• Transactions of Materials Processing
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• v.32 no.6
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• pp.335-343
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• 2023

Spur Gear parts for automobile actuators using existing former forging technology were produced in a total of three processes on a former forging machine. However, in order to improve cost increase due to frequent mold breakage, Spur Gear parts were designed and manufactured in the cold forging process after forming the preform through former forging. In other words, in the existing former forging mold, product seating defects occurred due to horizontal movement, resulting in many product defects and mold damage, so there was an urgent need to improve mold life and product defects. In order to improve this, we tried to improve the mold life by improving the existing 3 former forging processes to a former forging process and 2 cold forging processes. Therefore, We developed Spur Gear parts for automobile actuators were developed by applying precision cold forging technology through a former forging process and 2 cold forging processes to improve mold life.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.4
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• pp.7-21
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• 2000

This paper describes an overview of the thixoforming and thixomolding processes. Semi-solid metalworking (SSM), which is called the thixoforming process of aluminium materials, incorporates the elements of both casting and for the manufacture of near net shape parts. The SSM has some advantages such as net shape or near net shape manufacturing, the ability to form thin walls, excellent surface finish, tight tolerance, and excellent dimensional precision. The thixomolding process of Mg alloy (AZ9l) is a combination of two technologies both conventional die casting and plastic injection molding. The feed material used is a machined chip with a geometry of approximately 1 mm square and a length of 2~3 mm. The semi-solid forming (SSF) of high quality aluminium and magnesium parts will be established in the automotive and electronic industry, in the future. The hybrid method of casting/forging has been caused attention. This process uses a preformed material made by casting instead of the wrought material and finishes it by a single forging process. This process is expected to lower costs without sacrificing the mechanical and finishes it by a single forging process. The process is expected to lower costs without sacrificing the mechanical properties. The authors, intending that the casting/forging process contributes to a reduction in production cost of aluminum automotive parts in Korea, describes the feature of the casting/forging process, aluminum alloys suitable for the cast preform, microstructure and mechanical properties of the cast preform, application examples of cast/forging, and further study.

• Composites Research
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• v.16 no.2
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• pp.33-40
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• 2003

In order to overcome one of the most pronounced shortcomings of conventional laminated composites, such as the low damage tolerance due to delamination, the thermoplastic materials and 3D (three-dimensional) preforms have been utilized in the manufacture of composite materials. From the newly developed process termed as the co-braiding, hybrid yarns of the thermoplastic fibers (PEEK) and reinforcing fibers (carbon) have been fabricated. In order to further enhance the delamination suppression, through thickness fibers have been introduced by way of 3D weaving technique in the fabrication of textile preforms. The preforms have been thermoformed to make composite materials. Complete impregnation of the PEEK into the carbon fiber bundles has been confirmed. For the comparison of mechanical performance of 3D woven composites, quasi-isotropic laminates using APC-2/AS4 tapes have been fabricated. Tensile and compressive properties of both the composites have been determined. Furthermore. the open hole, impact and CAI(Compression After Impact) tests were also carried out to assess the applicability of 3D woven textile reinforced thermoplastic composites in aerospace structures.

• Journal of Korea Foundry Society
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• v.23 no.1
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• pp.30-39
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• 2003

Porous hybrid preforms were fabricated by reactive sintering using the compacts consisting of SiC particles, Fe and Al powders. Squeeze casting processing was employed to produce the composite in which the matrix phase is Al-Si7Mg. The microstructural change and wear resistance of the composites were investigated in terms of an amount of SiC particles. The wear loss was increased with increasing the contact pressure in the alloy containing SiC particles coated with Cu. The most drastic change was found to the specimen tested at 2.5 MPa of contact pressure. Concerning the alloys containing SiC particles coated with Ni-P, a drastic increase in the wear loss exhibited at 2 MPa of contact pressure in those alloys containing 4 and 8 wt. % of SiC particles coated with Ni-P. In the alloy containing 16 wt. % a proportional increase in wear loss was observed to the change of contact pressure. With respecting to the sliding velocity, the wear loss of the alloy containing SiC particles coated with Cu increased at the initial stage of wear process and then decreased. Similar result was found in the alloys containing SiC particles coated with Ni-P. On the basis of the present results obtained, it was found that wear resistance of the alloys tested was improved to show in the order of the alloy reinforced by coated SiC particles > by uncoated SiC particles > by intermetallic compound without SiC particles.

• Composites Research
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• v.20 no.6
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• pp.1-7
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• 2007

Expanded graphite/carbon fiber hybrid conductive polymer composites were fabricated by the preform molding technique. The conductive fillers were mechanically mixed with a phenol resin to provide an electrical property to composites. The conductive filler loading was fixed at 60wt.% to accomplish a high electrical conductivity. Expanded graphites were excellent in forming a conductive networking by direct contacts between them while it was hard to get the high flexural strength over 40MPa with using only expanded graphite and phenol resin. In this study, carbon fibers were added in composites to compensate the weakened flexural strength. The effect of carbon fibers on the mechanical and electrical properties was examined according to the weight ratio of carbon fiber. As the carbon fiber ratio increased, the flexural strength increased until the carbon fiber ratio of 24wt.%, and then decreased afterward. The electrical conductivity gradually decreased as the increase of the carbon fiber ratio. This was attributed to the non-conducting regions generated among the carbon fibers and the reduction of the direct contact areas between expanded graphites.

