• Clean Technology
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• v.13 no.3
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• pp.228-234
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• 2007

In this study, the productivity and environmental effects of laser aided direct metal deposition (LADMD) process which is one of promising rapid manufacturing technology is evaluated. The production time predicted using PowerMill shows that the productivity of LADMD is superior to that of conventional milling process. Though LADMD is known as an environment-friendly technology, it has a disadvantage to utilize much energy to generate laser beam. Considering both productivity and environmental effects, LADMD is expected to be widely used in remanufacturing industry.

• Transactions of Materials Processing
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• v.29 no.2
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• pp.103-112
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• 2020

This study explores the effects of different pre-machining conditions on the deposition characteristics and mechanical properties of austenitic stainless steel samples repaired using direct energy deposition (DED). In the DED repair process, defects such as pores and cracks can occur at the interface between the substrate and deposited material. In this study, we varied the shape of the pre-machined zone for repair in order to prevent cracks from occurring at the slope surface. After repairs by the DED process, macro-scale cracks were observed in samples that had been pre-machined with elliptic and trapezoidal grooves. In addition, it was not possible to completely prevent micro-crack generation on the sloped interfaces, even in the capsule-type grooved sample. From observation of the fracture surfaces, it was found that the cracks around the inclined interface were due to a lack of fusion between the substrate and the powder material, which led to low tensile properties. The specimen with the capsule-type groove provided the highest tensile strength and elongation (respective of 46% and 571% compared to the trapezoidal grooved specimen). However, the tensile properties were degraded compared to the non-repaired specimen (as-hot rolled material). The fracture characteristics of the repaired specimens were determined by the cracks at the sloped interfaces. These cracks grew and coalesced with each other to form macro-cracks, they then coalesced with other cracks and propagated to the substrate, causing final fracture.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.9
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• pp.1-10
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• 2021

Recently, the repair and recycling of damaged mechanical parts via metal additive manufacturing processes have been industrial points of interest. This is because the repair and recycling of damaged mechanical parts can reduce energy and resource consumption. The directed energy deposition(DED) process has various advantages such as the possibility of selective deposition, large building space, and a small heat-affected zone. Hence, it is a suitable process for repairing damaged mechanical parts. The shaft is a core component of various mechanical systems. Although there is a high demand for the repair of the shaft, it is difficult to repair with traditional welding processes because of the thermal deformation problem. The objective of this study is to propose a repair procedure for a damaged shaft using the DED process and discuss its applications. Three types of cases, including a small shaft with a damaged surface, a medium-size shaft with a worn bearing joint, and a large shaft with serious damage, were repaired using the proposed procedure. The microstructure and hardness were examined to discuss the characteristics of the repaired component. The efficiency of the repair of the damaged shaft is also discussed.

• Journal of Powder Materials
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• v.29 no.4
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• pp.320-324
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• 2022

Lightweight steel is a crucial material that is being actively studied because of increased carbon emissions, tightening regulations regarding fuel efficiency, and the emergence of UAM, all of which have been recently labeled as global issues. Hence, new strategies concerning the thickness and size reduction of steel are required. In this study, we manufacture lightweight steel of the Fe-Mn-Al-C system, which has been recently studied using the DED process. By using 2.8 wt.% low-Mn lightweight steel, we attempt to solve the challenge of joining steel parts with a large amount of Mn. Among the various process variables, the laser scan power is set at 600 and 800 W, and the laser scan speed is fixed at 16.67 mm/s before the experiments. Several pores and cracks are observed under both conditions, and negligibly small pores of approximately 0.5 ㎛ are observed.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.12
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• pp.6980-6985
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• 2014

A micro-conductive pattern was fabricated on an insulating substrate ($SiO_2$) surface using a laser direct writing method. In the LIFT process, when the laser beam irradiates a thin metal film, the photon energy is absorbed by the film and converted to thermal energy, and the thermal decomposition reaction produced by the resulting heat conduction forms a deposit on the substrate. The resistivity of the micro-electrodes deposited through LIFT process with and without polymer coating was measured. The results showed that the electric conductivity of the micro-pattern and micro-structure can be increased approximatly two times when the deposited micropattern is fabricated through a LIFT process with a polymer coating, compared to the case without a polymer coating.

