• Journal of Korea Foundry Society
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• v.39 no.5
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• pp.87-93
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• 2019

The effects of mold materials on the microstructure and tensile properties were investigated to develop a mass production technique of aluminum alloy parts with excellent mechanical properties using a lost foam casting method. The microstructures of the plate-shaped cast alloy showed a tendency to be finer in proportion to the thickness of the plate, and a remarkably fine structure was obtained by applying a steel chill or a ball as a mold material compared to general sand. When a steel ball was used, it was observed that the larger the ball, the finer the cast structure and the better the tensile properties. The microstructure and tensile properties of the cast parts with complex shapes were greatly affected by the gating system, but the positive effects of the steel chill and the steel ball as a mold material were clear.

• Korean Journal of Metals and Materials
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• v.50 no.2
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• pp.176-182
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• 2012

The main purpose of this study was to evaluate the endurance against Al alloy melts and wear resistance of an in-situ synthesized titanium matrix composite (TMC) sleeve for aluminum alloy die-casting. The conventional die-casting shot sleeve material was STD61 tool steel. TMCs have great thermal stability, wear and oxidation resistance. The in-situ reaction between Ti and $B_4C$ leads to two kinds of thermodynamically stable reinforcements, such as TiBw and TiCp. To evaluate the feasibility of the application to a TMCs diecasting shot sleeve, the interfacial reaction behavior was examined between Al alloys melts with TMCs and STD61 tool steel. The pin-on-disk type dry sliding wear test was also investigated for TMCs and STD61 tool steel.

• The Journal of Advanced Prosthodontics
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• v.10 no.2
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• pp.128-131
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• 2018

PURPOSE. This study aimed to evaluate the marginal discrepancy of full-arch frameworks in implant-supported prostheses fabricated using pre-sintered soft alloy (PSA). MATERIALS AND METHODS. Full-arch metal frameworks were fabricated on the edentulous implant model using casting alloy (CA), fully-sintered hard alloy (FHA), and PSA (n = 4 in each group). To evaluate the misfit of the framework to the abutments, the absolute marginal discrepancy (AMD) values of the frameworks were measured in cross-sectional images that had been drawn as part of the triple-scan protocol. The AMD values were compared among the tested alloy groups using the Kruskal-Wallis test, with a post hoc Mann-Whitney U test (${\alpha}=.05$). RESULTS. The FHA and PSA groups showed lower marginal discrepancies than the CA group (P<.001). However, the FHA group did not differ significantly from the PSA group. CONCLUSION. Soft alloy milling is comparable to hard alloy milling, and it is more precise than casting in terms of the marginal fit of implant-supported, full-arch prostheses.

• Journal of Korea Foundry Society
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• v.32 no.5
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• pp.219-224
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• 2012

The effects of Mg and Si contents on the microstructure and mechanical properties in Al-Mg alloy (ALDC6) were investigated. The results showed that phase fraction and size of $Mg_2Si$ and $Al_{15}(Fe,Mn)_3Si_2$ phase in the microstructure of Al-Mg alloy were increased as the Mg and Si contents were raised from 2.5 to 3.5 wt%. With Si content of 1.5 wt%, freezing range of the alloy was significantly reduced and solidification became more complex during the final stage of solidification. While there was no significant influence of Mg contents on mechanical properties, Si contents up to 1.5 wt%, strongly affected the mechanical properties. Especially elongation was reduced by about a half with more than 1.0 wt%Si in the alloy. The bending and impact strength were decreased with increased amount of Si in the alloy, as well. The lowered mechanical properties are because of the growth of particle shaped coarse $Mg_2Si$ phase and precipitation of the needle like $\beta$-AlFeSi in the microstructure at the last region to solidify due to presence of excess amount of Si in the alloy.

