Date of Award


Degree Type


Degree Name

Master of Science in Mechanical Engineering (MSME)


Mechanical Engineering

First Advisor

Amy M. Marconnet

Second Advisor

Matthew J. Krane

Committee Chair

Amy M. Marconnet

Committee Co-Chair

Matthew J. Krane

Committee Member 1

Ilias Bilionis


High pressure die casting (HPDC) is a famous manufacturing technology in industry. This manufacturing process is simulated by commercial code to shed the light on the quality of casting product. The casting product quality might be affected by the uncertainty in the simulation parameter settings. Thus, the uncertainty quantification on HPDC process is significant to improve the casting quality and the manufacturing efficiency.

In this work, three uncertainty quantifications and sensitivity analyses on the A380 aluminum alloy HPDC process of intermediate speed plate are performed. The material thermophysical properties, boundary conditions of the model, and operational as well as artificial parameters with their uncertainties, are considered as the inputs of interest. Uncertainty quantification and sensitivity analyses are investigated for the outputs of interest including percent volume of porosity result, percent volume of fraction solid less than 1, and the percent volume that solidified during multiple solidification times. The most influential input parameter for predicting the outputs of interest is the boundary condition of metal-die interfacial air gap.