• Journal of Korea Foundry Society
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• v.31 no.6
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• pp.336-341
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• 2011

Recently, aluminium usage in the automobile industry has been increased cause of its lightweight. The aluminium has a melting-solidification process in producing line and another melting process was needed in manufacturing process. Two times of melting process for making ingot and casting not only makes the loss of time and money but contaminates the air with Sox, Nox. For this reason, the holding furnace with laminated adiabatic material was developed. This holding furnace can deliver the molten aluminium directly to the industry needing molten aluminium. Recent holding furnace has above $15^{\circ}C/h$ of cooling rate and that causes solidification of molten aluminium. The ANSYS software was used to analysis the heat transfer. The adiabatic materials were laminated with optimized arrangement and holding furnace shape was changed with optimized modelling by ANSYS analysis for reducing the cooling rate of molten aluminium in holding furnace.

• Transactions of Materials Processing
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• v.23 no.4
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• pp.238-243
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• 2014

Recently, magnesium alloys have been widely used in the automotive, aerospace and electronics industries with the advantages of high specific strength, excellent machinability, high electrical conductivity, and high thermal conductivity. Deep drawn magnesium alloys not only meet the demands environmentally and the need for lighter products, but also can lead to remarkably improved productivity and more rapid qualification of the product The current study reports on a failure prediction procedure using finite element modeling (FEM) and a ductile fracture criterion and applies this procedure to the design of a deep drawing process. Critical damage values were determined from a series of uniaxial tensile tests and FEM simulations. They were then expressed as a function of strain rate and temperature. Based on the plastic deformation histories obtained from the FEM analyses of the warm drawing process and the critical damage value curves, the initiation time and location of fracture were predicted. The proposed method was applied to the process design for fabrication of a Mg automotive compressor case and verified with experimental results. The final results indicate that a Mg case part 39% lighter than an Al die casting part can be produced without any defects.

• Journal of Korea Foundry Society
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• v.34 no.6
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• pp.200-213
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• 2014

Pure magnesium and magnesium alloys have been applied to various kinds of industrial fields, especially automotive and electronic parts. These parts are manufactured mainly through a diecasting process. These days, magnesium ingots are used as raw material, and recycled ingots are often used for commercial purposes. But the quality of virgin magnesium and recycled ingots is not secure. Therefore, massive casting defects can occur, and some things manufactured can be damaged by these defects. This study evaluated the inclusions of virgin magnesium and recycled ingot. It also included composition analysis by spectrometer, measuring inclusion contents by SEM & EDS, and performing a brightness test on fractured surfaces. The brightness test is generally very easy and obtains results quickly, so its results have been compared with the results obtained from various test methods. From the test results, we obtained a satisfactory result in evaluating inclusion and oxide. The brightness values are lower as the inclusion contents are higher. When the brightness value is over 47 in AM50A and 44 in AZ91D, the mechanical properties are expected to be good.

• Journal of Korea Foundry Society
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• v.22 no.3
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• pp.130-136
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• 2002

The growing use of aluminum for castings over the past decade has brought with it the increased scrutiny of component properties. One area that has received much attention is the effect of in inclusions - or impurities particles held in the metal - on casting properties. A new method of electromagnetic separation for removal of inclusions in aluminum alloy melts is proposed. The principle is that as the electromagnetic force induced in metal acts on inclusions due to low electric conductivity, they are moved to the direction opposite to electromagnetic force and can be separated and removed from the melt. Experiments were carried out on A356 melt mixed alumina particles and commercial Al alloys of ADC 10 and 12. In the experiment using A356, it was proved that $Al_2O_3$ particles was separated and removed continuously from matrix melt by electromagnetic force. Based on these results, the continuous separation experiment that used ADC 10, 12 was carried and the cleanliness of melt was assessed by the amount of porosity, hydrogen contents, PoDFA and mechanical properties through tensile test. As the results of analyses, the amount of porosity and hydrogen contents decreased without variation of chemical composition in the specimen that passed the electromagnetic continuous separator. In addition, tensile strength and elongation of this specimen increased by $20{\sim}30%$ because of reduction of inclusions.

• Journal of Korea Foundry Society
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• v.28 no.3
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• pp.129-135
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• 2008

The reheating stage of electromagnetically stirred Al billet is a critical factor in the thixoforming process. When reheated to the solid-liquid state, the microstructure evolves to a more globular and more homogeneous structure by a coarsening mechanism, the kinetics depending on the initial microstructure. Microstructural evolution has been characterized by conventional parameters (mean size of particle and shape factor) as a function of holding time in the solid-liquid state. The aim of this study is to report experimental results concerning microstructural evolution in the solid-liquid state of electromagnetically stirred Al billet. The material was elaborated in the form of continuously cast bars solidified with electromagnetic stirring to degenerate the dendritic structure. The choice of the reheating conditions is determined by a dendritic ripening and coalescence mechanism, involving variations of both the shape and size of the particles. The reheating time has to be long enough to allow a minimum degree of spheroidizing, but has to be limited as much as possible in order to avoid excessive ripening. The optimum microstructure was obtained at the reheating temperature of near $584^{\circ}C$ and the holding time of 5 min. The only means of combining high productivity with good casting quality was to use feedstock billets whose microstructure showed rapid transformation characteristics.

