate due to the complexities of the interactions amongst thermal, fluid, and solute transport regimes in the solidifying domain, along with the interface. The existing casting simulation software lacks the [...] Read more.
Net-shaped casting processes in the automotive industry have proved to be difficult to simulate due to the complexities of the interactions amongst thermal, fluid, and solute transport regimes in the solidifying domain, along with the interface. The existing casting simulation software lacks the necessary real-time estimation of thermophysical properties (thermal diffusivity and thermal conductivity) and the interfacial heat-transfer coefficient (IHTC) to evaluate the thermal resistances in a casting process and solve the temperature in the solidifying domain. To address these shortcomings, an axial directional solidification experiment setup was developed to map the thermal data as the melt solidifies unidirectionally from the chill surface under unsteady-state conditions. A Dilute Eutectic Cast Aluminum (DECA) alloy, Al-5Zn-1Mg-1.2Fe-0.07Ti, Eutectic Cast Aluminum (ECA) alloys (A365 and A383), and pure Al (P0303) were used to demonstrate the validity of the experiments to evaluate the thermal diffusivity (α) of both the solid and liquid phases of the solidifying metal using an inverse heat-transfer analysis (IHTA). The thermal diffusivity varied from 0.2 to 1.9 cm2/s while the IHTC changed from 9500 to 200 W/m2K for different alloys in the solid and liquid phases. The heat flux was estimated from the chill side with transient temperature distributions estimated from IHTA for either side of the mold–metal interface as an input to compute the interfacial heat-transfer coefficient (IHTC). The results demonstrate the reliability of the axial solidification experiment apparatus in accurately providing input to the casting simulation software and aid in reproducing casting numerical simulation models efficiently. Full article
(This article belongs to the Special Issue Multi-Phase Flow and Heat Transfer Processes in Thermal Engineering and Technology)
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26 pages, 5802 KB  
Article
Estimation of Thermophysical Properties as Functions of Temperature in Rapid Radial Solidification of Metallic Alloys
by Remon Basily, Ahmed M. Teamah, Mohamed S. Hamed and Sumanth Shankar
Processes 2025, 13(12), 3939; https://doi.org/10.3390/pr13123939 - 5 Dec 2025
Cited by 1 | Viewed by 441
Abstract
Recent global efforts to produce lightweight electrified vehicles have motivated the push toward advanced lightweight materials which led to the creation of novel alloys optimized for use in high-pressure die casting (HPDC). HPDC enables the fabrication of near-net-shape automotive parts, significantly reducing or [...] Read more.
Recent global efforts to produce lightweight electrified vehicles have motivated the push toward advanced lightweight materials which led to the creation of novel alloys optimized for use in high-pressure die casting (HPDC). HPDC enables the fabrication of near-net-shape automotive parts, significantly reducing or eliminating additional machining steps. A key feature of HPDC is the extremely fast cooling that forces the alloy to solidify within only a few seconds. Because of these rapid cooling conditions, it becomes essential to accurately evaluate the thermophysical behavior of newly designed lightweight alloys during severe quenching. Precisely quantifying these material properties is crucial for properly controlling HPDC operations and for building reliable numerical models that simulate filling and solidification. The thermophysical characteristics of such alloys vary markedly with temperature, especially when the material undergoes the fast solidification typical of HPDC. Therefore, understanding how these properties change with temperature during intense cooling becomes a critical requirement in alloy development. To address this need, a dedicated experimental system was designed to solidify molten metal samples under controlled and variable cooling conditions by applying multiple impinging water jets. An inverse heat-transfer algorithm was formulated to extract temperature-dependent thermal conductivity and diffusivity of the alloy as it solidifies under rapid cooling. To verify the reliability of both the inverse model and the measurements, experiments were performed using pure Tin, a reference material with well-documented thermophysical properties. The computed thermophysical properties of Tin were benchmarked against values reported in the literature and demonstrated reasonable consistency, with a maximum deviation of 13.6%. Full article
(This article belongs to the Special Issue Multi-Phase Flow and Heat Transfer Processes in Thermal Engineering and Technology)
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21 pages, 2703 KB  
Article
Experimental and Numerical Replication of Thermal Conditions in High-Pressure Die-Casting Process
by Abdelfatah M. Teamah, Ahmed M. Teamah, Mohamed S. Hamed and Sumanth Shankar
Processes 2025, 13(12), 3815; https://doi.org/10.3390/pr13123815 - 25 Nov 2025
Cited by 1 | Viewed by 550
Abstract
Acquiring reliable thermal data during the high-pressure die-casting (HPDC) process remains a significant challenge due to its complexity and rapidly evolving thermal environment. In industrial settings, the influence of process parameters is typically evaluated after solidification by examining the final casting quality, as [...] Read more.
Acquiring reliable thermal data during the high-pressure die-casting (HPDC) process remains a significant challenge due to its complexity and rapidly evolving thermal environment. In industrial settings, the influence of process parameters is typically evaluated after solidification by examining the final casting quality, as direct temperature measurements within the die during operation are difficult to obtain. Additionally, most casting simulation tools lack accurate correlations for the interfacial heat transfer coefficient (IHTC) as a function of process parameters. To address this limitation, a laboratory-scale hot chamber die-casting (HCDC) apparatus was developed to replicate the fluid flow and the thermal conditions of industrial HPDC operation while enabling direct thermal measurements inside the die cavity using embedded thermocouples. The molten metal temperature was estimated using the lumped capacitance method, and the IHTC was determined through a custom inverse heat conduction algorithm incorporating an adaptive forward time-stepping scheme. This algorithm was validated by solving the forward heat conduction problem using the ANSYS 2025 R1 Transient Thermal solver. The experimentally obtained IHTC values showed good agreement with those measured during industrial HPDC trials, with a maximum deviation of about 14% in the peak value, while the full width at half maximum (FWHM) differed by less than 12%. These results confirm that the developed HCDC setup can reliably reproduce industrial thermal conditions and generate high-quality thermal data that can be used in numerical casting simulations. Full article
(This article belongs to the Special Issue Multi-Phase Flow and Heat Transfer Processes in Thermal Engineering and Technology)
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