• 한국주조공학회지
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• 제24권3호
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• pp.165-174
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• 2004

The pore formation characteristic of Mg alloy during Lost Foam Casting(LFC) was investigated with reduced pressure test and real casting, which was compared with the results of previous work for Al alloy. Cast Mg alloys in LFC had much lower porosities in comparison with those of Al alloys. Also, the proper pouring temperature gave the minimum porosity like Al alloy although it was higher than that of Al alloys due to the worse fluidity of Mg alloy. The pore formation mechanism of Mg alloy in LFC was similar to that of AI alloy but the critical temperature showing the different mechanism is higher than that of Al alloy as much as $30{\sim}50^{\circ}C$. The result that Mg alloy in LFC had the lower porosity comparing with Al alloy was due to the extra solubility of hydrogen gas although the solubility of Al alloy was easily exceeded by the external sources like pyrolyzed polystyrene products. The mold evacuation gave the lower porosity due to the removal of polystyrene pyrolysis products, and reduced shrinkage defects. Also, there was a proper evacuation pressure that gave a porosity of almost 0vol%. But much higher vacuum degree than this proper pressure caused the severe entrapment of polymer pyrolysis products that gave the large porosity.

• 한국산학기술학회논문지
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• 제20권7호
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• pp.347-352
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• 2019

본 연구는 소형 유도전동기 회전자를 생산공장에서 금형주조(die casting)로 제작 시 발생하는 cast 부 품질문제를 개선하기 위하여 수행되었다. 1차 연구결과와 현장 적용성을 고려한 수많은 parametric study를 통하여 새로운 rotor core cast model을 제안하였으며, 그 제안된 model에 대한 유효성을 평가, 검증하기 위하여 주조해석 전용프로그램을 사용한 수치해석과 실제품에 대한 현장실험을 통하여 다음과 같은 결론을 얻었다. 첫째, 유도전동기 회전자의 새로운 cast model에 대한 충진해석을 수행한 결과 용탕은 하부 end ring 부를 먼저 충진하고 이동하여 상부 end ring, core slot 부분을 충진하고 최종적으로 core slot 부분에서 충진이 완료된다. 둘째, 새롭게 제안된 rotor core cast model에 대한 용탕의 유동 양상을 보면 하부 end ring 부에 용탕의 유동에 의한 와류가 적게 발생하였으며, 현장실험 결과 하부 end ring 부 단면에서 소량의 작은 결함만이 발견되었다. 셋째, 유도전동기 회전자 제작 시 rotor core cast 형상 변경을 통하여 end ring 부 결함 발생 면적이 약 70 % 감소한 양호한 품질의 회전자를 생산할 수 있다.

• 한국주조공학회지
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• 제26권2호
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• pp.77-84
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• 2006

The effect of alloy composition on the glass forming ability (GFA) of the Ca-rich Ca-Mg-Zn alloys has been investigated in $Ca_{65}Mg_{5+x}Zn_{30-x}$ and $Ca_{55+x}Mg_{15}Zn_{30-x}$ (x=0, 5, 10, 15, 20) alloys. In a wide composition range of 15-25% Zn and 10-20% Mg bulk metallic glass (BMG) samples with the diameter larger than 6 mm are fabricated by conventional copper mold casting method in air atmosphere. Among the alloys investigated, the $Ca_{65}Mg_{15}Zn_{20}$ alloy exhibits the highest GFA enabling to form BMG sample with the diameter of at least 15 mm. The crystalline phase formed during solidification of $Ca_{65}Mg_{15}Zn_{20}$ ($D_{max}=15\;mm$) could be identified as a mixture of $Ca_3Zn$ and $CaMg_2$ cause by the redistribution of the constituent elements on long-range scale. The compressive fracture strength and fracture elongation of the $Ca_{65}Mg_{15}Zn_{20}$ BMG are 602 MPa and 2.08% respectively. The ${\sigma}$ parameter which has been recently proposed for evaluating GFA exhibits better correlation with GFA of Ca-Mg-Zn alloys than other parameters suggested so far such as ${\Delta}T_x$, $T_{rg}$, K, ${\gamma}$, and ${\Delta}T^*$ parameters.