• Journal of Korea Foundry Society
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• v.41 no.3
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• pp.241-251
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• 2021

7000-series aluminum alloys are noted for their superior strength compared with other Al alloys, and their billets are generally fabricated by direct-chill (DC) casting. Surface defects in a DC-cast aluminum billet are mainly related to exudation and the meniscus freezing phenomenon, which are influenced by alloy compositions, casting speed, and casting temperature. 7000-series aluminum alloys have a wide freezing range during solidification, which makes it easy for casting defects to occur. In this study, we investigated surface defect evolution in casting billets of Al-8Zn-2Mg-2Cu alloy fabricated by a DC casting process. The billets showed "wavy" or "dotted" surfaces. The wavy surface was formed by meniscus freezing at a lower casting speed (200 mm/min) and temperature (655 ℃). In the wavy surface, refined dendritic cells were observed in a concave region due to the constitutional supercooling caused by meniscus freezing. Meanwhile, at a higher casting temperature (675 ℃), the dotted surface was formed by pore formation. In the dotted surfaces in the billet formed at a high casting speed (230 mm/min), an exudation layer was formed by the high metallostatic head pressure. The dotted region and the smooth region had a refined dendritic morphology and a columnar morphology at the exudation layer, respectively. This is attributed to the formation of gas pores in the dotted region.

• Journal of Korea Foundry Society
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• v.40 no.3
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• pp.66-75
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• 2020

The aim of this study was to optimize a solid solution treatment for a high pressure die casting Al-10Si-0.3Mg-0.6Mn alloy to avoid blistering and to improve the strength of the alloy. To achieve this goal, the number density of the blisters and the strength of the alloy under various solid solution treatment (SST) conditions were evaluated. The SST was performed at 470, 490, 510 and 530℃ for 20, 60, 120, 240 and 480 min on the alloy. The number density of the blisters increased with the increasing temperature and time of the SST and the defect area fraction. The yield strength of the alloy after the T6 heat treatment increased with the increasing SST temperature and time. Based on the results, it is suggested that SST should be performed at 510℃ within 60 min. or at 470 and 490℃ within 240 min. to avoid blistering and to improve the strength.

• Metals and materials international
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• v.24 no.6
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• pp.1315-1326
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• 2018

In this work, ultrasonic vibration (UV) and rheo-squeeze casting was first applied on the Mg alloy reinforced with long period stacking ordered (LPSO) structure. The semisolid slurry of Mg-Zn-Y alloy was prepared by UV and processed by rheosqueeze casting in succession. The effects of UV, Zr addition and squeeze pressure on microstructure of semisolid Mg-Zn-Y alloy were studied. The results revealed that the synergic effect of UV and Zr addition generated a finer microstructure than either one alone when preparing the slurries. Rheo-squeeze casting could significantly refine the LPSO structure and ${\alpha}-Mg$ matrix in $Mg_{96.9}Zn_1Y_2Zr_{0.1}$ alloy without changing the phase compositions or the type of LPSO structure. When the squeeze pressure increased from 0 to 400 MPa, the block LPSO structure was completely eliminated and the average thickness of LPSO structure decreased from 9.8 to $4.3{\mu}m$. Under 400 MPa squeeze pressure, the tensile strength and elongation of the rheocast $Mg_{96.9}Zn_1Y_2Zr_{0.1}$ alloy reached the maximum values, which were 234 MPa and 17.6%, respectively, due to its fine ${\alpha}-Mg$ matrix (${\alpha}1-Mg$ and ${\alpha}2-Mg$ grains) and LPSO structure.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.10a
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• pp.253-254
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• 2006

• Transactions of Materials Processing
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• v.14 no.4 s.76
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• pp.338-350
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• 2005

Recently, in the field of automobile industry, to solve the problem of reducing the weight of automobile for the improvement of fuel efficiency and the protection of environment, the aluminum alloy parts have been substituted for the steel parts. However, the aluminum alloy does not have as good mechanical property as the steel part. To improve the mechanical property, the semi-solid die casting process is performed to make automobile parts. In the fabrication of semisolid material the control of the liquid segregation is very important to improve the material properties of aluminum alloy. In the present paper we examine the influence of the liquid segregation by the injection conditions in the semi-solid die casting has been investigated.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.2
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• pp.138-142
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• 2016

In this study, a strength analysis was performed to assess die-cast aluminum alloy brake pedals as an improved alternative to wrought alloys. Aluminum brake pedal shapes are considered to be suitable for the die-casting process. The strength criterion of Volvo trucks was used as the criterion for the pedal strength. The results of this analysis showed that the frame thickness of the aluminum brake pedal must be increased from 12 mm to 18 mm to have a strength superior to that of a steel brake pedal. Additionally, the stress and weight of the aluminum brake pedal were found to be approximately 24% and 26% lower than those of the steel brake pedal, respectively. Mounting tests and strength assessments verified that the proposed die-cast aluminum alloy brake pedal demonstrated sufficient strength.