• Transactions of Materials Processing
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• v.23 no.2
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• pp.116-121
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• 2014

Low pressure die casting and flow forming have been successfully used to produce sound road wheels from magnesium alloy AM80. In the current study, high speed compression testing was initially conducted to simulate the flow forming of a Mg wheel. Subsequently the flow forming was simulated with "Forge$^{TM}$", an FEM software package. On the basis of flow forming simulations, the flow forming of the Mg wheel was performed under different conditions. For the flow forming experiments, the preform castings were made by low pressure die casting from AM80, a commercial magnesium alloy. In flow forming of the magnesium preform wheel, the flow forming of the Mg wheel was successfully accomplished when the feed rate was less than half that for the forming of an aluminum road wheel. The reduction in feed rate was 52%. Finally, a comparison with the flow forming simulations was made.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2006.09b
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• pp.714-715
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• 2006

The Application of powder metallurgy (PM) aluminum structural parts is at its early growing stage, despite of some automotive applications. The market potential for PM aluminum, however, is large. Growth is expected from the market expansion of the existing applications and new applications, including the replacements of aluminum and zinc based castings and some ferrous PM automotive parts by PM aluminum. Compared to castings, PM is an efficient mass production technology. The PM aluminum is more competitive than die casting for some automotive applications. Besides weight saving leading to performance improvement, the total cost increase for aluminum PM parts is less than 15% compared to ferrous PM automotive parts. The future is promising for PM aluminum.

• Transactions of Materials Processing
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• v.11 no.1
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• pp.45-53
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• 2002

The forming process of metal matrix composites by die casting and squeeze casting process are limited in size and dimension In term of final parts. The melt strirring method have the problems that the homogeneous distribution of the reinforcements is difficult due to the low weldability and the density difference between the molten metal and the reinforcement. The thixoforming process for metal matrix composites has numerous advantages compacted to die casting, squeeze casting and compocasting. However, for the thixofoming process, the billet with the desired volume fraction must be heated to obtain a uniform temperature distribution over the entire cross-sectional areas. To obtain the reheating conditions of composites, the particulate reinforced metal matrix composites for thixoforming were fabricated by combined stirring process which is simultaneously performed with electro-magnetic stirring and mechanical stirring process. The matrix alloy and reinforcement are used to aluminum alloy(A357) and SiCp with diameter 14, $25{\mu}m$, respectively. The microstructure characteristics were investigated by changing the volume fraction and reinforcement size. The heating conditions to obtain the uniform temperature distribution in cross section area of fabricated metal matrix composites billet are proposed with heating time, the heating temperature and the holding time.

• Journal of Korea Foundry Society
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• v.18 no.4
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• pp.373-382
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• 1998

Particulate reinforced aluminum alloys produced by indirect squeeze casting are difficult to shape by cutting or milling. Therefore near net shape forming of complex shapes is of high economic and technical interest. The complex shape products of $SiC_p/6061$ Al composites are fabricated by the melt-stirring and indirect squeeze casting process. The mold temperatures are $200^{\circ}C$ and $300^{\circ}C$ and applied pressures are 70, 100, and 130 MPa. The volume fractions of the reinforcements are in the range of 5 vol% to 15 vol%. The reinforcement dispersion state are observed using on optical microscope. By employing observed results systematically a correlation is demonstrated among the microstructure, particles behavior, mechanical properties and processing parameters for an optimum melt-stirring(compocasting) and indirect squeeze casting process of MMCs. A procedure to establish the optimum squeeze casting of Al-MMCs is proposed.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.8
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• pp.1371-1379
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• 2003

RP&M (Rapid Prototyping and Manufacturing) is the most appropriate technology for the small-lot production system, because the production cycle is getting shorter owing to various needs of the consumer. In this paper, rapid tooling technology is applied to the casting process. The casting process has the ability to reflect complicated shapes in one process. But it has not been widely used to make a die and mold because of the poor surface quality caused by air bubbles on the surface of the casting product. In this study, the porous casting mold is fabricated from a mixture of plaster and water-soluble binder. The porous casting mold can improve the characteristics of casting products with the help of the vacuum sealed casting process. The vacuum sealed casting process is an advanced technology that removes the air bubbles between the porous casting mould and the liquid metal, thus making the surface of the casting product finer. The purpose of this paper is to develop a high quality shoe mold using porous casting mold and to apply the RP&M technology to the shoe industry.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.12
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• pp.7-13
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• 1999

The potential for growth and the future impact of Rapid Prototyping that it will have on the product development cycle are enormous. Since making tools, precedes making parts, Rapid Tooling becomes widely used in automobile, aerospace, electronic, and other industries. In this study, master models formed by Rapid Prototyping of Stereolithography have been applied for vacuum casting to obtain silicone patterns which have transformed into epoxy models. The epoxy models have been measured to check dimension errors, and tested their functions. These checking and measurement have provided information on plastic injection possibilities and data for die design, Temporary die making with the materials of Aluminum/Epoxy and powder injection metal (PIM) has also been discussed in terms of hardness, surface roughness, and SEM microstructures.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2006.05a
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• pp.425-428
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• 2006

A semi-solid forming technology has some advantages compared with conventional forming processes such as die casting, squeeze casting and hot/cold forging. In this study, the numerical analysis of semi-solid filling has been studied with solid fraction fs = 30% of A356 aluminum alloys. The finite difference program of two-phase flow model of Navier Stokes' equation coupled with heat transfer and solidification has been developed to predict a filling pattern, liquid segregation and temperature distribution of semi-solid metals. It gives die filling patterns and final solidification area. It can predict mechanical properties of semi-solid forming processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.05a
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• pp.299-302
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• 2005

Semisolid A356 slurries were prepared by electromagnetic stirring casting and by inoculation of Al-5Ti-B master alloy. As stirring time and addition of Al-5Ti-B are different, the grain size of the primary phase is different. Through the experiment of rheocast in a Buhler horizontal die casting machine, it was found that the finer the equiaxed primary dendrites, the smoother the die filling and better cast quality. Small equiaxed primary dendrite also results in less liquid segregation on the surface.

• Design & Manufacturing
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• v.15 no.2
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• pp.30-35
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• 2021

The casting method uses a mold to solidify a liquid metal to make a solid metal. Since it uses a liquid metal with the least deformation resistance, it has the characteristic that it can easily manufacture even a complex shape. However, the process of solidifying a liquid metal into a solid metal inevitably involves a volume change and contains internal defects such as shrinkage holes. Therefore, in the design of the casting plan, an excess volume called a pressurization compensates for the volume shrinkage. in the product, and it induces the shrinkage hole defects to occur in parts other than the product1). In this study, casting analysis was performed using casting analysis software (anycasting) in order to optimize the design of the tilting gravity casting method for automobile brackets. In particular, the filling and solidification analysis according to the shape and volume of the pressurized metal was conducted, and applied to the actual product to study the effect of the pressurized metal on the shrinkage defect. Through this study, it is possible to understand the effect of the pressure metal on shrinkage defects in the actual product and propose a design of the pressure metal that improves reliability and productivity.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.371-374
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• 2009

Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D. Samples of metal parts were subsequently fabricated by using hydraulic press machinery.