• 한국주조공학회지
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• 제26권6호
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• pp.241-248
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• 2006

The effects of silicon content and melt treatment on the fluidity of Al-Si alloys during squeeze casting were investigated. The fluidity of Al-3.0 wt%Si alloy was found to be lower than that of Al-1.0 wt%Si and the fluidity of the alloy with more than 3.0 wt%Si increased with the silicon content upto 13.0 wt% and rather decreased with15.0 wt%. The fluidity was also increased by the separated treatment of grain refinement or eutectic modification, and even more by the simultaneous treatment of both. The fluidity of hypereutectic alloy was increased by the refinement of primary silicon particle.

• 한국주조공학회지
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• 제20권5호
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• pp.344-353
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• 2000

In order to find out the casting conditions of the thin wall stainless steel exhaust manifold for automobile, the melt flow and solidification behavior simulated by the Z-CAST program were evaluated, and experimental casting result on the test casting and exhaust manifold of SSC13 alloy were investigated. From the results of this study, it was shown that the calculated results on fluid flow were in good agreement with practical thin wall test castings under the same casting conditions, as pouring metal is austenitic stainless steel(SSC13) and pouring temperature is 1575, 1630, and $1665^{\circ}C$ respectively. That calculated result with designed thin wall exhaust manifold was predicted filling up into the mold cavity, and practical casting was sound. The solidification simulation was predicted shrinkages at the bosses for original exhaust manifold, and designed it without bosses was predicted no defect. Therefore practical exhaust manifold casting was sound and in good agreement with calculated solidification results.

• 한국주조공학회지
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• 제26권3호
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• pp.133-139
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• 2006

The effects of applied pressure, superheat and silicon content on the fluidity of Al-Si alloy during squeeze casting were investigated. The Fluidity of Al-7.0wt%Si alloy during squeeze casting was increased with applied pressure up to 60 MPa, meanwhile it rather decreased beyond that. Therefore, the optimum squeeze casting pressure was 60 MPa. The fluidity was increased with superheat up to $150^{\circ}C$. On the other hand, it rather decreased at the superheat of $200^{\circ}C$. The fluidity of Al-Si alloy during squeeze casting was decreased with silicon content in the range of $0.0{\sim}3.0\;wt%$, increased in the range of $3.0{\sim}13.0\;wt%$. The fluidity of Al-15.0 wt%Si alloy was lower than that of Al-13.0 wt%Si alloy.

• 한국주조공학회지
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• 제16권6호
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• pp.565-575
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• 1996

In this study, to gain the semi-solid alloy we employed the electromagnetic rotation by a induction motor of 3-phases and 2-poles for Al-7wt%Si alloy and observed the size of primary solid particle, distribution state of primary solid particle, the degree of sphericity, and fraction of primary solid for the evaluation of its results. The size of primary solid particle increases from $98{\mu}m$ to $118{\mu}m$ as solid fraction increases from 0.2 to 0.5. The degree of sphericity increased as the solid fraction increased. Solid particles obtained from the microstructures of isothermally held sample were coarsened and the degree of sphericity was enhanced as isothermal holding time increased. However, when the sample was stirred for more than 40min, solid particles merged together and liquid phase was entrapped within the cluster of solid particles. The size of primary solid particle was not changed significantly with the variation of input voltages by 160V over which solid particles began to merge together to be a large cluster of about $170{\mu}m$ at 180V. The standard deviation and the degree of sphericity were not changed significantly with the variation of input voltage.

• 한국전산유체공학회지
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• 제2권1호
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• pp.117-128
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• 1997

Effects of dam and weir on the fluid flow and behavior of inclusions in the continuous casting tundish have been studied using the CFD (Computational Fluid Dynamics) technique. Inclusions affecting the quality of steel products have been considered to be passive: the fluid flow has been obtained for unstaggered grid points defined on body-fitted generalized cuvilinear coordinates with no attention on inclusions, and the spatial propagation of inclusions has been determined by using the flow field data. The result show that the dam and weir direct the flow to the free surface and increase the residence time of inclusions significantly, and thereby that inclusions have much more chance to be floated to the free surface of the tundish where it is eliminated. It is also found that they offer more margin on the geometric design of exit nozzles connected to moulds. This finding is particularly important for twin casting operations where the quality of steel products from the two moulds be kept uniformly.

