• 한국산학기술학회논문지
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• 제20권7호
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• pp.347-352
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• 2019

본 연구는 소형 유도전동기 회전자를 생산공장에서 금형주조(die casting)로 제작 시 발생하는 cast 부 품질문제를 개선하기 위하여 수행되었다. 1차 연구결과와 현장 적용성을 고려한 수많은 parametric study를 통하여 새로운 rotor core cast model을 제안하였으며, 그 제안된 model에 대한 유효성을 평가, 검증하기 위하여 주조해석 전용프로그램을 사용한 수치해석과 실제품에 대한 현장실험을 통하여 다음과 같은 결론을 얻었다. 첫째, 유도전동기 회전자의 새로운 cast model에 대한 충진해석을 수행한 결과 용탕은 하부 end ring 부를 먼저 충진하고 이동하여 상부 end ring, core slot 부분을 충진하고 최종적으로 core slot 부분에서 충진이 완료된다. 둘째, 새롭게 제안된 rotor core cast model에 대한 용탕의 유동 양상을 보면 하부 end ring 부에 용탕의 유동에 의한 와류가 적게 발생하였으며, 현장실험 결과 하부 end ring 부 단면에서 소량의 작은 결함만이 발견되었다. 셋째, 유도전동기 회전자 제작 시 rotor core cast 형상 변경을 통하여 end ring 부 결함 발생 면적이 약 70 % 감소한 양호한 품질의 회전자를 생산할 수 있다.

• 반도체디스플레이기술학회지
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• 제17권1호
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• pp.27-34
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• 2018

Industrially, die-casting products are formed through casting, and so the methods to inspect the defects inside them are very restrictive. External inspection methods including visual inspection, sampling judgment, etc. enables researchers to inspect possible external defects, but x-ray inspection equipment has been generally used to inspect internal ones. Recently, they have been also applying three-dimensional internal inspections using CT equipment. However, they have their own limitations in applying to the use of industrial inspection due to limited detection size and long calculation time. To overcome the above problems, this paper has suggested a method to inspect internal defects by comparing the CAD data of the product to be inspected with the 3D data of the CT image. In this paper, we proposed a method for fast and accurate inspection in three dimensions by applying x-ray inspection to find internal defects in industrial parts such as aluminum die casting products. To show the effectiveness of the proposed method, a series of experiments have been carried out.

• 한국주조공학회지
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• 제19권5호
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• pp.410-418
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• 1999

To overcome the undesirable deformation, peeling off and geometrical restrictions which were mainly caused by differences in thermal expansion coefficients during the cladding of aluminum strip and stainless strip, new processing method based on vacuum die casting is designed and implemented in fabricating Fe-17wt%Cr steel (stainless steel). To increase cast-bonding ability, the surface of Fe-17wt%Cr steel is electrochemical etched to have optimum pit size (above 0.2 mm) and pit density (above 30%). The implementation of vacuum die casting by using surface treated stainless steel (Fe-17wt%Cr Steel) produces good trial products having acceptable cast-bonding ability. The enabling conditions for cast-bonding are pouring temperature $690^{\circ}C$, filling speed 30 m/sec and casting pressure $800\;kg/cm^2$. The microscopic observation of cast-bonded Al/Fe-17wt%Cr steel does not show any evidence of intermetallic compounds. The bonding strength of trial products is $150-400\;kg/cm^2$ and this is stronger than conventionally cladded metal having $30-70\;kg/cm^2$.

• 한국주조공학회지
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• 제29권3호
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• pp.138-143
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• 2009

Vacuum suction is applied to the mold during pouring in the inclined gravity die casting to remove defects such as misrun and gas porosity in the brake master cylinder. Casting defects are observed after solidification and their cause is analyzed by using the calculated results with commercial solidification and flow analysis code(ZCAST). The optimum vacuum suction is -2 cmHg, and when the start time of vacuum suction is 3 seconds after pouring, better filled result is obtained by holding it for 15 seconds. Reproducibility test under the optimum conditions attained from the above pouring tests is performed, and it is confirmed that these pouring conditions can be applied to the mass production immediately.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2007년도 춘계학술대회 논문집
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• pp.131-134
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• 2007

A semi-solid forming technology has a lot of advantages compared to the die casting, squeeze casting and hot/cold forging, so semi-solid forming has been studied actively. Semi-solid forming has two methods. One is thixoforming with reheating of prepared billet, the other is rheoforming with cooled melt until semi-solid state. Thixoforging technology can produce non-dendritic alloys for semi-solid forming complex shaped parts in metal alloys. In this study, the thixoforging was experimented with made rheology materials by the spiral stirrer equipment. Rheology materials for forging were made by A356 casting aluminum alloy and A6061 wrought aluminum alloy. After experiment, forged samples were measured microstructure and were heat treated for high mechanical properties.

