• The Journal of Korean Academy of Prosthodontics
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• v.45 no.4
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• pp.522-533
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• 2007

Statement of problem: Despite of the recent development of the titanium casting system methods, the casting defects such as imperfect casting and internal porosity were frequently observed. Purpose: The purposes of this study were to compare and measure the castability, microhardness, and surface reaction between Grade 2 pure titanium and Ti-6Al-4V by casting these alloys from the different sprue design conditions. Material and methods: Depending on the sprue designs and titanium alloys, 42 ready-made wax patterns were used. By analyzing the remodeling of the cast, internal porosity, microhardness, and titanium surface layer of SEM, there were several results we observed. Results: 1. The measured castability of titanium were categorized in the ascending order: individual sprue group, runner bar group, and single group. This data are based on the statistically signigicant differences. 2. The castability of titanium has not showed the statistically significant differences among the alloys. However, CP-Ti groups were superior to Ti-6Al-4V groups by showing the noticeable castability. 3. The surface layers of the castings of all groups have showed $5{\mu}m$ titanium oxide layers irrespective of sprue designs and titanium alloys. Conclusion: From the above study results, by fabricating the restorations from the centrifugal casting machine direct sprue designs revealed better castability. As we increased the number of sprues in the wax pattern, it revealed better castability. The castability of pure titanium rather than that of Ti-6Al-4V was remarkable. To fabricate the complex forms of the restorations, further researches on the efficient sprue designs and titanium alloys must be made.

• Journal of Technologic Dentistry
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• v.34 no.2
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• pp.75-81
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• 2012

Purpose: All ceramic crown, made from zirconia instead of metal for core material, is recognized the best esthetical prosthesis. Recently, high-priced zirconia blocks and expensive CAD/CAM machines come into use for making zirconia core. In this study, slip casting process is adapted to evaluate the possibility of the recycling the remained parts of zirconia block after machining. Methods: Remained zirconia blocks were reduced to powders with zirconia mortar, and screened with 180 mesh sieve. Passed powders were ball milled under various conditions to obtain the optimum zirconia slip for casting. Solid casting method was used for casting the specimens with plaster mold. Formed specimens were dried and biscuit fired at $1,000^{\circ}C$ for 1 hour. Biscuit fired specimens were finished with exact shape of square pillar. Finished specimens were fired from $1,200^{\circ}C$ to $1,550^{\circ}C$ at $50^{\circ}C$ intervals for 1 hour. Linear shrinkage, apparent porosity, water absorption, bulk density, and flexural strength were tested. Microstructures were observed by SEM. Results: Above examinations indicated that the optimum firing temperture was $1,500^{\circ}C$, and when fired at this temperature for 1 hour, apparent porosity was 0% and flexural strength was 680MPa. SEM photomicrographs showed uniform 200~300nm grain size, which is equal with microcture of sintered commercial zirconia block. when compare 24% linear shrinkage of cast specimen with 20% linear shrinkage of CAD/CAM machined block, it was estimated that the size controlling of cast core was not so difficult. Conclusion: According to the all of this experimental results, the cast zirconia core produced from the remained parts of zirconia block was possible to use for all ceramic denture.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.3
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• pp.88-97
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• 2009

The vacuum die casting techniques can diminish the porosity of products and provide better surface appearance by the ordinary high pressure die casting process. The vacuum system can also reduce the cold laps in the die casting process and minimize the overflow pockets of the die. The vacuum system does not need high pressures to die cast compared to the ordinary die casting process, and so enables die casting of large parts for a given machine size. Parts made by the vacuum system have higher strength and more elongation than parts made by the ordinary die casting systems. In this paper, we designed and produced the Magnesium seat frames using the vacuum die casting processes. The new Magnesium seat frame was designed to satisfy safety regulations. Some safety test procedures of the seat frame were simulated by the finite element method. We obtained 10% weight reduction by design modification of seat frames compared to the current model. Flow simulations were carried out to minimize the trial and error in producing the parts. The die casted parts using vacuum systems resulted in better mechanical characteristics and no defects compared to those without vacuum systems.

• Transactions of Materials Processing
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• v.21 no.3
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• pp.195-201
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• 2012

A vacuum ladling die casting system is suggested as a means to obtain a high vacuum level. A high vacuum of 17.8 mmHg is obtained by sealing the inner space of the mould. The sample product is a rear-head housing for an auto-compressor, and the die-casting with 6-cavities was conducted. The flow analysis shows that the filling speed during vacuum ladling is faster than for a non-vacuum system. The air holes in the sample product were too small to be seen with the naked eye in X-ray films. Density tests show that the high vacuum ladling system reduces the internal porosity as much as 57.8% when compared to the non-vacuum system. A defective rate of only 0.17% was found from leak testing. The results of this research prove that the high vacuum die-casting process is useful for manufacturing of aluminium components under high internal pressure.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.11a
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• pp.902-905
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• 2000

As the manufacturing processes of automotive engine piston, gravity die-casting, squeeze casting, hot forging and powder forging process are generally used for the various specifications. As the semi-solid forming(SSF) is compared with conventional casting such as gravity die-casting and squeeze casting for the characteristics of its process, the product without inner defects such as gas porosity and segregation can be obtained and its microstructure is globular grain. In SSF process, the materials are heated up to the temperature between the solvus and liquidus line at which the materials exists in the form of liquid-solid mixture. In this time, Discussion is given about reheating process of row material and results are presented regarding accurate temperature and process variables controlling for right solid fractions.

