• Journal of computational fluids engineering
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• v.6 no.1
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• pp.1-13
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• 2001

The natural convection heat transfer and solidification in a stratified pool are studied. The flow and heat transfer characteristics in a heat generating pool are compared between single-layered and double-layered pools. And local Nusselt number distributions on outer walls are obtained to consider thermal loads on a vessel wall. The cooling and solidification of Al₂O₃/Fe melt in a hemispherical vessel are simulated to study the mechanism of heat transfer and temperature distribution. A unstructured mesh is chosen for this study because of the non-orthogonality originated from the boundaries of double-layered pool. Interface between the layers is modeled to be fixed. With this assumption mass flux across the interface is neglected, but shear force and heat flux are considered by boundary conditions. The colocated cell-centered finite volume method is used with the Rhie-Chow interpolation to compute cell face velocity. To prevent non-physical solutions near walls in case body force is large the wall pressure is extrapolated by the way to include body force. The numerical solutions calculated by current method show that averaged downward heat flux of the double-layered pool increases compared to single-layered pool and maximum temperature occurs right below the interface of the layers.

• 한국전산유체공학회:학술대회논문집
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• 2004.10a
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• pp.53-59
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• 2004

A general purpose program NUFLEX for the analysis of 3-D heat/fluid flow in complex geometry with pre/post processor have been developed, which consists of a flow solver based on FVM and a dedicated pre/post processor. The program employs a general non-orthogonal grid system and solve laminar and turbulent (lows with standard and RNG $\kappa-\epsilon$ turbulence models. NUFLEX is capable of analysing two-phase flow with topologically complex interface, turbulent diffusion combustion, solidification problems and magnetic flow. For the purpose of verification of the program and testing the applicability, several practical problems are solved and compared with the available data. Comparison of the NUFLEX results with that by the STAR-CD program has been also made for the same flow configuration and grid structure.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.6 no.1
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• pp.19-31
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• 1996

To invetigate the impurity distribution in GaAs crystal grown by horizontal Bridgman method, we constructd the mathematical model describing heat transfer, mass transfer and fluid flow n transient growth of GaAs. Galerkin finite element method and implicit time integration were used to solve the equations and simulate the transient growth. The concentration distribution is similar to the case of diffusion controlled growth when Gr - 0. With the increase of Gr the concentration profile is distroted and the minimum solute concentration appears near the interface. As solidification prosceeds, interface deflection increases steadily and transverse segregation increases until mixing by flow becomes steady. The axial segregation increases with solidification. But, with high intensity of flow axial segregation becomes steady after short transient. At small and large Gr the result showed a good agreememt with the prediction Smith and Scheil.

• Journal of Korea Foundry Society
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• v.17 no.2
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• pp.118-129
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• 1997

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.4
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• pp.946-957
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• 1994

In the steel industries, direct rolling process for production of strip from molten metal has been investigated to simplify processes, to minimize energy consumption, and to improve quality of the strip. In this study, two kinds of practicable scale cooling rollers are proposed. And heat transfer analysis of pool region and cooling roller considering flow of molten metal and roll rotation respectively using the finite element method are performed to obtain the proper initial condition and to observe cooling characteristics of cooling roller. From the results, variations of solidification final points and temperature distribution in roller are observed quantitatively according to roll rotation.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.23 no.10
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• pp.1254-1264
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• 1999

A three-dimensional coupled turbulent fluid flow and solidification process were analyzed in a continuous casting process of a steel slab with Electromagnetic Brake(EMBR). A revised low-Reynolds number $k-{\varepsilon}$ turbulence model was used to consider the turbulent effects. The enthalpy-porosity relation was employed to suppress the velocity within a mushy region. The electromagnetic field was described by Maxwell equations. Tile application of EMBR to the mold region results in the decrease of the transfer of superheat to the narrow face, the increase of temperature in free surface region and most liquid of submold region, and the higher temperature gradient near the solidifying shell. The increasing magnetic flux density effects mainly to the surface temperature of the solidifying shell of narrow face, hardly to the one of wide face. It is seen that in the presence of EMBR a thicker solidifying shell is obtained at the narrow face of the slab.

