• Journal of Korea Foundry Society
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• v.32 no.2
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• pp.65-74
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• 2012

In this paper, we present the results of our studies on optimal die design towards development of a vacuum die casting process to fabricate fuel cell bipolar plate with micro-channel array. Cavity and overflow shape is designed by computational filling analysis of MAGMA soft. Optimal die design consists of seven overflows at the end of cavity and three overflows at each side wall of cavity. The molten metal that passed the gate and reached the side wall flowed into the side overflow, no turbulent flow occurred, and the filling behavior and velocity distribution were uniform. In addition, partially solidified molten metal passing through the channel was perfectly eliminated by overflow without back-flow. When vacuum pressure, injection speed of low and high region was 300 mbar, 0.3 m/s and 2.5 m/s respectively with Silafont 36 die casting alloy, sound sample without casting defects was obtained. The experimental results are nearly consistent with simulation results.

• Korean Journal of Metals and Materials
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• v.48 no.6
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• pp.551-556
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• 2010

In this report, we describe mold materials that were used to produce movable metal type by the investment casting method during the Joseon dynasty period in Korea. Samples were obtained from the Wibuinja collection, which is held by the National Museum of Korea. Most of the mold material remnants were found in the depressed areas of the movable type specimens, and we therefore performed non-destructive analyses including XRF, EDS, and XRD. Through these analyses, we were able to identify the mold remnants as hydrocerussite [trilead dihydroxide dicarbonate, $Pb_3(CO_3)_2(OH)_2$] formed in platy hexagonal crystallites. Hydrocerussite was first used to make white pigments and cosmetics in ancient Greece, but this is the first report of hydrocerussite used as mold material applied around a disposable pattern for investment casting. The results of this study will further the understanding of the production process for early movable metal type and ancient casting technologies.

• 제어로봇시스템학회:학술대회논문집
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• 1991.10b
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• pp.1910-1914
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• 1991

In the continuous casting process, mold level fluctuation Is the major cause of the surface and sub-surface defects. In the No.3 bloom continuous caster at Kobe Works, we ensured that the major cause of mold level fluctuation was mechanical hysteresis which existed in the driving system of mold level control. Moreover, we found out that it was possible to greatly Improve the stability of mold level by estimating this mechanical hysteresis and compensating It on-line. As a result of applying a new level control system based on this method, we got accurate control over good stability.

• Transactions of Materials Processing
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• v.14 no.1 s.73
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• pp.49-56
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• 2005

In the semi-solid die casting process, an important thing is the flow behavior of semi-solid materials. The flow patterns of the semi-solid material can make the defects during die filling. To control the flow patterns is very important and difficult. In this paper, the flow behavior of the semi-solid A356 alloy material during die filing at various die gate shapes has been observed with the grain size controlled material. The effect of the gate shape on the die filling characteristics was investigated. The filling tests in each plunger stroke were experimented, and also simulated on the semi-solid material die casting process by MAGMAsoft. According to the filling tests and computer simulation, the effect of the gate shape on liquid segregation has been investigated.

• Journal of Korea Foundry Society
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• v.18 no.6
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• pp.555-562
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• 1998

Modified fluid critical solid fraction method was utilized as a prediction parameter to describe the shrinkage formation including the position, shape and amount of shrinkage cavities. A numerical scheme was implemented adapting this method for the evaluation of solidification defects in various casting processes. In the present numerical code, the form of shrinkage cavity can be simultaneously determined when an isolated loop is predicted to occur by the fluid critical solid fraction method. An auxiliary parameter, shrinkage potential, was also used in order to calculate the amount of residual liquid during solidification. Solidification analysis was carried out for the validation of the present scheme. It was shown that the calculated results were in good agreement with those of practical casting runs in all of the casting processes envolved in the present research. It may be concluded that the present program successfully predicts the detailed shrinkage formation behavior without the consideration of interdendritic fluid flow analysis.

• Journal of the Korea Institute of Information and Communication Engineering
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• v.20 no.8
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• pp.1546-1552
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• 2016

In addition, because it uses preheating to dissolve an alloy in general, it is hard to regulate the appropriate melting temperature of the alloy and brewing time and shows the defect of the supplementation thing due to the super-heating. Once the alloy is molten and then most of the casting by attaching a sight glass or non-contact temperature sensor is suitable casting temperature the operator pressing a button to generate a centrifugal force to inject the molten alloy into a crucible in the casting ring. These results, and most of the cast temperature is too high or too low to generate a lot of casting defects do not get into a uniform cast body. In this paper, we developed a dental casting machine for high frequency using a single temperature sensor which can measure the actual temperature of the alloy than the temperature of the external non-contact measurement using a temperature sensor.

