• KEPCO Journal on Electric Power and Energy
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• v.5 no.2
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• pp.93-101
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• 2019

The mechanical properties and microstructure of 1st stage used and casted buckets of $1,100^{\circ}C$ class gas turbine were analyzed to evaluate quality of the components. Gas turbine 1st stage buckets are exposed and operated in the most severe environment except 1st nozzle among the hot path gas components. Additionally, since the 1st stage bucket is a rotating component, so it may cause additional damage to the rear buckets and nozzles which cause a huge financial loss. Therefore, the quality of the casted bucket must be evaluated prior to use at the plant site. In this study, the microstructure analysis and mechanical properties of the casted bucket were evaluated to verify the casting quality and it was confirmed that the quality conditions designed by KEPCO were satisfied. A bucket operated 46% (11,067EOH) of its life time also evaluated for quality comparison.

• Journal of Korea Foundry Society
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• v.41 no.1
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• pp.3-10
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• 2021

In the compound casting between the aluminum alloy and the cast iron, the iron component may be dissolved from the cast iron during the process and mixed into the aluminum melt, thereby forming various iron-containing intermetallic compounds and significantly deteriorating the tensile properties of the aluminum alloy. On the other hand, unlike Fe, which is added as an impurity, Cu is added to improve the mechanical properties of the aluminum alloy. In this study, the change in microstructure and tensile properties of aluminum alloys due to the addition of Fe and Cu was investigated. A large amount of iron-containing compounds such as coarse Al₅FeSi phases were formed when the iron content was 1% or more, and the tensile properties were significantly reduced. In the case of the aluminum alloy to which Cu was added, an Al₂Cu phase was additionally formed and the tensile strength was clearly improved.

• Journal of Korea Foundry Society
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• v.43 no.3
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• pp.107-136
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• 2023

Natural silica sand was commonly used for sand casting of cast steel products, and chromites sand was used to suppress seizure defects due to the lack of thermal properties of silica sand. However there are disadvantages such as deterioration by repeated use, system sand mixing problem, difficulty separating and removing, increased during mold according to high density and to being waste containing chrome. Recently, industrial waste reduction and atmospheric environment improvement have been highlighted as important tasks in the casting industry. In order to solve the problems that occur when using foundry Sand and to improve the environment of casting factories, various artificial sands that can be applied instead of natural silica sand have been developed and introduced. Artificial sands can be classified into artificial sand manufactured by the electric arc atomization or gas flame atomization, artificial sand manufactured by the spray drying & sintering process, artificial sand manufactured by the sintering & crushing process and exhibit different physical properties depending on the type of raw-minerals and manufacturing method. In this study, comparative evaluation tests were conducted on the physical properties of various foundry sands, mold strength, physical durability, thermal durability, and casting test pieces. When comprehensively considering the actual amount of molding sand used according to density, the mold strength according to the shape of sand, the physical and thermal durability of foundry sand, and the heat resistance characteristics of foundry sand, 'Molten artificial sand A1' or 'Molten artificial sand B' is judged to be the most suitable spherical artificial sand for casting of heavy steel castings.

• Journal of Korea Foundry Society
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• v.41 no.3
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• pp.252-259
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• 2021

The magnesium is one of the important alloying elements in the conventional aluminum alloys. The addition of magnesium to aluminum is well known to increase the mechanical strength of the aluminum without the trade-off of the decreased elongation. However, the content of magnesium in aluminum alloys has been limited to be lower than about 5wt.% because of the high oxidation tendency of magnesium element during the manufacturing processes such as casting, hot-forming and post heat-treatments, which can deteriorate the quality and properties of the final products. In this study, new 'ECO-Almag6~9' (containing 6~9wt%Mg) alloys were investigated to be made of the ECO-Mg master alloy, which has been invented to reduce the oxidation tendency of itself. It was successfully demonstrated that ECO-Almag6~9 alloys can be fabricated through the mass-production facilities of DC casting and extrusion routes without the problems of magnesium oxidation. In addition, it was confirmed that the strength and ductility were simultaneously improved due to the addition of high magnesium contents.

