• Journal of Conservation Science
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• v.28 no.4
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• pp.367-376
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• 2012

The ironware production technology is a measure to fathom the society's level of development in time. To understand iron-manufacure methods in the past, various investigations on the fine structures and additions of ironware remains and Iron ingot have been conducted in a way of natural science. This study metallurgically reclassifies remains excavated in iron-manufacture remains located in Beokje, Goyang, which are thought to be in time of Goryeo Dynasty, and draws an inference from the element analysis on the iron-manufacture and smelting technology. Iron ingot samples with a cast iron structure are divided into those with a white cast iron structure and those with a grey cast iron rich in P. The P content of grey cast iron appeared to be the result of adding a flux agent like lime, iron ingot and carbon steel iron ingot with a cast iron structure excavated in the area is regarded as pig iron which was made without a refining process. In this study it seems that two methods of making ironware were used in the area; one is the method of making ironware by pouring cast iron to the casting, and the other is the method of making carbon steel through the refinement of pig iron. It appears that highly even steel structure of carbon steel and a small amount of MnS inclusion are very similar with that of the modern steel to which Mn is artificially added. Nevertheless, these data alone cannot be used to determine the source of Mn in the carbon steel of the excavated from the iron-manufacture remains, which raises the need for further studies on the source and the possibility of carbon steel via the iron-manufacture process of cast iron.

• Journal of Computational Design and Engineering
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• v.3 no.2
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• pp.140-150
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• 2016

Normally all manufacturing and fabrication processes introduce residual stresses in a component. These stresses exist even after all service or external loads have been removed. Residual stresses have been studied elaborately in the past and even in depth research have been done to determine their magnitude and distribution during different manufacturing processes. But very few works have dealt with the study of residual stresses formation during the casting process. Even though these stresses are less in magnitude, they still result in crack formation and subsequent failure in later phases of the component usage. In this work, the residual stresses developed in a shifter during casting process are first determined by finite element analysis using ANSYS(R) Mechanical APDL, Release 12.0 software. Initially the analysis was done on a simple block to determine the optimum element size and boundary conditions. With these values, the actual shifter component was analyzed. All these simulations are done in an uncoupled thermal and structural environment. The results showed the areas of maximum residual stress. This was followed by the geometrical optimization of the cast part for minimum residual stresses. The resulting shape gave lesser and more evenly distributed residual stresses. Crack compliance method was used to experimentally determine the residual stresses in the modified cast part. The results obtained from the measurements are verified by finite element analysis findings.

• Structural Engineering and Mechanics
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• v.71 no.4
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• pp.433-444
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• 2019

Shear studs are often used to connect steel girders and concrete deck to form a composite bridge system. The application of precast concrete deck to steel-concrete composite bridges can improve the strength of decks and reduce the shrinkage and creep effect on the long-term behavior of structures. How to ensure the connection between steel girders and concrete deck directly influences the composite behavior between steel girder and precast concrete deck as well as the behavior of the structure system. Compared with traditional multi-I girder systems, a twin-I girder composite bridge system is more simplified but may lead to additional requirements on the shear studs connecting steel girders and decks due to the larger girder spacing. Up to date, only very limited quantity of researches has been conducted regarding the behavior of shear studs on twin-I girder bridge systems. One convenient way for steel composite bridge system is to cast concrete deck in place with shear studs uniformly-distributed along the span direction. For steel composite bridge system using precast concrete deck, voids are included in the precast concrete deck segments, and they are casted with cast-in-place concrete after the concrete segments are erected. In this paper, several sets of push-out tests are conducted, which are used to investigate the heavier of shear studs within the voids in the precast concrete deck. The test data are analyzed and compared with those from finite element models. A simplified shear stud model is proposed using a beam element instead of solid elements. It is used in the finite element model analyses of the twin-I girder composite bridge system to relieve the computational efforts of the shear studs. Additionally, a parametric study is developed to find the effects of void size, void spacing, and shear stud diameter and spacing. Finally, the recommendations are given for the design of precast deck using void for twin I-girder bridge systems.

• Journal of Korea Foundry Society
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• v.6 no.4
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• pp.284-289
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• 1986

Decarburization phenomena have been studied by plasma in stainless steel, plain carbon steel and cast iron. It was also investigated the movement of impurity element P,S in the plasma jet metal pool. The plasma jet was obtained by $Ar\;-\;CO_2$ gas mixture with 5 kVA DC power source. It produced enough temperature to dissociate into activated oxygen atom by reaction of $CO_2{\leftrightarrows}CO+O^+$ and it reacted with ${\underline{C}}$ in metal pool. Decarburization rate was increased about 5 times in comparing with the conventional induction melted metal pool by $CO_2$ gas decarburization. Even under the Ar plasma jet, decarburization was obtained by agitation of metal bath by $Ar^+$ bombardment and dilution phenomena of carbon atom under the very high plasma temperature. But heavy element P and S are not much removed because they are too heavy in mass to be activated by $Ar^+$ion bombardment. Desulphurization was achieved by $Ar\;-\;CO_2$ plasma in plain carbon steel and cast iron by the reaction of $SO_2({\underline{S}}+O^+)$. But dephosphorization could not be obtained by $Ar\;-\;CO_2$ plasma, because gaseous reaction of phosphorous oxide (${\underline{P}}+O^+$) was not existed.

