• Proceedings of the KSME Conference
• /
• 2007.05b
• /
• pp.2050-2054
• /
• 2007

This study numerically and experimentally investigated on thermal strain analysis of aluminum alloy casting mold using metal foundry. To predict the numerical result of thermal strain in Al alloy casting mold during the cooling process, it is performed the investigation of temperature distribution, stress and displacement based on the physical properties of Al alloy. In results of this study, Al alloy casting mold represented rapidly cooling graph during initial 20minutes after beginning cooling process, therefore value of stress and displacement is rapidly changed during initial 20minutes after beginning cooling process. In addition to, temperature distribution obtained by experiment confirmed corresponding pattern then compared numerical analysis with experiment. These results are distribute to make the effective and the high precision casting mold.

• Journal of Korea Foundry Society
• /
• v.22 no.2
• /
• pp.75-81
• /
• 2002

The main objectives were to investigate the suitability of CaO crucible for melting TiAl alloys and to develop investment mold for investment casting of TiAl alloys. TiAl alloy specimen were prepared by plasma arc furnace under argon atmosphere. After melting of TiAl alloy using CaO crucible, the results showed that there is little contamination of oxygen in the TiAl bulk. Conventional vacuum induction furnaces can be readily adaptable to produce cast parts of TiAl without high skilled techniques. The determination of optical metallography and microhardness profiles in investment cast TiAl alloy rods has allowed the gradation of the relative thermal stability of the oxides examined. The molds used for the present study were $ZrO_2$, $Al_2O_3$, CaO stabilized $ZrO_2$ and $ZrSiO_4$. Even although high temperature of mold preheating, $Al_2O_3$ mold is a promising mold material for investment casting of TiAl alloys in terms of thermal stability, cost and handling strength. It is important to take thermal stability and preheating temperature of mold into consideration for investment casting of TiAl alloys.

• Journal of Korea Foundry Society
• /
• v.13 no.6
• /
• pp.532-539
• /
• 1993

The effect of casting variables for making pure Al and Al-5wt%Si alloy rods free from any surface and inside defects was studied by adopting the horizontal continuous casting method with heated mold. The rods were cast under the casting conditions such as the mold temperature of $670{\sim}690^{\circ}C$, water flow rate of $0.2{\sim}0.6{\ell}/min$, and rod diameter of $4{\sim}8mm$, when the melt temperature and mold to cooler distance was fixed at $700^{\circ}C$ and 20mm, respectively. The results represented that the casting speed for good quality rod increased as the water flow rate increased, whereas, the casting speed decreased as the rod diameter or mold temperature increased. The statistical analysis of $2^3$ factorial design was also applied and the results represented that the averaged optimum casting speed for pure Al(302mm/min) was higher than that of Al-5wt%Si alloy(273mm/min) resulting from the difference of superheat applied. The effect of rod diameter on the optimum casting speed was the highest for pure Al as well as Al-5wt%Si alloy. The effect of water flow rate and mold temperature on the optimum casting speed was in decreasing order.

• Journal of Korea Foundry Society
• /
• v.36 no.5
• /
• pp.153-158
• /
• 2016

The lost foam casting process was used to fabricate Al-Si-Mg cast specimens, and the effects of the chemical composition and process variables on the tensile properties and the mold filling ability were investigated. Some porosity formation was observed in thick sections of the casting and better tensile properties were obtained for thin sections, presumably because of their lower porosity and the higher cooling rate. Tensile properties were not clearly enhanced by grain refining treatment with Ti; however, the elongation was significantly improved by Sr modification of the Al-Si-Mg alloy. The mold filling distance was generally proportional to the pouring temperature of the melt, and the distance was also increased by the addition of Ti.

• Journal of Korea Foundry Society
• /
• v.29 no.2
• /
• pp.78-85
• /
• 2009

Functionally graded microstructure of centrifugal cast Al-Si alloy, especially distribution of primary Si particles according to the changes of melt pouring temperature and rotation frequency was investigated by numerical simulation. Moving velocity of Si particles increased as the melt pouring temperature and rotational frequency of mold increased. Therefore, segregation tendency of primary Si particles toward inner side of cylindrical sample increased as the melt pouring temperature and rotational frequency of mold increased. Rich distribution region of particles was located at 0.9, 0.7, 0.4 mm from inner surface of cylindrical sample under the centrifugal cast condition of $750^{\circ}C$ melt pouring temperature and 1500, 2000 and 2500 rpm mold rotational frequencies, respectively, by numerical simulation.