• Journal of Technologic Dentistry
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• v.32 no.4
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• pp.307-315
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• 2010

Purpose: The purpose of this study was to investigate the change of microstructures and mechanical properties of pure titanium casting specimens as a function of mold temperatures. Methods: The pure titanium castings were fabricated using the centrifugal vacuum casting method with different mold temperatures of $200{\sim}500^{\circ}C$. The resulting castings were characterized by optical microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy and vicker,s hardness tester. Results: In case of the mold temperatures over $400^{\circ}C$, the porosity, surface crack and large grain size were observed in resulting castings. Conclusion: In this work, The most suitable mold temperature in casting of pure titanium was $300^{\circ}C$.

• Journal of the Korean institute of surface engineering
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• v.37 no.5
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• pp.296-300
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• 2004

The defects of partial denture frameworks are mainly shrinkage porosity, inclusions, micro-crack, particles from investment, and dendritic structure. In order to investigate a good casting condition of partial denture frameworks, the three casting alloys and casting methods were used and detected casting defects were analyzed by using electrochemical methods. Three casting alloys (63Co-27Cr-5.5Mo, 63Ni-16Cr, 63Co-30Cr-5Mo) were prepared for fabricating partial denture frameworks with various casting methods; centrifugal casting (Kerr, USA), high frequency induction casting (Jelenko Eagle, USA), vacuum pressure casting (Bego, Germany). The casting temperature was $1,380^{\circ}C$ (63Co-27Cr-5.5Mo and 63Ni-16Cr) and $1,420^{\circ}C$ (63Co-30Cr-5Mo). The casting morphologies were analyzed using FE-SEM and EDX. The corrosion test of the dendritic structure was performed through potentiodynamic method in 0.9% NaCl solutions at $36.5^{\circ}C$ and corrosion surface was observed using SEM. The defects of partial denture frameworks improved in the order of centrifugal casting, high frequency induction casting, and vacuum pressure casting method, especially, pore defects were found at part of clasp in the case of centrifugal casting method. The structure of casting showed dendritic structure for three casting alloys. In the 63Co-27Cr-5.5Mo and 63Co-30Cr-5Mo, $\alpha$-Co and $\varepsilon$-Co phases were identified at matrix and $${\gamma}$-Ni_2$Cr second phase were shown in 63Ni-16Cr. Also, the corrosion resistance of cast structure increased in the order of vacuum pressure casting, high frequency induction casting, and centrifugal casting method.

• Transactions of Materials Processing
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• v.14 no.3 s.75
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• pp.224-232
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• 2005

The high-pressure die-casting is one of the most effective methods to produce a large amount of products in short cycle time. This process, however, has a problem that the gas porosity defect appears easily. The generation of gas porosity is known mainly due to the air entrapment during the injection stage. Most of numerical simulations for the molten metal flow pattern observations have done in the treating of one phase fluid flow but the gas-liquid interface is essentially multi- phase phenomenon. In this paper, the two-phase fluid flow numerical simulation methods have been adapted to predict the gas porosity generations in the molten metal. The accuracy and the usefulness of the new simulation module have been emphasized and verified through some comparison experiments.

• Journal of Korea Foundry Society
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• v.43 no.6
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• pp.294-301
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• 2023

The effects of Cu on feeding and macro-porosity characteristics were investigated in hypo- (A356 and 319) and hypereutectic (391) aluminum-silicon alloys. T-section and Tatur tests showed that the feeding and macro-porosity characteristics were significantly different between the hypo- and hypereutectic alloys. The hole and the pipe in the T-section and the Tatur casting in hypereutectic alloy showed a rough and irregular shape due to the faceted growth of the primary silicon, while the results of the hypoeutectic alloys exhibited a rather smooth surface. However, the addition of Cu did not strongly affect the macro-feeding behavior. It is known that copper segregates and interferes the feeding process in the last stage of solidification, possibly leading to form more amount of micro shrinkage porosity by the addition of Cu. The macro porosity formation mechanism and feeding properties were discussed upon T-section and Tatur tests together with an alloying addition.

• Journal of Korea Foundry Society
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• v.12 no.4
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• pp.346-354
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• 1992

In Al-Pb monotectic alloys Pb particles are difficult to uniformly distribute over the Al matrix because of the gravity segregation of pb element. Therefore the effects of centrifugally spray casting process on microstructures and distributions of Pb particle were investigated. As the preform thickened the sine of Pb particle became larger, the amount of porosity became lower and microstructures showed the change from spray-deposition microstructures in the lower part of the preform to spray-casting microstructures in the upper part of it. The size of Pb particles, amount of porosity and splat layer boundaries in hot forged preform showed still less than of as-deposited preform.