In this paper, we present the results of our studies on optimal die design towards development of a vacuum die casting process to fabricate fuel cell bipolar plate with micro-channel array. Cavity and overflow shape is designed by computational filling analysis of MAGMA soft. Optimal die design consists of seven overflows at the end of cavity and three overflows at each side wall of cavity. The molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and velocity distribution were uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. When vacuum pressure, injection speed of low and high region was 300 mbar, 0.3 m/s and 2.5 m/s respectively with Silafont 36 die casting alloy, sound sample without casting defects was obtained. The experimental results are nearly consistent with simulation results.

In this study, we are aimed to prevent grain growth of semi-solid AZ31 magnesium alloys during reheating process. The semi-solid AZ31+(Ca) billets were investigated by using metallographic analysis, X-ray diffraction, scanning electron microscopy and energy dispersive spectroscopy in order to elucidate the effect of Ca addition during reheating process. The grain growth of semi-solid AZ31+(Ca) billet was reduced with increasing Ca content during reheating. The grain size of AZ31+(Ca) billet decreased with increasing volume fraction of Al2Ca particles. The grain growth rate constant K calculated by Oswald ripening LSW theory in AZ31+1.5wt.% Ca billet was the lowest 129.

The effects of section size and melt holding time on the mechanical properties and microstructure of high silicon ductile cast iron were investigated. The strength, elongation and hardness of the test specimen with smaller cross-section were higher than those with larger one. The nodule count and volume fraction of pearlite of the former were higher than those of the latter. The mechanical properties decreased with increased melt holding time before pouring. Nodularity and nodule count decreased and the volume fraction of pearlite rather slightly increased with it.

Aluminium-silicon based casting alloys have received an attention for high electrical and thermal conductivity applications, however relatively low conductivity of Al-Si alloys often limits the application. Efforts have been made to develop new high conductivity aluminium casting alloys containing no or less silicon. In this study Al-Zn-Fe based alloys were selected as the new alloys, and the effect of Mg additions on their properties and casting characteristics were investigated. As the magnesium content was increased, the tensile strength of Al-2Zn-0.2Fe based alloy was remarkably increased, while the electrical conductivity was deteriorated. It was observed that the fluidity of the alloys was generally inversely proportional to the Mg content but the hot cracking resistance was rather proportional to it. Cooling curve analyses were carried out to measure the actual solidification range and dendrite coherency temperature.

The effects of Bi and Sb additions on the microstructures and casting properties in lead-free Cu-Zn-Sn broze were investigated. (1) When only Bi was added to the bronze, Bi was precipitated on the ${\delta}$ phase of ${\alpha}$ dendrite cell boundary. When Bi and Sb were added together, Bi was precipitated on the ${\delta}_A$ which was the Sb-rich area in the ${\delta}$ phase. (2) The addition of Sb accelerated the formation of ${\delta}$ phase, and when Sb, Bi and Pb were added, Bi and Pb were precipitated as mixed solution in the ${\delta}_A$ phase. (3) The combined addition of Sb and Bi resulted in the suppression of shrinkage due to the complementary effects of the mass feeding of ${\alpha}$-dendrite cluster covered with ${\delta}$ phase and sealing of micro-shrinkage in the ${\delta}$ phase by solidification expansion of Bi.

Recently, development of Al-based alloys for high mechanical performance has been an important issue in automotive industry. The present study focused on the design of a high strength Al-based alloy for rheo-diecasting. The research was based on thermodynamic calculation and experimentals to optimize the alloy compositions. Two important considerations were carried out: i) to obtain uniform slurry with fine and globular microstructures for rheo-diecasting, ii) to be strengthend by T6 heat treatment. In order to evaluate the effect of Si content on the slurry microstructure and castability, thermodynamic calculation and fluidity test were carried out. The effects of various alloying components, such as Mg, Cu and Zn, on age hardenability were also investigated. The mechanical properties of the rheo-diecasting products using the newly developed alloy are 324MPa in tensile strength, 289MPa in yield strength, and 11.2% in elongation after T6 heat treatment.

The effect of heat treatment on mechanical properties of 0.4C-2.3Si(wt%) steel with bainitic ferrite matrix were investigated. This steel has been synthesized intergrating concepts from TRIP(Transformation Induced Plasticity) steel & Austempered Ductile Cast Iron(ADI) technology. The low alloy medium carbon (0.4 %C) steel with high silicon (2.3 %Si) was initially annealed for 60 min at $800^{\circ}C$, $820^{\circ}C$ and $840^{\circ}C$ respectively in the intercritical region and then subsequently austempered at various temperatures at $260^{\circ}C$, $320^{\circ}C$ and $380^{\circ}C$ for 30 min in a salt bath. The mechanical properties were measured by using a tensile test. A detailed study of the microstructure of this steel after heat treatment was carried out by means of electron back scattering diffraction (EBSD) technic. In this study, a new low alloy steel with high strength (780~1,050MPa) and exceptionally high ductility (20~40%) was obtained.