• Proceedings of the KWS Conference
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• 2009.11a
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• pp.239-242
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• 2009

Friction stir spot welding (FSSW), developed based on principle of friction stir welding, has been paid attention as a new solid-state spot welding process. Since FSSW can produce high-quality weld in Al alloys more easily than resistance spot welding, this process has been already used for construction of Al components in the automotive industries. Despite the large industrial interests in FSSW, fundamental knowledge on welding phenomena of this process has not been fully understood. In this study, FSSW phenomena, such as the consolidation mechanism, the microstructural evolution and the material flow, were examined in Al alloy 6061. This study clarified that the elliptical zone found in the vicinity of the pin hole on the cross section was characterized by the initially lapped surface of two sheets. Moreover, the following material flow was proposed; capture of the upper material with the threads on the pin surface, spiral flow along the tool rotation, and then release at the tip of the pin.

• Journal of Welding and Joining
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• v.28 no.1
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• pp.86-91
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• 2010

In the present study, two-dimensional plane deformation thermo elasto-plastic analysis has been carried out, in order to investigate the thermal and mechanical behaviour (residual stress, plastic strain, magnitude of stress and their distribution and production mechanism) on multi-pass FCA butt weldment of high strength EH36-TMCP ultra thick plate. Moreover, this study can be considered as a basis for analysing the fracture toughness, KIC, and its effect on welding residual stress redistribution with notch on multi-pass FCA butt weldment, in future. The results of welding residual stress obtained from thermo elasto-plastic analysis has been compared and verified with the results measured by XRD.

• Applied Microscopy
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• v.48 no.3
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• pp.73-80
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• 2018

Ductile cast iron is widely used for many automotive components due to its high wear resistance and fatigue resistance in addition to the low cost of fabrication. The improvement of wear resistance and fatigue properties is key to the life time extension and performance increase of the automobile parts. Surface nanocrystallization is a very efficient way of improving the performance of materials including the wear- and fatigue-resistance. Shot peening treatment, as one of the popular and economic surface modification methods, has been widely applied to various materials. In this study, ductile cast iron specimens were ultrasonic shot peening (USP) treated for 5 to 30 min using different ball size. The microstructures were then microscopically analyzed for determination of the microstructural evolution. After the USP treatment, the hardness of pearlite and ferrite increased, in which ball size is more effective than treatment time. With USP treatment, the graphite nodule count near the surface was decreased with grain refinement. The lager balls resulted in an increased deformation, whereas the smaller balls induced more homogenously refined grains in the deformation layer. In addition, formation of nanoparticles was formed in the surface layer upon USP.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.17 no.1
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• pp.63-68
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• 2018

At present, ultra-precision cutting technology has been studied in Korean research institutes, focusing on development of ultra-precision cutting tool technology and ultra-precision control engineering. However, the developed technologies are still far behind advanced countries. It focuses on metals including aluminum, copper and nickel, and nonmetals including plastics, silicone and germanium which require high precision while using a lathe. It is hard to implement high precision by grinding the aforementioned materials. To address the issue, the ultra-precision cutting technology has been developing by using ultra-precision machine tools very accurate and strong, and diamond tools highly abrasion-resistant. To address this issue, this study aims to conduct ultra-precision cutting by using ECTS (Error Compensation Tool Servo) to improve motion precision of elements and components, and compensate for motion errors in real time. An IR camera is used for analyzing cutting accuracy differences depending on the heat generated in diamond tools in cutting to examine the heat generated in cutting to study cutting accuracy depending on generated heat.

• Journal of Power System Engineering
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• v.17 no.5
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• pp.13-22
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• 2013

This paper reports the investigation of the physical and chemical characteristics of the prepared 3Pt-2MgO-$3ZrO_2$-$2CeO_2/Al_2O_3$ DOC, based on its hydrothermal aging. As a result of impregnating and reducing the $H_2PtCl_6$ $6H_2O$ precursor on a ${\gamma}-Al_2O_3$ basis, it was well dispersed into small particles with the range 2-3nm. This was because the $Al_2O_3$ acted as a barrier to prevent movement of the catalyst particles. For a hydrothermally aged catalyst for 9h at $700^{\circ}C$, its performance when purifying harmful gases decreased compared to a fresh catalyst, but its specific surface area was at the same level. This was because the performance of the catalyst was reduced by the sintering of the precious metal Pt, rather than by washcoat sintering and pore clogging. For an excessively hydrothermally aged catalyst for 9h at $850^{\circ}C$, Pt grew into an approximately 50nm class, formed a cluster compared to a fresh catalyst. The $CeO_2$ promoters also formed clusters among components of the same type, reducing their specific surface area to $114m^2/g$, which was 14% less than a fresh catalyst.