• Journal of Korea Foundry Society
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• v.12 no.4
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• pp.326-334
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• 1992

Particle-reinforced metal matrix composites via the Osprey spray casting process were fabricated by injecting second phase particles of $Al_2O_3$(＜$40{\mu}m$) and W($6{\mu}m$) into the spray of Cu droplets, and the thermal behaviors of the composite droplets during flight were considered theoretically on the basis of mixing modes between the Cu droplets and the reinforced particulates injected. It was found that the W-injected spray is comprised of particle-embedded droplets, and the $Al_2O_3-injected$ spray comprises particle-attached droplets. From the predicted results of the thermal behaviors of the composite droplets and preforms produced, it is concluded that the thermal behaviors of the composite droplets during flight, and during the subsequent deposition are strongly influenced by its mixing modes between the reinforced particulates and Cu droplets during flight.

• Journal of Surface Science and Engineering
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• v.42 no.6
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• pp.260-266
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• 2009

The anodic oxidation behaviour of a cast component of AC2A Al alloy with machined surface and ascast surface was investigated in sulfuric acid solution. The anodized specimen showed relatively uniform and thick anodic oxide films on the as-cast surface, while non-uniform and very thin oxide films were formed on the machined surface. Non-anodized as-cast surface was observed to be covered with thick oxide scales and showed a number of second-phase particles containing Si, while non-anodized machined surface showed no oxide scales and relatively very small number of Si particles. Thus, the very limited growth of anodic oxide films on the as-cast surface was attributed to the presence of thick oxide scales and Si-containing second-phase particles on its surface.

• Journal of Korea Foundry Society
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• v.38 no.3
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• pp.55-59
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• 2018

To optimize the conductivity and to reduce the weight by as much as possible, Al-Cu composites were prepared through a suction-casting procedure. Pure copper metal foam was infiltrated by melted aluminum with the use of the vacuum, after which warm rolling was conducted to remove several remaining pores at the interface between the Cu foam and the aluminum matrix. Despite the short casting time, significant dissolution of Cu into the melt was observed. Moreover, it was found that various Al-Cu intermetallic compounds arose at the interface during the isothermal heating process after the casting and rolling steps. The average thickness of the Al-Cu intermetallic compound tended to increase in proportion to the heating time. The electrical and thermal conductivity levels of the cast composites were found to be comparatively low, mainly due to the dissolution of the Cu foam and the formation of intermetallics at the interface.

• Journal of Korea Foundry Society
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• v.20 no.6
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• pp.400-406
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• 2000

Computer simulation for the predictions of casting defects is very important to produce high quality castings with less cost. Complicate shaped Al solenoid housing part was selected to be cold chamber die cast and a numerical simulation technique was applied for the optimization of the chill vent position and gating. A first design led to insufficient central flow. This flow left the last filled areas falling into the inner portion of the part. And last filled area did not fit the chill vent position. So these resulted in a high possibility of air entrapment in the casting and the design was not proper for the part. The design was improved by using a proper gating system, a more chill vent and proper overflow positions. New design provided a homogenous mold filling pattern and the last filled areas that being located at the overflow and chill vent. Casting plan which produce good quality solenoid housing part was established by using the computer simulation.

• Journal of Korea Foundry Society
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• v.36 no.1
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• pp.10-17
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• 2016

Numerical analysis has been performed to evaluate effect of the shape variables such as core length, slot width and slot length on misrun in aluminum die casting process for motor rotor. The predictive method for misrun in diecasting process was established by comparing the result of numerical analysis and an actual motor rotor. Solidification modulus was introduced to predict quantitatively the castability of aluminum diecasting process for motor rotor. It was found that there are minimum critical solidification modulus and slot width to prevent misrun according to core length through diecasting limit diagram proposed using the predictive method. The critical solidification modulus and slot width increase as core length increases to prevent misrun of aluminum motor rotor in diecasting process. Based on the results, the design criteria of slot shape to prevent misrun of aluminum motor rotor with various core length were established.

• Journal of Korea Foundry Society
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• v.28 no.5
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• pp.237-241
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• 2008

This study has been carried out to investigate the wear and heat resistant properties of durable moldwash agent for Al gravity casting according to mold washing process conditions. The wear properties of coated specimen were performed by sliding wear testing machine and heat resistance were evaluated by measuring the loss of coated moldwash agent during emerging of coated specimen in Al melts. During testing, experimental variables were mold surface temperature, moldwash agent/distilled wear, and additive concentrations. The lower additive concentration and mold temperature caused the smooth surface roughness of coated specimen, It was found that the specimen coated with moldwash/water ratio 1:3, additive concentration 9wt% and mold temperature higher than $200^{\circ}C$ showed superior wear and heat treatment. Also, these results were supported by fluidity test.