As the simulation quality increases, the determination of hot spots is not enough to foundry engineers anymore. The simulation results have to fit in a quality way into the real foundry world. More and more results of the simulation will be used to optimise the casting process. Here it is necessary to have a very precise knowledge of the physical data. as well as the description of the geometry. To make use of the simulation in especially the magnesium-casting development it is necessary to work with precise geometrical, physical and numerical models. In this paper we describe the development of physical data concerning the heat transfer during filling and solidification by different casting methods. The low pressure as well as the gravity die casting method are used to get real data to find out the right conditions in the simulation in order to simulate the real behaviour during production. Practical tests are done under different test conditions to develop the right physical data as well as the right conditions in the metal-mould interface. The different surface conditions and the influence of the die and the molten metal temperatures are important for the layout of the die casting process. Three different shapes were applied to different mould materials and casting methods. The cooling conditions are tested on specific items. The cooling shape is not restricted by the drilling conditions. The effect of different cooling conditions are generated and measured. The results form the basis for the heat transfer conditions. These results are applied to real castings, cellular phone housings by low-pressure die casting process. The use of the new conditions leads to a good process description.