• 대한기계학회논문집B
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• 제26권5호
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• pp.648-657
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• 2002

This paper presents a numerical analysis on the solidification characteristics in twin-roll strip casting. Unstructured fixed-grid system was employed to deal with phase change. Melting of pure gallium was analyzed to confirm the validity of present program in both structured and unstructured grid systems. An algorithm for simultaneous calculation of the temperature in the roll and the molten metal pool was developed. The flow field in the pool and heat transfer features between pool and roll were shown. The effect of process parameters was also studied. Since the geometry of the molten metal Pool significantly deforms along the casting direction, unstructured grid system is more efficient. The unstructured grid system gives almost the same accuracy, even though the number of grids is only 60% of the structure done.

• 한국주조공학회지
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• 제24권3호
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• pp.138-144
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• 2004

Effects of alloying elements such as Si, Mn, Zn on the fluidity and mechanical properties of high ductility Al-Mg based alloys were investigated. The fluidity of alloys was evaluated using a vacuum suction fluidity test, and Si addition was observed to increase the fluidity of AI-Mg binary alloys substantially while Zn somewhat decreased the fluidity. However, both the strength and ductility were significantly deteriorated by the Si additions. It was observed that a small amount of Mn addition to Al-Mg alloy increased the tensile strength effectively without losing much ductility but the effect of Zn addition on the strength was relatively small.

• 한국주조공학회지
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• 제33권5호
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• pp.204-209
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• 2013

The family mold casting have advantages which are able to make products with different shapes and dimensions simultaneously in a single mold. In this study, the design of the 4 cavity rotor family mold was used by "Anycasting" software, the defects occurred during die casting were predicted and suggested the best optimization conditions for sound products. The result of the experiment were that the optimum overflow design was needed for gas emission and control of residual oxides. It was clear that the defects positions formed by diecasting were agreed with nearly them predicted by simulation.

• 한국주조공학회지
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• 제36권6호
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• pp.208-214
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• 2016

Casting defects, which are closely related to entrapped air bubbles and metallic oxides, occur very frequently in the casting process. Many researchers have shown that these defects can be reduced by adopting an appropriate gating system design. But, it is difficult for field engineers to identify a specific gating system that is more appropriate for their products. In this study, we tried to draw a comparison of gating system designs with and without ceramic foam filters. A ceramic foam filter was added to the horizontal runner just after the sprue to prevent air bubble generation and to reduce turbulence without change of the gating system design. To verify the effects of initial pouring velocity, the experiment was conducted with four different amounts of water volume in the reservoir. Results of the water modeling experiment applying the filter showed remarkably changed flow characteristics. Although the study confirmed that use of the filter may change the flow characteristics, it needs to be noted that only filter use alone cannot solve all the problems caused by a poorly designed gating system.

• 한국주조공학회지
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• 제25권6호
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• pp.240-248
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• 2005

The rheocasting characteristics are strongly influenced by the microstructural morphology such as particle size, form factor and contiguity. In this study, the effect of structural morphology on fluid flow characteristics of A356 semi-solid alloy was investigated with a vacuum suction fluidity test. Semi-solid metal slurry was made by the mechanical stirring, the liquidus casting, and H-NCM to be analysed. H-NCM could obtain uniform and fine globular microstructures of 0.9 form factor and 55 ${\mu}m$ particle size. Inoculation was found to be effective for reducing particle size, however, for H-NCM it should be avoided due to the cause of increasing contiguity. The fluidity test indicated that the non-stirring method had higher fluidity and smaller liquid segregation in the same solid faction of 0.4 than the stirring method, for smaller particle size and higher form factor. It was observed that liquid segregation decreased as the particle size is smaller and form factor is higher. The results of die-casting experiment were a good agreement with those of fluidity test.