• Journal of the Korean Society of Manufacturing Process Engineers
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• v.14 no.2
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• pp.59-66
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• 2015

The production of high value-added products requires efficient processing and this constant demand for complex shape processing has led to the need for hybrid processing. In this study, the surface characteristics of hybrid machining, which combines wire-cut E.D.M and vibration, are examined. The selected experimental parameters are verticality, waveform, amplitude, peak current and frequency. The experimental results provide a guideline for selecting reasonable machining parameters. Surface roughness was improved by increasing the amplitude of the vibration.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.19 no.6
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• pp.49-54
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• 2020

The purpose of this study is to investigate the effects of the change in the spindle speed and the feed rate on the diameter change of a hole using a boring cutter for the internal boring process of AL6061-T4 alloys. The experimental results are quantitatively analyzed by applying the factor analysis and the response surface analysis of the experimental design method. The tendency of the diameter change according to the change in the spindle speed and feed level is also evaluated. During the internal boring process of AL6061-T4 alloys, the main factor affecting the diameter change is the spindle speed in which the diameter decreases as the number of revolutions increases. In addition, the diameter tends to increase as the feed is increased; however, as the number of spindle revolutions increases, the influence of the feed decreases.

• Transactions of Materials Processing
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• v.16 no.6
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• pp.443-446
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• 2007

The semi-solid process has been developed near net-shape components for kinds of methods. Thixo-forming with reheating prepared billet and rheo-forming with cooled melt until semi-solid state. Material is applied electromagnetic stirring system to slurry with aluminum 6061 alloy. An experiment has variation factors which are pressure, solid-fraction, stirring current and stirring time. The mechanical properties are compared to forge sample with to apply heat treatment T6. This study is researched function a virtual pressure and fine shape zone. Optimum pressure is found to prevent defect of porosity.

• Proceedings of the KWS Conference
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• 2006.05a
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• pp.68-70
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• 2006

For the aluminum material of the thick-thickness more than 100mm Penetration depth Electron beam welding is effectively applicable with a characteristic of high energy intensity. But Al 6061 alloy has high crack sensitivity due to minor alloys, which are silicon, magnesium, copper etc. With a sample block of 135mm thickness EBW test was performed in vertical position. As tensile strength has $210{\sim}220N/mm^2$ with weld area broken. Bend test shows low ductility with fracture of partly specimens. Chemical contents of alloys show no difference between weld and base metal. Defect in middle weld area figures out typical hot crack due to low melting materials. Micro structure of weld area has some difference compare to HAZ and base metal. As a result of EBW test for Al 6061 alloy, it shows that weld defect could be occurred even though establishing of optimum weld parameter condition.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2002.05a
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• pp.154-158
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• 2002

The mechanical properties of Al 6061 excluded bar were deformed in high temperature with the variable deformation conditions and characterized by the tensile test. Three types of different strain rate were experimentally performed by using hydraulic press, crank press and hammer and two types of the nominal strain 0.5 and 0.8 were achieved. To decide optimum forging process, the relationship among the strain rate, strain and mechanical properties was explained by analyzing the microstructures of the forged and heat heated parts. The strength was deeply related with the strain rate due to the dynamic recrystallization (DRX) in hot forging, and the best forging condition was presented in Al 6061 alloy.

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.5
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• pp.625-634
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• 1986

The strain distribution on a welded aluminum alloy transition joint produced by a static tensile load has been measured using a moire method combined with photoelastic coating method. The test specimens were made of aluminum alloy 6061-T6 and 2014-T6 butt welded with ER-4043 filler metal, and were post welded heat treated (solid solution heat treatment 502.deg. C 70min.) and precipitated (artificial aging 171.deg. C 600min.) to cause an abrupt change of mechanical properties between the base metals and weld metal. The photoelastic epoxy rubber was cemented on the specimen grating which had been reproduced on the specimen surface by using an electropolishing. The measurements were compared with strains computed by Finite Element Analysis. The following results were abtained. (1) The maximum strain were distributed along the center line in the transverse directiion of the weld metal. (2) The strain gradient along the fusion line increased approaching the V-groove tip and the maximum value was observed at a quarter of width from the V-groove tip. (3) The moire method combined with photoelastic coating was proved very useful for real time strain measurement in the welded aluminum alloy transition joint.

