• Journal of Korea Foundry Society
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• v.28 no.3
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• pp.113-118
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• 2008

A new approach of producing martensitic structure for guide-roll materials was developed using centrifugal casting instead of classic overlay welding process. Centrifugal casting offered a simpler process, fewer defects and even microstructures. Especially in terms of thermal fatigue cracking which usually occurs in the HAZ of welding beads of used continuous caster guide roll materials made by overlay welding process. A typical tensile strength of 1,600 MPa was obtained by this process and was higher than typical tensile strength($800{\sim}1,200\;MPa$) with overlay welding technique. Tempering at $400{\sim}550^{\circ}C$ for 2 hrs was observed to have significant precipitate hardening effect which increases strength and elongation. Nitrogen content from the Cr-N input in the casting process was found to have positive contribution to decrease the volume fraction of ${\delta}$-ferrite which directly corresponds to increasing strength of the roll materials.

• Korean Journal of Materials Research
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• v.16 no.11
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• pp.668-675
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• 2006

In the partial squeeze casting process, the filling behavior of liquid metal and solidification pattern in thick area have significant influence on the quality of casting products and die life. For the optimal casting design of automobile transmission gear housing, various analyses were performed in this study by using computer simulation code, MAGMAsoft and the simulation results were compared and analyzed with experimental results. By air pressure criteria, internal porosities caused by air entrap during the mold filling were predicted and reduced remarkably by modification of gating system. Also, optimal squeeze-time lag to apply partial squeeze pin in thick area was calculated and the castings was free from shrinkage defects with the result of solidification analysis. Consequently, casting design for automobile transmission gear housing was optimized and approved by Computer Tomography.

• Journal of Technologic Dentistry
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• v.41 no.4
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• pp.255-262
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• 2019

Purpose: Recently, the production technology of dental prosthesis using 3D Printer workpeices has been developed. However, the lack of information on the work processes and casting techniques of materials for 3D printing casting is expected to require research. Therefore, in this study, we intend to cast a Dental DLP 3D Printer workpiece, which is being commercialized, to identify its appearance and internal clearance, and to observe its castability. Methods: Castability of the 3D Printer workpiece was evaluated. The specimen is prepared in a cylindrical shape and in a 1 mm thick coping shape. The control specimen is made of wax and the experimental specimen is made of resin using two types of 3D printers. After casting, the appearance of the casting body was observed and the internal clearance of the coping was measured. Results: RP1 and RP2, cylindrical specimens, were partially cast or fin. When coping-type specimens were measured before casting, the internal clearance of PE2 was more accurate than that of PC and PE1. When coping-type specimens were measured after casting, CE1 was the most accurate in occlusal clearance and CE2n was the most accurate in axial clearance. Conclusion: 1. Exterior observations of the casting body indicated casting defects and fins. 2. Internal clearance observations show that the occlusal clearance of the castings is larger after casting, and the axial clearance of the castings is smaller after casting. 3. It is judged that the RP2 specimen is more likely to be applied for casting than the RP1 specimen.

• Journal of Korea Foundry Society
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• v.13 no.6
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• pp.532-539
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• 1993

The effect of casting variables for making pure Al and Al-5wt%Si alloy rods free from any surface and inside defects was studied by adopting the horizontal continuous casting method with heated mold. The rods were cast under the casting conditions such as the mold temperature of $670{\sim}690^{\circ}C$, water flow rate of $0.2{\sim}0.6{\ell}/min$, and rod diameter of $4{\sim}8mm$, when the melt temperature and mold to cooler distance was fixed at $700^{\circ}C$ and 20mm, respectively. The results represented that the casting speed for good quality rod increased as the water flow rate increased, whereas, the casting speed decreased as the rod diameter or mold temperature increased. The statistical analysis of $2^3$ factorial design was also applied and the results represented that the averaged optimum casting speed for pure Al(302mm/min) was higher than that of Al-5wt%Si alloy(273mm/min) resulting from the difference of superheat applied. The effect of rod diameter on the optimum casting speed was the highest for pure Al as well as Al-5wt%Si alloy. The effect of water flow rate and mold temperature on the optimum casting speed was in decreasing order.

• Journal of Korea Foundry Society
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• v.41 no.2
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• pp.127-131
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• 2021

Based on its good compatibility with high-temperature environments, the Ti-48Al-2Cr-2Nb alloy is used for high-temperature materials of industrial equipment. In this study, a Ti-48Al-2Cr-2Nb alloy turbocharger turbine wheel was fabricated by a vacuum centrifugal casting method. The conditions that prevent misrun defects of the turbocharger turbine wheel blade from centrifugal casting using alumina molds were investigated. The microstructure of the alloy prepared by vacuum centrifugal casting was studied by means of optical microscopy (OM), with a micro-Vickers hardness analyzer (HV), by X-ray diffraction (XRD) and by SEM-EDS. The HV and SEM-EDS examinations of the as-cast Ti-48Al-2Cr-2Nb alloy showed that the thickness of the oxide layer (α-case) was typically less than 50 ㎛. At a high preheating temperature of 1,100℃, a moderate RPM of 260, and with an alumina mold with a large gate size, there were almost no misrun defects. Therefore, it was confirmed that a Ti-48Al-2Cr-2Nb alloy turbocharger turbine wheel with fewer misrun defects could be achieved through a high preheating temperature, a moderate RPM, a large gate size and an alumina mold to suppress the formation of alpha-case components.