• Journal of Korea Foundry Society
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• v.22 no.1
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• pp.42-48
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• 2002

Effects of coating treatment of metallic Cu, Ni-P film on $SiC_p$, for $SiC_p$/iron aluminide composites were studied. Porous hybrid preforms were fabricated by reactive sintering after mixing the coated $SiC_p$, Fe and Al powders. Then the final composites were manufactured by squeeze casting after pouring AC4C Al alloy melts in preforms. The change of reactive temperature, density, microstructure of the preforms and microstructure of the composites were investigated. The exprimental results were summarized as follows. The thickness of Cu and Ni-P metallic layer formed on $SiC_p$ by electroless plating method were about $0.5{\mu}m$ and coated uniformly. There was no remakable change in the ignition temperature with variation of the mixing ratio of Fe and Al powder while in the case of coated $SiC_p$ it was lower about $20^{\circ}C$ than in the non-coated $SiC_p$. The maximum reaction temperature increased with increasing Al contents, but decreased with increasing $SiC_p$ contents. Expansion ratio of preform after reactive sintering increased with amount of Cu coated $SiC_p$. In the case of Fe-70at.%Al, the expansion ratio was about 7% up to 8wt.% of $SiC_p$, addition but further addition of $SiC_p$, increased the ratio significantly. And in the case of Fe-50 and 60at.%Al, it was about 20% up to 16wt.% of $SiC_p$ addition and about 28% in 24wt.% of $SiC_p$, addition. The microstructures of compounds showed that the grains became finer as amount of $SiC_p$, and mixing ratio of iron powder increased and the shape of compounds was changed gradually from irregular to spheroidal.

• Composites Research
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• v.34 no.2
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• pp.88-95
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• 2021

VARTM (Vacuum-assisted resin transfer molding) process is a low-cost process technology and affiliated with OoA (Out of Autoclave). Besides, it has been widely used in various fields. However, because of its lower quality than the autoclave process, it isn't easy to apply the VARTM process to the aerospace industry, which requires high reliability. The main problem of the VARTM process is the loss of mechanical properties due to the low fiber volume fraction and high void content in comparison to the autoclave. Therefore, many researchers have studied to reduce void and increase fiber volume fraction. This study examines whether the method of controlling atmospheric pressure could increase the fiber volume fraction and reduce void during the resin impregnation process. Reliability evaluation was confirmed by compressive strength test, fiber volume fraction analysis, and optical microscopy. As a result, it was confirmed that increasing the atmospheric pressure step by step in the VARTM process of impregnating the preform with resin effectively increases the fiber volume fraction and reduces void.

• Carbon letters
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• v.15 no.1
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• pp.25-31
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• 2014

A microstructure analysis is carried out to optimize the process parameters of a randomly oriented discrete length hybrid carbon fiber reinforced carbon matrix composite. The composite is fabricated by moulding of a slurry into a preform, followed by hot-pressing and carbonization. Heating rates of 0.1, 0.2, 0.3, 0.5, 1, and $3.3^{\circ}C/min$ and pressures of 5, 10, 15, and 20 MPa are applied during hot-pressing. Matrix precursor to reinforcement weight ratios of 70:30, 50:50, and 30:70 are also considered. A microstructure analysis of the carbon/carbon compacts is performed for each variant. Higher heating rates give bloated compacts whereas low heating rates give bloating-free, fine microstructure compacts. The compacts fabricated at higher pressure have displayed side oozing of molten pitch and discrete length carbon fibers. The microstructure of the compacts fabricated at low pressure shows a lack of densification. The compacts with low matrix precursor to reinforcement weight ratios have insufficient bonding agent to bind the reinforcement whereas the higher matrix precursor to reinforcement weight ratio results in a plaster-like structure. Based on the microstructure analysis, a heating rate of $0.2^{\circ}C/min$, pressure of 15 MPa, and a matrix precursor to reinforcement ratio of 50:50 are found to be optimum w.r.t attaining bloating-free densification and processing time.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.9
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• pp.5789-5794
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• 2015

Recently, thin and light-weight production technologies are needed in IT industry in accordance with increase of the smart phones and mobile PC products. In order to make light and high rigidity products, engineering plastic and aluminum materials are frequently used in products appearance and frame hat support structure. Especially aluminum extrusion and CNC Brick processes are widely used for high strength and high rigidity technology. But extrusion method has constraints to apply exterior design and CNC Brick process has relatively high production cost and low speed of manufacturing. In this research, a new process method is introduced in order to reduce material cost and to improve manufacturing speed dramatically. Plate forging process means basically that thickening of local wall area thickness after deform exterior shape by deep drawing and bending process. Therefore, it is possible to minimize the waste of material and the manufacturing time. In this study the process of plate forging is designed using finite element program AFDEX-2D and the thickness and the width of initial deformed blank. And it is verified as a sample which is a part of laptop developed through the proposed plate forging method.