• 소성∙가공
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• 제17권1호
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• pp.5-8
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• 2008

As the semi-solid forming technology has a lot of advantages compared to the die casting, squeeze casting and hot/cold forging, it has been studied actively. This paper focuses on the thixoforging of the rheological materials fabricated by the spiral mechanical stirring equipment with A356 casting aluminum alloy and A6061 wrought aluminum alloy. Formability tests of rheological materials fabricated by spiral mechanical stirring were carried out and the microstructures of forged sample were observed. After thixoforging experiment, the heat-treated conditions of forged samples are investigated to improve the mechanical properties. These results are able to suggest the possibility of commercialization for rheological materials fabricated by spiral mechanical stirring.

• 한국재료학회지
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• 제14권3호
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• pp.168-174
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• 2004

The aim of this study is to investigate the effect of process conditions on the microstructual changes and mechanical properties of large 7175 aluminum die forgings. The cast billets of 370 and 720 mm in diameter were homogenized and die forged after direct chill casting. The size and volume fraction of second phase particles in 720 mm billet were larger than those of 370 mm billet. The interdendritic sites containing the second phase particles was considered to be a crack initiation region in the process of cold upsetting. The tensile and yield strength of die forged specimens of 720 mm billet in the direction of Land L T were higher than those of 370 mm billet. However, the tensile strength of these specimens were 5 to 10% lower than that of American military specification. The plane strain fracture toughness of die forged specimens of 370 mm cast billet showed almost the same level of 720 mm billet, which was die forged after free forging.

• 한국주조공학회지
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• 제26권3호
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• pp.129-132
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• 2006

In the present study the new method was proposed by using the real-time X-ray observation and metal die in order to evaluate fluidity and viscosity of the molten metal during pouring into the mold. The special mold for the present experiment was introduced since X-ray could not transmit thick mold wall and scatter the image of the molten metal during pouring. The present study also discussed for evaluation of viscosities by using the flow data from radioscopy images, and the viscosities of six commercial aluminum alloys were evaluated and compared.

• 소성∙가공
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• 제16권3호
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• pp.178-186
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• 2007

Rheo-forging process of aluminum alloy is suitable for large parts of net shape without defects and excellent mechanical properties in comparison with conventional die casting and forging process. To control the microstructure of the product with high mechanical properties in rheo-forming, solid fraction is required to prevent porosity and liquid segregation. Therefore, in rheo-forging process, die shape, pressure type and solid fraction are very important parameters. The defects such as porosity, liquid segregation and unfitting phenomena occur during rheo-forging process. To prevent these defects, mechanical properties and microstructure analysis of samples versus the change of pressure are carried out and the problem and its solutions are proposed. Also, the mechanical properties versus various pressures were compared with and without heat treatment. The alloys used for rheo-forming are A356 and 2024 aluminum alloy. The rheology material is fabricated by electromagnetic process with controlling current and stirring time.

• 한국주조공학회지
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• 제41권6호
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• pp.535-542
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• 2021

본 연구에서는 주철-알루미늄 이종재료의 계면결합강도를 향상시키기 위하여 탈흑연 열처리를 통해 주철 표면에서 일정 깊이까지의 흑연을 제거하였다. 열처리 시간이 증가함에 따라 흑연이 제거되는 깊이는 증가하였으며, 열처리 시간과 깊이 사이에 선형 관계가 나타났다. 일정 깊이의 흑연이 제거된 주철에 알루미늄을 다이캐스팅 공법으로 주조접합하여 주철에서 흑연이 제거된 공간을 알루미늄으로 채운 후, 계면 반응 및 알루미늄 침투 깊이를 조사하고 계면접합강도를 평가하였다. 다이캐스팅 공법을 통한 알루미늄은 탈흑연 열처리된 주철 표면에서 일정한 깊이까지 채워지는 것으로 확인되었으며, 주철-알루미늄 계면에 금속간화합물이 생성되지는 않은 것으로 확인되었다. 계면접합강도는 열처리 시간과는 큰 관계없이 90MPa 수준의 접합강도를 나타내었으며 이는 탈흑연 열처리를 하지 않은 소재의 접합강도 12MPa에 비해 매우 높은 강도이며, 주철의 탈흑연 영역에서 고압 다이캐스팅 공정에 의해 침투된 알루미늄 용탕이 응고되면서 언더컷 구조의 기계적 결합에 의한 것으로 생각된다.