• The Journal of Korean Academy of Prosthodontics
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• v.41 no.3
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• pp.342-350
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• 2003

Statement of problem. Titanium-Nickel alloy might be used in various prosthetic restorations since it has a unique property such as super-elasticity and high fatigue resistance. However, little is known about the casting ability of this alloy. Purpose. This in vitro study compared the casting accuracy and the porosity made with different investments and various sprue designs to ascertain what casting condition would be better for the fabrication of Ti-Ni cast restorations. Material and methods. A total of 70 Ti-Ni alloy crowns were made and divided into 7 groups of 10 copings on a metal master die. For measuring the effect of the sprue numbers, two groups with one and two 8-gauge sprues were compared. Moreover, the results of the conventional sprue and the double thickness sprues were compared. Three investments were used; carbon free phosphate bonded investment, titanium investment and gypsum bonded investment. The cast restorations were evaluated at 48 points on the entire circumferential margin with a stereomicroscope measuring in micrometers. Each crown was radiographically examined for casting defects and porosity. Data on casting accuracy were analyzed using two-way and Post hoc Scheffe's comparison to determine whether significant differences existed at the 95% confidence level. Student-Newman-Keuls test were performed to identify significant differences in the number of voids. Results. The double sprueing group and double thickness group had significantly less marginal discrepancy than the single sprueing group (P<.05 and P<.01, respectively). The castings with phosphate bonded investment showed the least marginal discrepancy and the smoothest surface. The castings invested in the gypsum bonded investment had the greatest gaps in margin and the largest failure rate. The double sprueing group and phosphate bonded investment group had significantly smaller void numbers and smaller void size than the other groups. Conclusion. Within the limitations of this in vitro study, the casting accuracy of the groups using thicker, double sprue design and the phosphate bonded investment was significantly superior. Moreover, void number and size were less than other groups.

• Journal of Korean Neurosurgical Society
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• v.52 no.6
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• pp.541-546
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• 2012

Objective : The prefabrication of customized cranioplastic implants has been introduced to overcome the difficulties of intra-operative implant molding. The authors present a new technique, which consists of the prefabrication of implant molds using three-dimensional (3D) printers and polymethyl-methacrylate (PMMA) casting. Methods : A total of 16 patients with large skull defects (>100 $cm^2$) underwent cranioplasty between November 2009 and April 2011. For unilateral cranial defects, 3D images of the skull were obtained from preoperative axial 1-mm spiral computed tomography (CT) scans. The image of the implant was generated by a digital subtraction mirror-imaging process using the normal side of the cranium as a model. For bilateral cranial defects, precraniectomy routine spiral CT scan data were merged with postcraniectomy 3D CT images following a smoothing process. Prefabrication of the mold was performed by the 3D printer. Intraoperatively, the PMMA implant was created with the prefabricated mold, and fit into the cranial defect. Results : The median operation time was $184.36{\pm}26.07$ minutes. Postoperative CT scans showed excellent restoration of the symmetrical contours and curvature of the cranium in all cases. The median follow-up period was 23 months (range, 14-28 months). Postoperative infection was developed in one case (6.2%) who had an open wound defect previously. Conclusion : Customized cranioplasty PMMA implants using 3D printer may be a useful technique for the reconstruction of various cranial defects.

• Journal of the Korean Ceramic Society
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• v.36 no.1
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• pp.61-68
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• 1999

To analyze several defects and residual stress in sintering of layer structure materials, multiayer materials with TZP/SUS and ZT/SUS, and bilayer materials with porcelain/alumina and porcelain/Y-TZP were fabricated by sintering method. Multilayer materials prepared by pressureless sintering show the sintering defect such as warping, splitting, cracking originated from the difference of sintering shrinkage between each layer, which could be controlled by the adjustment of number and thickness in interlayer. In tape casting, a certain pressure given during sintering relaxed the sintering defects, specially warping. The residual stress in bilayer was examined with Vickers indentation method. A small tensile stress in porcelain/alumina and a large compressive stress in porcelain/Y-TZP were generated on the porcelain interface due to the thermal expansion mismatch, which affected the strength of bilayer materials. As a consequence, the sintering defects of multilayer materials and the residual stresses of bilayer materials were dominantly influenced on material design and starting material constants.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.905-909
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• 2001

The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.