• Proceedings of the Korean Vacuum Society Conference
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• 1999.07a
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• pp.73-73
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• 1999

A large area negative metal ion beam source is developed. Kinetic ion beam of the incident metal ions yields a whole nucleation and growth phenomena compared to the conventional thin film deposition processes. At the initial deposition step one can engineer the surface and interface by tuning the energy of the incident metal ion beams. Smoothness and shallow implantation can be tailored according to the desired application process. Surface chemistry and nucleation process is also controlled by the energy of the direct metal ion beams. Each individual metal ion beams with specific energy undergoes super-thermodynamic reactions and nucleation. degree of formation of tetrahedral Sp3 carbon films and beta-carbon nitride directly depends on the energy of the ion beams. Grain size and formation of polycrystalline Si, at temperatures lower than 500deg. C is obtained and controlled by the energy of the incident Si-ion beams. The large area metal ion source combines the advantages of those magnetron sputter and SKIONs prior cesium activated metal ion source. The ion beam source produces uniform amorphous diamond films over 6 diameter. The films are now investigated for applications such as field emission display emitter materials, protective coatings for computer hard disk and head, and other protective optical coatings. The performance of the ion beam source and recent applications will be presented.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.41 no.2
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• pp.103-109
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• 2017

Metal 3D printing, which is an additive metal manufacturing (AMM) process, enables the development of full-density metallic tools and parts using metal powders that are precisely delivered and controlled for deposition with no powder bed. However, some unknown geometric defects and irregular geometric features on an STL model can possibly result in incorrect metal part fabrication after the build. This study first proposes a methodical approach for verifying the build part, including the missing facet problems in an STL model, by defining some irregular features that possibly exist on the part. Second, 2D tool paths on each build layer were investigated for detecting any singular region inside the layer. The method was implemented for building two sample STL models using a direct energy deposition process, and finally, it was visually simulated for diagnosis.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.15 no.5
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• pp.100-108
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• 2016

In various industries, many researches studies have been done in using nano thin film fabrication technology. In the field of printed electronics, various electronic devices can be fabricated using a direct printing process of on multiple functional materials. It has the advantages of low prices, environment-friendly environmentally friendly, flexibleility, large scale, mass production produced, simple process and so on. In this study, a viable thin film fabrication technology has beenwas introduced using the surface acoustic wave mechanism for thin film deposition. Fabrication of thin films using organic, inorganic and composite of organic/inorganic materials have been were analyzed through the experimental research. In this experiment, organic material MEH:PPV, inorganic material ZnO and composite material MEH:PPV/ZnO have been depo sited as thin films.

• 한국신재생에너지학회:학술대회논문집
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• 2010.06a
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• pp.135.2-135.2
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• 2010

Carbon nanotube(CNT) has been spotlighted as a promising candidate for catalyst support material for PEMFC (proton exchange membrane fuel cell). The considerable properties of CNT include high surface area, outstanding thermal, electrical conductivity and mechanical stability. In this study, to fully utilize the properties of CNTs, we prepared directly oriented CNT on carbon paper as a catalyst support in the cathode electrode. The CNT layer was prepared by a chemical vapor deposition(CVD) process. And the Pt particles were deposited on the CNT oriented carbon paper by impregnation and eletro-deposition method. The potential advantages of directly oriented CNT on carbon paper can include improved thermal and charge transfer through direct contact between the electrolyte and the electrode and enhanced exposure of Pt catalyst sites during the reaction.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.5
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• pp.475-480
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• 2017

In this paper, the conductivity of the fine pattern is improved in the insulating substrate by laser-induced forward transfer (LIFT) process. The high laser beam energy generated in conventional laser induced deposition processes induces problems such as low deposition density and oxidation of micro-patterns. These problems were improved by using a polymer coating layer for improved deposition accuracy and conductivity. Chromium and copper were used to deposit micro-patterns on silicon wafers. A multi-pulse laser beam was irradiated on a metal thin film to form a seed layer on an insulating substrate(SiO2) and electroless plating was applied on the seed layer to form a micro-pattern and structure. Irradiating the laser beam with multiple scanning method revealed that the energy of the laser beam improved the deposition density and the surface quality of the deposition layer and that the electric conductivity can be used as the microelectrode pattern. Measuring the resistivity after depositing the microelectrode by using the laser direct drawing method and electroless plating indicated that the resistivity of the microelectrode pattern was $6.4{\Omega}$, the resistance after plating was $2.6{\Omega}$, and the surface texture of the microelectrode pattern was uniformly deposited. Because the surface texture was uniform and densely deposited, the electrical conductivity was improved about three fold.