• Korean Journal of Materials Research
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• v.15 no.1
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• pp.14-18
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• 2005

Ni-Cr-Sn-Bi alloys were prepared by air melting and sand casting method and their anti-galling behaviors were examined. Anti-galling properties were dominantly influenced by Bi-rich low temperature precipitates. Alloying effects on the anti-galling properties were investigated for several alloying elements to improve anti-galling properties of the alloy. An alloy with $1-3wt\%$ of Te showed markedly improved anti-galling properties. Metallographic and tribological tests were carried out to find out reasons for excellent properties. It was found that Te containing alloy has finely distributed precipitates of Bi-rich phase. The addition of Te changed the morphology of the Ni-rich primary phase from globular to fine dendritic. As a result, the anti-galling phase precipitated between dendrite arms with fine distribution showed excellent anti-galling properties.

• Journal of the Korean Society of Mechanical Technology
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• v.20 no.6
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• pp.745-750
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• 2018

In this study, the thermal behavior of adaptor housing was analyzed by the numerical method. The boundary conditions used to die casting process were the temperature of molten metal and injection time. As the temperature of the molten metal increased, the tensile strength of the product decreased by the blow hole generated in the molten metal, and the decreasing tendency was gradually decreased. As the injection time of the molten metal increased, the heat flux rose, but the degree of the increase was very small. So, the injection time of the molten metal had little effect on the thermal behavior and diffusion of the adapter housing. As a result, the heat of the molten metal was transferred into the housing and the thermal behavior spread widely.

• Korean Journal of Metals and Materials
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• v.49 no.2
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• pp.145-152
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• 2011

Mechanical and property corrosion resistance of Mg-Zn-Y alloys with an atomic ratio of Zn/Y of 6.8 are investigated using optical microscopy, scanning electron microscopy, transmission electron microscopy, uniaxial tensile test and corrosion test with immersion and dynamic potentiometric tests. The alloys showed an in-situ composite microstructure consisting of ${\alpha}$-Mg and icosahedral phase (I-phase) as a strengthening phase. As the volume fraction of the I-phase increases, the yield and tensile strengths of the alloys increase while maintaining large elongation (26~30%), indicating that I-phase is effective for strengthening and forms a stable interface with surrounding ${\alpha}$-Mg matrix. The presence of I-phase having higher corrosion potential than ${\alpha}$-Mg, decreased the corrosion rate of the cast alloy up to I-phase volume fraction of 3.7%. However further increase in the volume fraction of the I-phase deteriorates the corrosion resistance due to enhanced internal galvanic corrosion cell between ${\alpha}$-Mg and I-phase.

• Korean Chemical Engineering Research
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• v.51 no.5
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• pp.622-627
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• 2013

Colloidal silica is used in various industrial products such as chemical mechanical polishing slurry for planarization of silicon and sapphire wafer, organic-inorganic hybrid coatings, binder of investment casting, etc. An accurate determination of particle size and dispersion stability of silica sol is demanded because it has a strong influence on surface of wafer, film of coatings or bulks having mechanical, chemical and optical properties. The study herein is discussed on the effect of measurement results of average particle size, sol viscosity and electrophoretic mobility of particle according to the volume fraction of eight types of silica sol with different size and surface properties of silica particles which are presented by the manufacturer. The measured particle size and the mobility of these sol were changed by volume fraction or particle size due to highly active surface of silica particle and change of concentration of counter ion by dilution of silica sol. While in case the measured sizes of small particles less than 60 nm are increased with increasing volume fraction, the measured sizes of larger particles than 60 nm are slightly decreased. The mobility of small particle such as 12 nm are decreased with increase of viscosity. However, the mobility of 100 nm particles under 0.048 volume fraction are increased with increasing volume fraction and then decreased over higher volume fraction.

• Journal of Hydrogen and New Energy
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• v.11 no.4
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• pp.161-169
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• 2000

In the case of photocatalytic hydrogen production from water, the performance-property relationships of CdS-TiO2 film type composite catalysts were investigated. To control the physical properties of the primary particles, the mixture of CdS and TiO2 nano-sols prepared by the sol-gel method at room temperature was hydrothermally treated at 240oC for 12hr. The film electrodes were prepared by the casting method. The photocurrents measured by a photoelectrochemical method and the hydrogen production rates measured by a photochemical method were closely dependent on the physical properties such as crystalline form, primary particle size and CdS/TiO2 mole ratio, and these varied in the range of 1.2~2.6 mA/cm2 and $1.0{\sim}1.6{\times}10-3mol/hr$, respectively.