• Korean Journal of Materials Research
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• v.12 no.5
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• pp.414-422
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• 2002

Three different multi-component white cast irons alloyed with Cr, V, Mo and W were prepared in order to study their as-cast and solidification structures. Three combinations of the alloying elements were selected so as to obtain the different types of carbides and matrix structures : 3%C-10%Cr-5%Mo-5%W(alloy No.1), 3%C-10%V-5% Mo-5%W(alloy No. 2) and 3%C-17%Cr-3% V(alloy No.3). The as-cast microstructures were investigated with optical and scanning electron microscopes. There existed two different types of carbides, $M_7C_3$ carbide with rod-like morphology and $M_6C$ carbide with fishbone-like one, and matrix in the alloy No. 1. The alloy No. 2 consisted of MC carbide with chunky and flaky type and needle-like $M_2C$ carbide, and matrix. The chunky type referred to primary MC carbide and the flaky one to eutectic MC carbide. The morphology of the alloy No. 3 represented a typical hypo-eutectic high chromium white cast iron composed of rod-like $M_7C_3$ carbide which is very sensitive to heat flow direction and matrix. To clarify the solidification sequence, each iron(50g) was remelted at 1723K in an alumina crucible using a silicon carbide resistance furnace under argon atmosphere. The molten iron was cooled at the rate of 10K/min and quenched into water at several temperatures during thermal analysis. The solidification structures of the specimen were found to consist of austenite dendrite(${\gamma}$), $ ({\gamma}+ M_7C_3)$ eutectic and $({\gamma}+ M_6C)$ eutectic in the alloy No. 1, proeutectic MC, austenite dendrite(${\gamma}$), (${\gamma}$+MC) eutectic and $({\gamma}+ M_2C)$ eutectic in the alloy No. 2, and proeutectic $M_7C_3$ and $ ({\gamma}+ M_7C_3)$ eutectic in the alloy No 3. respectively.

• Journal of Korea Foundry Society
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• v.29 no.3
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• pp.138-143
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• 2009

Vacuum suction is applied to the mold during pouring in the inclined gravity die casting to remove defects such as misrun and gas porosity in the brake master cylinder. Casting defects are observed after solidification and their cause is analyzed by using the calculated results with commercial solidification and flow analysis code(ZCAST). The optimum vacuum suction is -2 cmHg, and when the start time of vacuum suction is 3 seconds after pouring, better filled result is obtained by holding it for 15 seconds. Reproducibility test under the optimum conditions attained from the above pouring tests is performed, and it is confirmed that these pouring conditions can be applied to the mass production immediately.

• Transactions of Materials Processing
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• v.9 no.4
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• pp.413-420
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• 2000

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of front housing part of aircon compressor, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the filling and solidification stages for the sound casting products. Two cases of casting design that have different types of gating system are considered in the analysis. The potential sites where the casting defects may occur is examined by computer simulation and an improved design process is proposed. Also the effect of partial squeeze on the quality of casting products is considered and the optimal time lag after filling process is determined. For the die-stability, the effect of operational parameters such as die temperature, heat cycle and spot cooling on the die life has also been analyzed.

• 연구논문집
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• s.29
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• pp.173-183
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• 1999

The vacuum investment casting process for a large gas turbine component, Inner Preswirl Support (IPS), was simulated by using commercial FEM package ProCAST(TM) with view factor radiation method. The solid fraction in mushy zone was directly measured by Differential thermal analysis(DTA-DSC mode). Three types gating design. considering liquid flow and heat release through it. were proposed. Solidification had begun at the ribs or thin sections of the IPS casting and advanced further through the upper and lower gates. The computed temperature gradient G and G/R values at 70% solidified temperature were used for prediction of microshrinkage formation during casting. The effect of mold preheat on the thermal history of the casting displayed minute effect on the microshrinkage formation.