• Journal of Korea Foundry Society
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• v.33 no.2
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• pp.63-68
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• 2013

Generally, metal is the most important material used in many engineering applications. Therefore, it is important to understand and predict the damage of metal as result of the impact. The objective of this research is to evaluate the damage criterion on the impact performance of A356 Al-alloy castings. Both experimental method and computational analysis were used to achieve the research objective. In this paper, we performed impact test according to various impact velocities to the A356 cast aluminium specimen for damage prediction. Impact computational simulation was done by applying properties obtained from the tensile test, and damages was predicted according to the damage criteria based plastic work. The good agreement of the results between the experiment and computer simulation shows that the reliability of the proposed FE simulation method to predict fracture of A356 casting components by impact.

• Korean Journal of Materials Research
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• v.13 no.2
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• pp.74-80
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• 2003

The effects of risering design and alloying element on the formation of defects such as external depression, primary and secondary shrinkage cavities in ductile cast iron were investigated. Two types of risering design for the cylindrically step-wise specimen, No. 1(progressive solidification) and No. 2(directional solidification) risering designs, were prepared and six different alloy compositions were casted. In the No. 1 risering design, external depression or primary shrinkage cavities due to liquid contraction were observed in all the specimens from SG 10 to SG 60. The defects caused by liquid contraction seemed to be more affected by risering design than alloying elements. The secondary shrinkage cavities were also observed in all the specimens but a swollen surface was not observed in all the castings. The primary shrinkage cavities were located right under the top surface or connected to the top surface, and were characterized by smooth surfaces. On the other hand, the secondary shrinkage cavities were positioned in the thermal center of the specimen steps 3 and 4, and characterized by rough surfaces. In the No. 2 risering design, no external depression or primary shrinkage cavities due to liquid contraction were observed in all the specimens from SG 10 to SG 60. However, the secondary shrinkage cavities were formed in the thermal center of specimens SG 40, 50 and 60. Like the No. 1 risering design, a swollen surface was not observed in all the castings.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.8
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• pp.835-841
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• 2012

We measured the mechanical and thermal properties of four types of cast irons used for manufacturing the brake discs of railway vehicles. It was found that these properties could be controlled by varying the composition of Ni, Cr, and Mo. Thermal fatigue tests were carried out by using a thermal fatigue tester in which thermal cycles could be controlled. Thermal crack initiation and propagation were measured on cylindrical specimens. Finally, we simulated the thermal fatigue test procedure by finite element analysis and calculated the thermal fatigue lifetimes by Manson-Coffin's equation and the maximum principal strain. The estimated thermal fatigue lifetimes corresponded to the measured lifetimes when the total crack length was $40{\mu}m{\sim}1mm$.

• Geomechanics and Engineering
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• v.5 no.2
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• pp.119-142
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• 2013

Pile load tests using Osterberg cells (O-cell) were conducted on cast-in-place concrete piles founded in oil sand fill and in situ oil sand at an industrial plant site in Fort McMurray, Alberta, Canada. Interpreted pile test results show that very high pile shaft resistance (with the Bjerrum-Burland or Beta coefficient of 2.5-4.5) against oil sand could be mobilized at small relative displacements of 2-3% of shaft diameter. Finite element simulations based on linear elastic and elasto-plastic models for oil sand materials were used to analyze the pile load test measurements. Two constitutive models yield comparable top-down load versus pile head displacement curves, but very different behaviour in mobilization of pile shaft and end bearing resistances. The elasto-plastic model produces more consistent matching in both pile shaft and end bearing resistances whereas the linear elastic under- and over-predicts the shaft and end bearing resistances, respectively. The mobilization of high shaft resistance in oil sand under pile load is attributed to the very dense and interlocked structure of oil sand which results in high matrix stiffness, high friction angle, and high shear dilation.

• Journal of Korea Foundry Society
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• v.21 no.2
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• pp.127-134
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• 2001

Misch metal (rare earth element, Ce, La, Nd, Pr) which has large influence on high-temperature stability and toughness was added to the Al-5%Ni-5%Mg alloy, and squeeze casting was used for Al-5%Ni-5%Mg-(Mm) alloys. The effect of applied pressure and misch metal additions on mechanical properties in Al-5%Ni-5%Mg alloy by direct squeeze casting has been investigated. The applied pressure were 0 MPa(gravity casting), 25, 50 and 75 MPa. Squeeze-cast Al-5%Ni-5%Mg-(Mm) alloys had better mechanical properties than those of non-pressurized cast alloys because of the increased cooling rate by the application of pressure during solidification. By the addition of misch metal in Al-5%Ni-5%Mg alloy, better combination of strength and elongation was obtained. The addition of 0.3%Mm in Al-5%Ni-5%Mg alloy improved the heat resistant property due to the formation of fine eutectic phases.

• Journal of the Korean Society for Precision Engineering
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• v.12 no.1
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• pp.87-96
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• 1995

A new fungivle material named Epoxy-Granite composite is applied to the column structure of drilling center in order to investigate the advanced dynamic charateristics comparing with a conventional cast iron material. The dimensions of new column structure are adjusted to keep the same stiffness (EI value) and the manufacturing conditions are formulated based on the preceeding research experience about the development of Epoxy-Granite structural material. The two kinds of experiments are set up, one of which is for the measurement of natural mode and frequency using experimental modal analysis, and the other one is for the measurement of vibration amplitude during idling operation of a machine tool. The comparison of maximum accelerance values at each natural frequency of bending mode shows a Epoxy-Granite column have larger modal damping ratios(over 2times) than a cast iron column. The vibration amplitude of Epoxy-Granite column measrued on the bed, motor base, and top of column are also much smaller (up to 12%) than the case of cast iron column. It is therefore confirmed that a Epoxy-Granite material exhibits a good anti- vibrational propderty even if it is used under the actual operational environments of machine tool as a practical structural element.