• Journal of the Microelectronics and Packaging Society
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• v.22 no.4
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• pp.65-70
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• 2015

A study on thermal properties for a single-layer metal and two-layer composites was investigated for the heat-sink application. For the single-layer metal, an aluminum alloy (Al6061) was selected. A screen printed aluminum nitride (AlN) layer on the Al6061 substrate was chosen for the two-layer composites. The thermal conductivity of the sample was determined from the thermal diffusivity measured by the light flash analysis (LFA), specific heat and density. Measured thermal property values were compared to calculated values using the data from the references. The thermal conductivity of composites with screen printed AlN layer on the Al6061 substrate decreased linearly with increasing the thickness of AlN layer. Measured values of the thermal conductivity for composites with $53{\mu}m$ and $163{\mu}m$ thick AlN layers were $114.1W/m{\cdot}K$ and $72.3W/m{\cdot}K$, respectively. In particular, the thermal conductivity of the screen-printed AlN layer was demonstrated by appling the rule of mixture in view point of thermal resistivity. Measured values of the thermal conductivity for AlN layers with the thickness of $53{\mu}m$ and $163{\mu}m$ showed $9.35W/m{\cdot}K$ and $12.40W/m{\cdot}K$, respectively.

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.3
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• pp.5-10
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• 2001

Due to the development of high-strength fibers and adhesives, it is now possible to repair cracked metallic plates by bonding reinforced patches to the plate over the crack. In this study, pre-cracked aluminum 6061-T6 alloy plates repaired with bonded carbon/epoxy composite patch are applied to investigate the effect of various patch shapes on the tensile strength and the fatigue behavior of the structure. A non-patch-boned cased and 2 type-50$\times$50, 40$\times$20 mm-composite patch-bonded cases were tested to obtain fracture loads and fatigue crack growth rate. The results showed that the patch-bonded repair improves the static strength by 17% and the fatigue life by 200% compared to non-repaired case. It means that patch-boned repair is more effective in the fatigue life. It was also revealed that the patching method along crack growth direction is more efficient in cost and weight reduction. By observing the fractography, patch-bonded repair specimens demonstrated zigzag fracture patterns compared with the non-patched specimens, which shows a typical ductile fracture.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.29 no.6 s.237
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• pp.822-827
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• 2005

The characteristics of elastic waves emanating from crack initiation and propagation in 6061 aluminum alloy subjected to fatigue loading with different stress ratio was investigated. The objective of this study is to determine the properties of the signals generated from each stage of fatigue crack growth. AS a crack propagates, substantial elastic wave occurred just prior to penetration. Then it decreased and the crack penetrated. The waveforms and their power spectra were found to be dependent on the different stress ratio associated with the signals. It is determined that high-frequency signal $0.5{\sim}0.75$ MHz is most likely emitted during crack propagation at peak load of fatigue cycle which release the highest energy. It is determined that 0.3 MHz is closely related to crack closure effect. The frequency peaks below 0.25 MHz may be attributed to fretting or hydraulic noise.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.7
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• pp.673-680
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• 2009

In this study, die cooling system using the nitrogen gas has been applied to hot aluminum extrusion process for refining grains and reducing of grain growth. Computational fluid dynamics(CFD) has been carried out to evaluate die cooling effect by nitrogen gas, and the results of CFD have been used to FE-simulation for the prediction of the extrudate temperature in hot extrusion process. Experimental hot extrusion has been performed to observe microstructure and to measure temperature of extrudate. The results of FE-Simulation have been good agreement with those of experiment. Finally, process condition of hot extrusion can be established to reduce grain growth of Al6061 through the experiment.