• 대한기계학회논문집A
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• 제34권7호
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• pp.919-928
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• 2010

연속주조 시에 폭변경 속도를 향상시키기 위해 폭조정의 4 가지 패턴에 대해 연구하였다. 주요 사항은 폭변경 장치의 구동력을 최소화하고, 몰드 내의 응고막의 변형해석 모델을 개발하고, 폭변경 속도 상승을 제한하는 주요인자를 도출하는 것이다. 폭변경 실험을 근간으로 4 개 패턴의 주요 특징을 도출하였고, 각 패턴에 대한 힘을 비교하였다. 실험은 각 패턴의 구동력 비교를 위해 동일한 주조속도에서 수행하였다. 응고막변형 해석모델의 변수를 조정하기 위해 실험결과를 모델에 적용하였다. 폭변경 속도를 상승시키고, 구동력을 저감시키기 위해 패턴의 변수를 제어하였다. 가장 효율적인 패턴은 고속패턴이었으며, 구동력을 저감하기 위한 주요인자는 구동장치가 이동할 때의 기울기였다.

• 한국세라믹학회지
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• 제56권4호
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• pp.365-373
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• 2019

Pond ash is a mixture of mostly coarser fly ash and bottom ash. The recycling rate of pond ash is low because pond ash is mixed with seawater and deposited in ponds. The pond ash is also subjected to natural weathering over a period of time. In this study, we investigated whether pond ash can be used as a raw material of geopolymers, without any purification process or through a minimal purification process. In addition, we investigated whether synthetic basalt made by adding foaming agent to geopolymer or casting it into a mold can show the surface of the natural basalt as it is. The highest 7-day compressive strength in geopolymers from pond ash without purification process was 26 MPa. The highest 7-day compressive strength in geopolymers from pond ash with impurities removed through dry sieve analysis was found to improve to 80 MPa. On the other hand, synthetic basalt made with geopolymer was shown to be more advantageous aesthetically when produced by casting it in a silicone mold rather than by adding a foaming agent. Non-purified pond ash can be made into geopolymers having low strength. Pond ash purified by sieving can, without use of an aggregate, be made into geopolymer having high-strength. Also, it is possible to produce synthetic basalt with the same appearance as natural basalt and sufficient strength for commercialization. This process will contribute to the mass consumption and recycling of pond ash.

• Journal of Korean Neurosurgical Society
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• 제52권6호
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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.

• 한국의학물리학회지:의학물리
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• 제30권1호
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• pp.32-38
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• 2019

Purpose: The objective of this study is to evaluate the geometrical accuracy of a patient-specific bolus based on a three-dimensional (3D) printed mold and casting method. Materials and Methods: Three breast cancer patients undergoing treatment for a superficial region were scanned using computed tomography (CT) and a designed bolus structure through a treatment planning system (TPS). For the fabrication of patient-specific bolus, we cast harmless certified silicone into 3D printed molds. The produced bolus was also imaged using CT under the same conditions as the patient CT to acquire its geometrical shape. We compared the shapes of the produced bolus with the planned bolus structure from the TPS by measuring the average distance between two structures after a surface registration. Results and Conclusions: The result of the average difference in distance was within 1 mm and, as the worst case, the absolute difference did not exceed ${\pm}2mm$. The result of the geometric difference in the cross-section profile of each bolus was approximately 1 mm, which is a similar property of the average difference in distance. This discrepancy was negligible in affecting the dose reduction. The proposed fabrication of patient-specific bolus is useful for radiation therapy in the treatment of superficial regions, particularly those with an irregular shape.

