• Journal of Korea Foundry Society
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• v.31 no.4
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• pp.205-211
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• 2011

Al-Si alloys have been steadily used as a potential material for the achievement of an efficient weight reduction in the automobile and aerospace industries due to its excellent castability and high strength-to-weight ratio. In this study, riser effect and mechanical properties were investigated according to the size of the sleeve. In addition, the effects of riser size on mechanical properties of castings were investigated. On the other hand flow and solidification process were simulated with a hybrid FDM/FEM package named ZCast. As a result, results of simulation and experiments were comparable regarding to the yield strength, tensile strength, elongation and hardness of casting. It proves the reliability of the simulation. It is expected that the proper size of riser can improve the recycling rate of metallic materials and reduce the cost of casting.

• Journal of Korea Foundry Society
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• v.41 no.1
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• pp.11-15
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• 2021

Scrap steel used as a charge material in melting process of cast iron foundry is mostly press scrap. The press scrap usually causes several problems including energy loss, workability, safety, and so on. By charging the shredded scrap instead of the press scrap, it is expected that the above-mentioned problems can be solved. In this study, the power basic units to produce cast iron by using the press and shredded scrap are compared in 3t/h medium-frequency induction melting furnace. Charging the shredded scrap instead of the press scrap was confirmed that the power basic unit is improved by about 15%. The characteristics and restrictions of the usage according to the shape and size of scrap steel were considered.

• Journal of Korea Foundry Society
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• v.25 no.1
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• pp.16-22
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• 2005

This study aims to investigate the effects of the microstructures and nodule type on the fatigue characteristics of cast iron. Fatigue tests were carried out in tension-tension mode using a servo-hydraulic testing machine with load control mode operating at a frequency of 15 Hz. The tests were conducted at stress ratio R=Kmin/Kmax, of 0.1. Initial crack ${\Dalta}K$ values were highly performed with increase in tensile strength of DCI fatigue specimens. ${\Dalta}K_{th}$ region, fatigue crack propagation was primarily advanced through cell boundary and in periphery of near nodule. Fatigue crack propagation rate of D2 consisted with 2Phase(Ferrite+Pearlite) was slow due to crack closure enhanced by crack deflection and occurred crack branching. The generation of crack branch was occurred due to interaction of crack-nodule. At Threshold and Paris zone, the fractographs of the fatigue fracture surface for DCI show typical striations of a ductile fracture and isolated cleavage planes near graphite. The effect of microstructure on fatigue crack propagation of GC strongly depends on the type of flake. The generation of crack branch occurred due to interaction of crack-nodule. The fractographs of the fatigue fracture surface for GC show cleavage plane along the flake graphite.

• Journal of Korea Foundry Society
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• v.25 no.1
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• pp.23-29
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• 2005

Mechanical characteristics of Hi-Cr cast irons containing 16.8%Cr and 3.0%C were studied with various heat treatments. After as-cast Y-block ingots were annealed fully, the ingots were machined into cylinderical specimens with the size of 9mm in diameter and 20mm in length in order to investigate the effect of heat-treatments on mechanical characteristics of high Cr cast irons. All specimens were heat-treated by quenching- tempering, austempering and cyclic heat at the various temperatures(950, 1000, 1050 and $1100^{\circ}C$) respectively. The wear amount was measured for each heat-treated specimens against the counterpart of a hardened SKD11 steel at the following conditions; wearing velocity: 0.7 m/s, load: 100N and sliding distance: 70 km. After as-cast specimens were annealed, fine $M_{3}C$ carbides were formed, which affected the hardness and the wear resistance of Hi-Cr specimens. High hardness and good wear resistance were appeared on the specimens treated at 950 and $1000^{\circ}C$ and the austempered specimens show excellent wear resistance as well as high hardness.

• Journal of Korea Foundry Society
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• v.12 no.4
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• pp.317-325
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• 1992

Diamond is the hardest material known to humans, also possesses the highest thermal conductivity and a very low thermal expansion coefficient. Therefore, these properties of diamond make them logical choices for many difficult grinding application. Bonding material is a very important factor to performance of a grinding wheel. Grinding glass constitutes one of the major application areas of diamond grinding wheels, and Cu-Sn tin bronze matrix is widely used as a metal bond of diamond wheel in grinding glass but these studies are rarely reported. The bronze test pieces excluding diamond are sintered by the method of hot sizing respectively at $600^{\circ}C$, $650^{\circ}C$, $700^{\circ}C$, with a composition(Cu-10wt%Sn) on ${\alpha}$ phase and two compositions(Cu-20wt%Sn and Cu-23wt%Sn) on ${\alpha}+{\beta}$ phase. The rupture strength of Cu-10wt%Sn is highest. The bronze bonded diamond wheels are manufactured by same conditions as the bronze test pieces. The results of grinding ratio of wheels are highest in case of Cu-10wt%Sn bonded wheel sintered at $650^{\circ}C$ and grinding power is highest in same composition sintered at $700^{\circ}C$.

