• Transactions of Materials Processing
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• v.32 no.1
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• pp.12-19
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• 2023

The armature core is a part responsible for the skeleton of the steering wheel. Currently, in the case of commercial trucks, the main parts of the parts are manufactured separately and then the product is produced through welding. In the case of this production method, quality and cost problems of the welded parts occur, and an integrated armature core made of magnesium alloy is used in passenger vehicles. However, in the case of commercial trucks, there is no application case and research is insufficient. Therefore, this study aims to develop an all-in-one armature core that simultaneously applies a magnesium alloy material and a die casting method to reduce the weight and improve the quality of the existing steel armature core. The product was modeled based on the shape of a commercial product, and finite element analysis (FEA) was performed through Ls-dyna, a general-purpose analysis program. Through digital image correlation (DIC) and uniaxial tensile test, the accurate physical properties of the material were obtained and applied to the analysis. A total of four types of compression were applied by changing the angle and ground contact area of the product according to the actual reliability test conditions. analysis was carried out. As a result of FEA, it was confirmed that damage occurred in the spoke area, and spoke thickness (t_spoke), base thickness (t_base), and rim and spoke connection (R) were designated as design variables, and the total weight and maximum equivalent stress occurring in the armature core We specify an objective function that simultaneously minimizes . A prediction function was derived using the sequential response surface method to identify design variables that minimized the objective function, and it was confirmed that it was improved by 22%.

• Journal of Korea Foundry Society
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• v.17 no.4
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• pp.402-410
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• 1997

Developing a salt core for squeeze casting process, two different salt cores(pure salt core and mixed salt core) were fabricated and investigated. Pure salt core was composed of 100% NaCl and mixed salt core was made by mixtures of NaCl with MgO(1%), $Na_2B_4O_7$(2%), and talc(1%) as a binder or a strengthening agent. Salt cores were compacted to various theoretical density, heat treated, and then squeeze-cast with molten Al alloy(AC8A). The compression strength of salt cores were measured and the squeeze-cast products were examined for shape retention, infiltration of molten metal into the cores, and microstructures. The shape of salt core compacted at above 75% of the theoretical density was maintained stably. The higher theoretical density of salt cores gave higher compression strength, and the compression strength of mixed salt core was higher than that of pure salt core. Namely at 90% theoretical density, the compression strength of mixed salt core was $6.3 kg/mm^2$, compared to $4.6 kgmm^2$ for pure salt core. At a squeeze casting pressure of $1000 kg/cm^2$, molten Al alloy was infiltrated into pure salt core of under 85% of the theoretical density. At squeeze casting pressure of $1000 kg/cm^2$, only mixed salt core above 90% of the theoretical density were valid, but the shape of the core was altered in the case of pure salt core at 90% of theoretical density. A key factor for developing a salt core for squeeze casting process was estimated as the ultimate compressive strength of salt core.

• Journal of Magnetics
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• v.2 no.1
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• pp.12-15
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• 1997

Fe-(3∼6.5wt%) Si alloy powders having a high magnetic induction(Bs) and a low core loss value for high frequency use were obtained by an extractive melt spinning as well as a centrifugal atomization technique. Sintered core rings made by the rapidly solidified Fe-6.5wt% Si powders exhibited the high frequency magnetic properties : megnetic induction(B8) of 1.23 T, coercivity(Hc) of 0.12 Oe, relative permeability(${\mu}$a) of 6321, and core loss(W10/50) of 1.27 W/kg from the rings of 1.1 mm thick. The magnetic induction values were found to be almost identical to those of non-oriented Fe-6.5wt% Si steel sheet and double the value of 6.5wt% Si sheet prepared by the CVD technique. The high frequency core losses(W) up to 10 kHz(W10/10k) were measured to be competitive to those of grain-oriented Fe-6.5wt% Si steel sheet.

• Particle and aerosol research
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• v.8 no.2
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• pp.83-88
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• 2012

The electrical wire explosion process in liquid media is promising for nano-sized metal and/or alloy particles. The hybrid Pt/Fe-Cr-Al and Pt/Ni-Cr-Fe nanoparticles for exhaust emission control system are synthesized by electrical wire explosion process in liquid media. The alloy powders have spherical shape and nanometer size. According to the wire component, while Pt/Fe-Cr-Al nanoparticles are shown the well dispersed Pt on the Fe-Cr-Al core particle, Pt/Ni-Cr-Fe nanoparticles are shown the partially separated Pt on the Ni-Cr-Fe core particle. Morphologies and component of two kinds of hybrid nano catalyst particles were characterized by transmission electron microscope and energy dispersive X-ray spectroscopy analysis.

• Corrosion Science and Technology
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• v.18 no.1
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• pp.8-15
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• 2019

A high-temperature gas-cooled reactor (HTGR) is recognized as the best candidate reactor for next generation nuclear reactors. Helium is used to be the coolant in the core of the HTGR with temperature expected to exceed $900^{\circ}C$ at the core outlet. Several iron- and nickel-based superalloys, including Alloy 800H, Hastelloy X, and Alloy 617, are potential structural materials for intermediate heat exchanger (IHX) in an HTGR. Oxidation behaviors of three selected alloys (Hastelloy X, Alloy 800H, and Alloy 617) were investigated at four different temperatures from $650^{\circ}C$ to $950^{\circ}C$ under helium environments with various concentrations of $O_2$ and $H_2O$. Preliminary results showed that chromium oxide as the primary protective layer was observed on surfaces of the three tested alloys. Based on results of mass gain and SEM analyses, Hastelloy X alloy exhibited the best corrosion resistance in all corrosion tests. Further details on the oxidation mechanism of these alloys are presented in this study.