• Design & Manufacturing
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• 제14권4호
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• pp.71-77
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• 2020

Various manufacturing technologies, including over-molding and insert-injection molding, are used to produce hybrid plastics and metals. However, there are disadvantages to these technologies, as they require several steps in manufacturing and are limited to what can be reasonably achieved within the complexities of part geometry. This study aims to determine a practical approach for producing metal/plastic hybrid components by combining plastic injection molding and metal die casting to create a new hybrid metal/plastic molding process. The integrated metal/plastic hybrid injection molding process developed in this study uses the proven method of multi-component technology as a basis to combine plastic injection molding with metal die casting into one integrated process. In this study, the electrical conductivity and ampacity were verified to qualify the new process for the production of parts used in electronic devices. The electrical conductivity was measured, contacting both sides of the test sample with constant pressure, and the resistivity was measured using a micro ohmmeter. Also, the specific conductivity was subsequently calculated from the resistivity and contact surface of the conductor path. The ampacity defines the maximum amount of current a conductive path can carry before sustaining immediate or progressive deterioration. The manufactured hybrid multi-components were loaded with increasing currents, while the temperature was recorded with an infrared camera. To compare the measured infrared images, an electro-thermal simulation was conducted using commercial CAE software to predict the maximum temperature of the power loaded parts. Overall, during the injection molding process, it was demonstrated that multifunctional parts can be produced for electric and electronic applications.

• 공업화학
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• 제20권3호
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• pp.317-321
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• 2009

고체 산화물 전해질로 사용되고 있는 초 이온 전도체인 $K^+-{\beta}/{\beta}"-Al_2O_3$의 고온 상관계와 소결성 분석을 위하여 $K_2O-LiO_2-Al_2O_3$ 삼성분계로부터 고상반응을 통하여 순수한 $K^+-{\beta}/{\beta}"-Al_2O_3$ 분말을 합성한 후 slip casting방법과 냉간정수압성형에 의하여 tube와 disk형을 각각 제작하였다. Slip casting은 40 wt%의 고체함량을 가지는 슬러리를 사용해 알루미나 몰드에서 이루어졌고 냉간정수압성형은 20 MPa의 압력하에서 수행되었다. 성형체들은 $1600^{\circ}C$, $1700^{\circ}C$, $1750^{\circ}C$에서 각각 소결하여 성형방법에 따른 상관계와 소결밀도를 조사하였다. 냉간정수압성형에 의한 시편이 $1700^{\circ}C$까지 ${\beta}"-Al_2O_3$의 상분율이 월등히 높은 반면, 소결밀도에 있어서는 slip casting방법의 경우가 다소 높았다. 소결 시 상대밀도는 $1750^{\circ}C$에서 1 h 경과 후, 두 경우 모두 약 83%를 나타내었다. 90 min 이상 소결하였을 때는 입자의 과대성장과 기공으로 인해 오히려 밀도가 낮아졌다.

• Design & Manufacturing
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• 제7권1호
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• pp.45-49
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• 2013

Since the shell-molds are used to make casting the metal parts for the automobile industry, the quality may well be inconsistent with the lower productivity, increasing the cost of the end products. The primary elbow design shell molded steel castings being produced through extrusion process has $180^{\varnothing}$ O.D., $150^{\varnothing}$ I.D., 14mm thickness and 400mm length, while being processed onto the left side of the tubing. The primary cause for the poor processing is the uneven manual shell molding. If the manual shell molds should be produced to have even quality, they would not be processed for tube linking. The purpose of this study was to develop the flask-molds for manufacturing of the shell molds to ensure mass-production, consistent quality, ommission of processing and comfortable working environment. For this purpose, four flask-molds were produced and thereby, four shell molds were assembled. In particular, the shell molds for processing were formed of the fine coated sand to be blown. As a result, productivity increased about three times, while a consistent quality was ensured. Furthermore, the tubes could be linked with each other without being processed, while pallets could be stacked, stored, transported and managed more easily. In a nut-shell, the molding theory could be applied more effectively. However, it is conceived that this study should be followed up by future studies which will research into reliability and endurability of the end products.