• Journal of Korea Foundry Society
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• v.30 no.3
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• pp.115-120
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• 2010

Recently, an advanced raw material supplying system in diecasting industry that molten metal produced by the raw material supplier can be directly delivered to the diecasting shops was proposed. It was known to have advantages of reducing melting process cost and improving working environment. However, for its successful mass production, the development of high insulation ladle is inevitable. In this study, the optimal mixing ratio of $SiO_2-Al_2O_3$ was investigated and the high insulation ladle with computer simulation result was built in a prototype and evaluated. The prototype which has refractory wall of $SiO_233%-Al_2O_3$ 35%-CaO 33% showed high insulation sufficient for carrying the Al molten metal for 138 minutes. Gas quantity result and SEM-EDS analysis on the melt poured in the ladle also showed extremely low level of 0.028 cc / 100 g and no penetration of Al molten metal into the refractory wall, satisfying the requirements for mass production.

• Journal of Korea Foundry Society
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• v.21 no.2
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• pp.119-126
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• 2001

Al/15%Gr. composite have been manufactured by mixing, compacting, and extruding aluminium powder and graphite powder. Then, Al-6%Si/x%Gr., Al-12%Si/x%Gr., and Al-18%Si/x%Gr.(x: 0, 2, 4, 6, 8) composites have been manufactured by remelting the extruded materials(Al/15%Gr.), Al-33.3%Si alloy, and Al ingot, etc. We conducted experiments to chracterize the microstructure, and damping properties and hardness. The result of microstructure experiment on Al-x%Si/y%Gr. composites reveals the good dispersion of graphite. As to Al-Si/y%Gr. composites, the more the graphite contents, the less the tensile strength. And the tensile strength varied according to contents of Si: with its highest value in Al-18%Si/y%Gr. composites and lowest in Al-6%Si/y%Gr. composites. As to Al-x%Si/y%Gr. composites, the more the contents of graphite, the more the vibration damping properties. And we can get the highest vibration damping rate in Al-12%Si/y%Gr. composites which matrix structure is an eutectic component.

• Journal of Korea Foundry Society
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• v.15 no.4
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• pp.368-376
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• 1995

An Al-composite material was fabricated with using the rheocompocasting process and the microstructure of the Al-Cu/SiCp composite material was investigated depending on the stirring times and the amount of Ti additions. The distribution of SiC dispersion shows the good result at the stirring time of 30 min. The degree of microdistribution of the $Al_2Cu$ and SiCp is improved when the amount of Ti addition is increased. At the compositon of 0.3%Ti, the primary solid is the compound of $Al_3Ti$ and no exist of the SiCp and $Al_2Cu$ phase around the primary $Al_3Ti$. In the process of compositization, SiCp is found at the primary and final solid parts and is found at the final solid part after remelting. $Al_2Cu$ and SiCp are distributed around and outside of dendrite or independently after remelting, which is different from the process of compositization.

• Journal of Korea Foundry Society
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• v.34 no.3
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• pp.107-111
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• 2014

Permeability is the ability of a material to transmit fluid/gases. It is an important material property and it depends on mould parameters such as grain fineness number, clay, moisture, mulling time, and hardness. Modeling the relationships among these variable and interactions by mathematical models is complex. Hence a biologically inspired artificial neural-network technique with a back-propagation-learning algorithm was developed to estimate the permeability of green sand. The developed model was used to perform a sensitivity analysis to estimate permeability. The individual as well as the combined influence of mould parameters on permeability were simulated. The model was able to describe the complex relationships in the system. The optimum process window for maximum permeability was obtained as 8.75-10.5% clay and 3.9-9.5% moisture. The developed model is very useful in understanding various interactions between inputs and their effects on permeability.

• Journal of Korea Foundry Society
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• v.34 no.6
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• pp.187-193
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• 2014

In the present work, the effect of adding Ce on the corrosion behavior of Mg-4Al-2Sn-1Ca alloy was investigated. The studied alloys were fabricated by gravity casting method and a potentiodynamic polarization, A.C. impedance and hydrogen evolution tests were carried out in a 3.5% NaCl solution with pH 7.2 at room temperature to measure the corrosion properties of Mg-4Al-2Sn-1Ca-xCe alloys. The microstructure of the Mg-4Al-2Sn-1Ca alloy was composed of ${\alpha}$-Mg, Mg17Al12, Mg2Sn and CaMgSn phase. Also, a $Al_{11}Ce_3$ phase was newly formed by the addition of Ce. With an increase of the Ce contents, the microstructure became refined and the corrosion resistance improved.