• Journal of Korea Foundry Society
• /
• v.8 no.3
• /
• pp.271-281
• /
• 1988

Al-bronze has a good mechanical property, corrosion resistance and castability, so being highlighted for the new copper alloy. So, effects of alloy composition and cooling rate in the mechaincal properties and solidification behavior have been investigated. The results obtained are as follows; 1) Change in volume on solidification is larger in metal mold casting than in sand mold casting. And it decreases by the addition of Al. 2) The mechanical property in metal mold casting is superior to the one in sand mold casting, and the inclination is obvious up to 9% Al, after heat-treatment ($885^{\circ}C$, $1.5hrs\;{\rightarrow}\;W\;{\cdot}\;Q\;{\rightarrow}\;540^{\circ}C$, 3hrs) 3) By adding Al, the mechanical property is slightly increased up to 9% Al, Above 9% Al, it is increased rapidly, and is accelerated by adding Fe. 4) Cooling rate and hardness, and grain size and cooling rate are related as follows in the range of $1100^{\circ}C$ to $1200^{\circ}C$ pouring temperature. Grain size(${\mu}m$)=$929.6422{\times}cooling\;rate(^{\circ}C\;/\;sec)^{-0.51537}$ Hardness(BHN)=$765.45713{\times}grain\;size({\mu}m)^{-0.31058}$.

• Journal of Korea Foundry Society
• /
• v.23 no.1
• /
• pp.40-46
• /
• 2003

Semisolid forming requires alloys with non-dendritic microstructure of the thixotropy. Recently, low pouring temperture method without stirring, i.e. liquidus casting has been found out new fabrication method of the semisolid metals. Effects of melt superheat and mold conditions on the globulization of primary Al of $AlSi_7Mg$ alloy were investigated in gravity casting process without stirring. The microstructures of primary Al as function of melt superheat and mold temperature show globular, rosette and dendritic shapes. The conditions for globular microstructure of primary Al were low melt superheat < 35 K and low mold temperature < 500 K. The thermal conditions for globular microstructure of primary Al were undercooled melt at early solidification stages and slow cooling < 0.6 K/s. It was found that the initial microstructure was maintained throughout the solidification and the globules of primary Al can be obtained by high nucleation of fine and spherical nuclei due to enhanced undercooling of melt.

• Journal of Korea Foundry Society
• /
• v.35 no.2
• /
• pp.36-43
• /
• 2015

In this study, the influences of aluminum and tin additions (individual and combined) on corrosion behavior of magnesium alloy have been determined. The studied alloys were fabricated by permanent mold casting method to measure the corrosion properties, a potentiodynamic test, hydrogen evolution test and immersion test were carried out in a 3.5% NaCl solution at pH 7.2. From the results of microstructure analysis, the Mg-9Al-1Zn alloy was found to be composed of ${\alpha}$-Mg and rod-like $Mg_{17}Al_{12}$ phase and the Mg-5Sn-5Al-1Zn alloy was found to be composed of ${\alpha}$-Mg, rod-like $Mg_{17}Al_{12}$ and $Mg_2Sn$ phases. In the case of the Mg-9Sn-1Zn alloy, the microstructure was composed of ${\alpha}$-Mg and eutectic $Mg_2Sn$ phase. With Sn addition (individual and combined), the corrosion resistance of the Mg alloys improved.

• Journal of Korea Foundry Society
• /
• v.37 no.6
• /
• pp.186-192
• /
• 2017

The lost foam casting method was used to fabricate Al-Si alloy thin sheet specimens; the effects of chemical composition and process variables on the mold filling and mechanical properties were investigated. The mold filling capability was observed to be proportional to the pouring temperature, and both the vibration imposed during the casting and the application of a pattern coating had rather negative effects. The mold filling capability also decreased with the addition of Mg or TiB. When the Mg content increased, the tensile strength of the cast alloy was enhanced, but the elongation decreased. However, after T6 heat treatment, both the strength and the elongation were improved. TiB addition for grain refining or pattern coating did not significantly affect the tensile properties.

• Journal of Korea Foundry Society
• /
• v.17 no.3
• /
• pp.237-244
• /
• 1997

This study has been carried out to investigate into the influence of solidification conditions mold on the structure and mechanical properties of Al-5wt%Mg alloy by metallic mold casting. The percentage of equiaxed grain of Al-5wt%Mg alloy castings increased both when pouring temperature decreased and when the low part or bottom of metallic mold was cooled. The hardness was checked and showed that hardness of outside in the castings was higher than that inside, and that it is the highest at the pouring temperature of $680^{\circ}C$. The castings had the highest U.T.S. and elongation when the bottom of metallic mold was cooled. At the same pouring temperature, the structure of castings was changed as the position of cooling parts of metallic mold was varied. When the castings were solidified through cooling of the bottom of the metallic mold, the morphology of Fe intermetallic compound has tendency to change to a Chinese script and the U.T.S. and elongation of Al-5wt.%Mg alloy castings was increased.