• Journal of Powder Materials
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• v.20 no.4
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• pp.285-290
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• 2013

$Ti_2AlN$ composites are a laminated compounds that posses unique combination of typical ceramic properties and typical metallic(Ti alloy) properties. In this paper, the powder synthesis, SPS sintering, composite characteristics and machinability evaluation were systematically conducted. The random orientation characteristics and good crystallization of the $Ti_2AlN$ phase are observed. The electrical and thermal conductivity of $Ti_2AlN$ is higher than that of Ti6242 alloy. A machining test was carried out to compare the effect of material properties on micro electrical discharge drilling for $Ti_2AlN$ composite and Ti6242 alloy. Also, mixture table as a kind of tables of orthogonal arrays was used to know how parameter is main effective at experimental design. Consequently, hybrid $Ti_2AlN$ ceramic composites showed good machining time and electrode wear shape under micro ED-drilling process. This conclusion proves the feasibility in the industrial applications.

• Journal of Powder Materials
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• v.20 no.4
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• pp.302-307
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• 2013

A5J32-T4 and A5052-H32 dissimilar aluminum alloy plates with thickness of 1.6 and 1.5 mm were welded by friction stir lap welding (FSLW). The FSLW were studied using different probe length tool and various welding conditions which is rotation speed of 1000, 1500 rpm and welding speed of 100 to 600 mm/min and material arrangement, respectively. The effects of plunge depth of tool and welding conditions on tensile properties and weld nugget formation. The results showed that three type nugget shapes such as hooking, void, sound have been observed with revolutionary pitch. This plunge depth and material arrangement were found to effect on the void and hooking formation, which in turn significantly influenced the mechanical properties. The maximum joint efficiency of the FSLWed plates was about 90% compared to base metal, A5052-H32 when the A5052-H32 was positioned upper plate and plunge depth was positioned at near interface between upper and lower plates.

• 연구논문집
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• s.34
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• pp.121-129
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• 2004

The influence of powder size and ball-milling time on the magnetic properties of $Fe_{73}Si_{16}B_7Nb_3Cu_1$ nanocrystalline alloy powder was investigated. Flake-shaped powders were produced by pulverizing the ribbons annealed at $550^\circC$ for 1 hour. The powders were classified and consolidated into core shapes at a pressure of 18ton/$cm^2$. The initial permeability at 100kHz of the inductor core produced using $53-75\mum$ powders showed the highest value although its consolidated density showed the lowest one. The reason for the result is due to the cracking of the particles larger than $75\mum$ during the consolidation process. The ball-milling of powders for 2-4 hours improved the consolidation density and the initial permeability of the cores. The intrinsic coercivity of the powder decreased as well, resulting from the stress relief of the powder by a short-time milling.

• Journal of Magnetics
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• v.1 no.1
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• pp.24-30
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• 1996

The relationship between effective permeability and the remanence ratio of an Fe-based amorphous alloy (Metglas 2605S3A) is investigated over a wide frequency range, in an effort to understand magnetization behavior of the alloy. In the frequency range from 1 to 200 kHz, the permeability is maximum at the remanence ratio of 0.4-0.5 and, at frequencies over 500 kHz, the correlation with negative coefficients emerges indicating that the permeability decreases with the remanent ratio, except for the ribbon coated with an insulating layer of MgO which exhibits both high values of the effective permeability and remanence ratio. It is considered from the correlation results that the boundary at which the dominant magnetization mechanism changes from domain wall motion to spin rotation is near 500 kHz. The core loss is also investigated as a function of annealing time when the samples are annealed at a fixed temperature of $435^{\circ}C$. The core loss in most cases decreases with the annealing time, the degree of the loss may consist of the hysteresis loss and anomalous eddy current loss. The two loss components are considered to be of similar magnitudes at low frequencies while, at high frequencies, the dominant contribution to the total loss is the anomalous loss.

• Journal of Welding and Joining
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• v.29 no.5
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• pp.82-89
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• 2011

The effect of welding condition on tensile properties of KS5J32 Al Alloy was investigated under various welding conditions. The 1.6 mm thick KS5J32 alloy sheets were joined by friction stir welding (FSW) technique with butt joint. The tool rotation speeds were 1000, 1250 and 1500 rpm, and the welding speeds were varied within the range from 100 to 600 mm/min. Voids mainly occurred at the advancing side of the tool probe, when the tool rotation speed was low, due to insufficient materials flow. When the weld pitch exceeded 0.4 mm/rev, voids were observed under all welding conditions and the area of voids increased with increasing weld pitch. For void-free specimens, fracture always occurred at base materials. However voids affected the location of fractures, base metal or welded zone, when the voids existed within the welds.