• Journal of Korea Ship Safrty Technology Authority
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• v.12
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• pp.36-43
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• 2003

Fatigue life estimation by the theoretical stress concentration factors are, in general, considerably different from test results. And in calculating stress concentration factor, it is very difficult to consider actual geometry and material property which are the notch shapes, imperfections or defects of materials such as porosities inclusions and casting defects, etc. Therefore, the paper deals with the experimental method to find out the more exact stress concentration factors by measuring the strain distributions on each specimen by 3D-ESPI(Electronic Speckle Pattern Interferometry) System. Then the fatigue lives are compared between theoretical calculations using stress concentration factors determined by 3D-ESPI system and fatigue test results

• Journal of Korea Foundry Society
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• v.17 no.5
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• pp.465-471
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• 1997

An integrated computer program consisting of a pre-processor, main solver, and post-processor was developed for the design of large steel castings. The pre-processor, based on the AutoCAD, enables the user to produce approval drawings, casting design drawings and mesh diagrams in sequence using a personal computer. In the main solver, two numerical models were employed; one models the fluid flow during mold filling, and the other models the heat transfer and solidification. The post-processor can be used to present simulation results such as flow pattern, mold filling sequences, solidification times, temperature gradients and location of shrinkage defects by color graphics. In order to validate the applicability of the present integrated program, a series of experiments on simple-shaped steel castings were carried out. After the validation of the present model, it was applied to the casting design of the large steel anchor of an SC42 alloy. Various solidification parameters such as a temperature distribution and a solidification time in the casting and the mold were compared with those obtained experimentally. Simulated results predicting shrinkage defects were in good agreement with those obtained experimentally. It was found that the present method can be successfully applied to the quantitative casting design for complex-shaped large steel castings.

• The Journal of Korean Academy of Prosthodontics
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• v.44 no.5
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• pp.654-664
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• 2006

Statement of problem: There has been a eat interest in the use of titanium for fixed and removable prostheses in recent because of its excellent biocompatibility. However, the melting temperature and chemical reactivity of titanium necessities casting system different from those used in conventional casting. The current titanium casting systems are based on an electric-arc design for melting the metal in an argon atmosphere and its exclusive investment. Despite the new development in Ti casting system, inadequate mold filling and internal porosity are frequently observed casting defects. Purpose : The purposes of this study were to compare the castibility and reaction layer of the casting titanium under the two casting machines and their investment condition. Material and method: coping and machine-milled titanium coping according to the casting methods and the marginal configurations. The total 28 specimens were used, and these are divided into 4 groups according to 2 casting machines and 2 investments. The castings were analyzed using x-ray microanalysis and microhardness testing. The reaction layer between margin of titanium casting and the investments was observed and analyzed with scanning electron microscope. Result: 1. Castabiliy of casting titanium specimen was best in the group of centrifugal casting machine and Selevest $CB^{\circledR}$ and good that of Selevest CB and pressure differential casting machine, Rematitan plus and centrifugal casting machine, Rematitan plus and pressure differential casting machine in order. 2. There was no significanct correlation in titanium castability in respect of casting machine. However ANOVA indicated that Selevest $CB^{\circledR}$ groups had significantly better castability than Rematitan $plus^{\circledR}$ groups.(p<0.05) 3. There was a significant microhardness difference between centrifugal casting machine groups and pressure differential groups.(p<0.05) Titanium castings in centifugal groups had significantly harder than those in pressure differential groups. 4. The addition of zirconia decreased interfacial reactivity. Conclusion: above result revealed that of the castability of titanium casting specimens had little correlation in casting machines and was better in magnesia-based investment contained ZrO2 groups. However in order to practice casting titanium in clininic, its castability should be improved, also there should be more research on factor of castability so that long-span prothesis and removable partial denture metla frame may be casted completly.

• Journal of the Korean Ceramic Society
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• v.50 no.2
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• pp.142-148
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• 2013

Conventional cold isostatic pressing, slip casting, and filter pressing are not completely suitable for fabricating large plates because of disadvantages such as the high cost of equipment and formation of density gradient. These problems could be avoided by employing pressure-vacuum hybrid slip casting (PVHSC). In the PVHSC, the consolidation occurs not only by the compression of the slip in casting room, but also by vacuum sucking of the dispersion medium around the mold. We prepared the alumina bodies by the PVHSC in a static- or stepwise-pressure manner for loading up to 0.5 MPa using an aqueous slip. The green bodies were dried at $30^{\circ}C$ with 40 ~ 80% relative humidity. Under static pressure, casting induced a density gradient in the formed body, resulting in cracking and distortion after the firing. However, the stepwise pressure loading resulted in green bodies with homogeneous density, and the minimization of the appearance of those defects in final products. Desirable drying results were obtained from the cast bodies dried with 80% RH environment humidity. When sintered at $1650^{\circ}C$ for 4 h, the alumina plate made by stepwise-pressure casting reached full density (> 99.7% relative density).

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.32 no.1
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• pp.25-32
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• 2022

Investment casting is a production method commonly used to manufacture precision equipment, medical fields, and accessories, and has continued to develop through the modernization of equipment and high quality of materials, and its scope of use has been expanded. The purpose of this study is to minimize the defect rate by deriving structural improvement and standardization of mold temperature, which are key elements of the investment casting process, to minimize the defect rate. The scope of the study is limited to jewelry manufacturing casting processes suitable for understanding the structure and principles of small gate, and an experimental research is to be conducted by using soft Wax, gypsum powder, and 14 K gold as research materials. According to the results, the most appropriate casting standard temperature for the casting pattern of Alloy 14 k was the lowest turbulence at 980℃ flask temperature of 550℃, so good products could be produced. As a future task of this study, detailed studies are needed to data the structure and system temperature of small gate, reduce production defects in the field, and provide data for excellent investment casting competitiveness.