• Corrosion Science and Technology
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• v.10 no.6
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• pp.199-204
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• 2011

Hot dip metallic coated steels like as galvanized (GI), zinc-aluminium (GL) and aluminium coated steels are mostly used where corrosion resistance is needed. There are two kinds (type 1 and type 2) of aluminium coated steel being commercially used among them. Type 1 aluminium coated steel is coated with an Al-5~11 wt%Si alloy and Type 2 aluminium coated steel consists of commercially pure aluminium. Type 1 Al coated steel is generally used in automotive components and electrical appliances while type 2 aluminium coated steel is mainly used in construction applications such as building cladding panels, air conditioning and ventilation system. In this study, Type 1 aluminium coated steels have tested by accelerated conditions (salt spray or corrosive gas) and outdoor exposure condition in order to understand their corrosion behaviour. Due to the distinct corrosion mechanism of Al which exposes to the severe chloric condition, Salt Spray Test cannot predict the ordinary atmospheric corrosion of Al based coated materials. In addition, the test results and their corrosion feature of Al coated steel sheets will be discussed comparing with other metallic coated steel sheets of GI and GL.

• Journal of the Semiconductor & Display Technology
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• v.19 no.1
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• pp.42-48
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• 2020

As global warming accelerates, eco-friendly electric cars are being developed to reduce carbon dioxide emissions, and power conversion inverters are used to drive motors. Among inverter components, DC-link capacitor is heated by high current usage, which causes problems such as performance and life-saving of inverter. Although metal cases with good thermal performance have been used to solve this problem, it is difficult to apply them in practice due to insulation problems with other parts. In this paper, the Heat-Generation influence factor of DC-link capacitor is analyzed. Variables on heat-generation are set at 3 levels for film width, inductance, and film thickness. Box-Behnken to 13 tests using the design and minimal deviations, e.g. through the experiment three times by each level. The surface of the film k type by attaching the sensor current is measured temperature. Capacitance was set to a minimum level of 200 ㎌ and had a frequency of 16 kHz with Worst case, ambient temperature of 85℃ and a ripple current of 50 Ams was applied. The temperature at the measurement point was collected in the data logger after sampling at 1 minute intervals for 2 hours after saturation with the ambient temperature. This experiment confirmed that setup factors are correlated with heat-generation.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.10a
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• pp.173-176
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• 2007

The characteristics of the tool system give many effects into the costs and qualities for the finished components. This study proposes a new method for manufacturing of high manufacturing productivity, production process reduction and low cost through back pressure forming. The Lock-up hub is manufactured through many processes, such as upsetting($1^{st}$ Forming), piercing, direct extrusion($2^{nd}$ Forming), final sizing process($3^{rd}$ Forming). In this study, process design for closed-die forging of a Lock-up hub used for a component of automobile transmission was made using three-dimensional finite element simulations, and the strain distributions and velocity distributions are investigated through the post processor. The rigid-plastic finite-element method for back pressure forging has been used in order to reduce development time and die cost. Using the FEM simulation, we found the optimum value of back pressure. The prototypes of Lock-up hub parts were forged into the net-shape. In the experiment, lead precision of tooth are measured by the CCMM(Contact Coordinate Measuring Machine). The dimensional accuracy of forged part was improved up to the 40% when back press was applied.

• Journal of Welding and Joining
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• v.18 no.5
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• pp.98-104
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• 2000

Aluminum alloys are being employed in automobile parts as strive to reduce overall vehicle weight to meet demands for improved fuel economy and reduction in vehicle emissions. Al-based composites reinforced with ceramic ($Al_2O_3,\;SiC,\;TiC\;and\;B_4C$) applications in a variety of components in automotive engines, such as liners, where the tribological properties of the material are important. In this study, Al-base composites reinforced with TiC particle powders has been developed for producing plasma spray coatings. The composite plasma spray powders were prepared Al-13Si-3Mg(wt%) alloy with TiC(40, 60 and 80wt%) particles ($0.2~5{\mu}textrm{m}$) by drum type ball milling. The composite powders ($36~76{\mu}textrm{m}$) were sprayed with plasma torch. Plasma sprayed coatings were heat-treated at $500^{\circ}C$ for 3 hours. The wear resistances of the plasma sprayed coatings were found to decrease with increasing TiC content and improved with heat treatment. AlSiMg-40% TiC heat-treated coatings were showed the best wear resistance in this study.

• Journal of Powder Materials
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• v.19 no.3
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• pp.189-195
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• 2012

A novel PM (powder metallurgy) steel for automotive power-train gear components was developed to reduce manufacturing cost, while meeting application requirements. The high-density PM steel was manufactured by mixing using special Cr-Mo atomized iron powders, high-pressure compaction, and sintering. Tensile strength, charpy impact, bending fatigue, and contact fatigue tests for the PM steel were carried out and compared to conventional forged steel. Pinion gears for auto-transmission were also manufactured by helical pressing, sintering, and surface densification process. In order to evaluate the durability of the PM parts, auto-transmission durability tests were performed using dynamometer tests. Results showed that the PM steel fulfilled the requirements for pinion gears indicating suitable tensile, bending fatigue, contact fatigue strengths and improved gear tooth profile. The PM gears also showed good performance during the transmission durability tests. As a result, the PM gears showed significant potential to replace the conventional forged steel gears manufactured by tooth machining (hobbing, shaving, and grinding) processes.