• Journal of Korea Foundry Society
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• v.21 no.4
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• pp.253-259
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• 2001

There are many methods to produce metal foams, which can be classified into three groups according to the state of the starting metal i.e. liquid or powder or solid. Three types of defects such as cell closing, cell deformation or breakdown and cell misrun are thought to be occurred when we make the open cell aluminum foams by precision casting. Filling ability of the mold slurry between preform is related with cell closing, mold collapsibility is related with cell deformation or breakdown, mold temperature and pouring pressure are related with cell misrun. These factors can be evaluated by measuring slurry fluidity, burnout strength and permeability of the mold. Properties of the plaster mold were evaluated to find optimum mold conditions for high quality open cell aluminum foam in this study. Permeability was almost zero independent of burnout conditions, however, crack initiation was found on the surface of all specimens one or two minutes after taking out from the furnace. Crack has grown and disappeared with time. This crack may facilitate the mold filling when molten metal is poured, because of the improved mold permeability. It was considered that crack initiation and disappearance was closely related with temperature difference between the surface and inner part. Knocking-out the mold is a difficult problem due to the small cell size, because continuous mesh structure of the metal foam is not strong. It is not easy to remove molding material after pouring. We can expect that water quenching can facilitate the knocking-out the mold after solidification without damaging cell structures. Collapsed particles after water quenching became bigger with the increase in time.

• Journal of Mechanical Science and Technology
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• v.20 no.3
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• pp.319-328
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• 2006

A simple approximation method for the stress intensity factor at the tip of the axial semielliptical cracks on the cylindrical vessel is developed. The approximation methods, incorporated in VINTIN (Vessel INTegrity analysis-INner flaws), utilizes the influence coefficients to calculate the stress intensity factor at the crack tip. This method has been compared with other solution methods including 3-D finite element analysis for internal pressure, cooldown, and pressurized thermal shock loading conditions. For these, 3-D finite-element analyses are performed to obtain the stress intensity factors for various surface cracks with t/R=0.1. The approximation solutions are within $\pm2.5%$ of the those of finite element analysis using symmetric model of one-forth of a vessel under pressure loading, and 1-3% higher under pressurized thermal shock condition. The analysis results confirm that the approximation method provides sufficiently accurate stress intensity factor values for the axial semi-elliptical flaws on the surface of the reactor pressure vessel.

• Journal of Welding and Joining
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• v.27 no.4
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• pp.32-37
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• 2009

Alloy 600 and Alloy 82/182 materials have been used widely in PWR plants. But these materials are known to be susceptible to PWSCC(Primary Water Stress Corrosion Cracking). Recently, there have been several PWSCC events in major components due to repair welding, because repair welding in the dissimilar metal welds during the construction increases residual stress significantly on the inner surface of welds. In this paper, various residual stress analyses for repair welding were performed using FEM to check the effect of repair welding on residual stress distributions in PZR safety/relief nozzle. The results indicate that for inside surface repair welding, high tensile residual stress is developed on the inside surface of the nozzles.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.25 no.4
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• pp.756-763
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• 2001

In the process of integrity evaluation for nuclear power plant components, a series of fracture mechanics evaluation on surface cracks in reactor pressure vessel(RPV) must be conducted. These fracture mechanics evaluation are based on stress intensity factor, K. However, under pressurized thermal shock(PTS) conditions, the combination of thermal and mechanical stress by steep temperature gradient and internal pressure causes considerably high tensile stress at the inside of RPV wall. Besides, the internal pressure during the normal operation produces high tensile stress at the RPV wall. As a result, cracks on inner surface of RPVs may experience elastic-plastic behavior which can be explained with J-integral. In such a case, however, J-integral may possibly lose its validity due to constraint effect. In this paper, in order to verify the suitability of J-integral, tow dimensional finite element analyses were applied for various surface cracks. A total of 18 crack geometries were analyzed, and $\Omega$ stresses were obtained by comparing resulting HRR stress distribution with corresponding actual stress distributions. In conclusion, HRR stress fields were found to overestimate the actual crack-tip stress field due to constraint effect.

• Tribology and Lubricants
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• v.27 no.5
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• pp.269-274
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• 2011

The purpose of this paper is to study and analyze the improvement method for the failure examples including the vehicle brake system in actual field. It was verified that the indicator plate of pad wear scratched the brake disk because of wearing after displacement of non- identification parts pad. The caliper of other vehicle was installed with brake system verified the phenomenon produced groove in center point because of one side wear when the pad was not fully contacted with the rub disk by other action surface pressure and pad action condition. It verified that the crack phenomenon fatigue was produced by brake thermal deformation because of decreasing the thickness by grinding to modify the non-uniformed wear of brake disk. It verified that the friction sound was produced by the friction phenomenon because of non-uniformed contact of lining and an alien substance with inner of the drum and lining braking by crack phenomenon with brake drum surface.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 2002.04a
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• pp.480-485
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• 2002

The purpose of this paper is the development of guidance algorithm for a mobile robot which is used to acquire the position and state information of the pipe defects such as crack, damage and through hole. The data used for the algorithm is the range data obtained by the range sensor which is based on an optical triangulation method. The sensor, which consists of a laser slit beam and a CCD camera, measures the 3D profile of the pipe's inner surface. After setting the range sensor on the robot, the robot is put into a pipe. While the camera and the LSB sensor part is rotated about the robot axis, a laser slit beam (LSB) is projected onto the inner surface of the pipe and a CCD camera captures the image. From the images the range data is obtained with respect to the sensor coordinate through a series of image processing and applying the sensor matrix. After the data is transformed into the robot coordinate, the position and orientation of the robot should be obtained in order to guide the robot. In addition, analyzing the data, 3D shape of the pipe is constructed and the numerical data for the defects of the pipe can be found. These data will be used for pipe maintenance and service.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.11 no.1
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• pp.74-78
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• 2015

Nuclear power plant steam generator that is one of the main component has several thousands of thin tubes. And the steam generator tube is subject to damage because of the severe operation conditions such as the high temperature and pressure. Therefore periodic inspections are conducted to ensure the integrity of steam generator component. Hanul unit 3 also has been inspected in accordance with in-service inspection program and is scheduled to be replaced for exceeding the plugging rate which was recommended by manufacturer. During the steam generator replacement activity, we found several clustered porosity on inner surface of main feed water pipe. Additionally crack-like indications were found at weld interface between base material and weld of main feed water pipe. This paper describes the field experience and visual testing results for inner surface of main feed water pipes. The destructive test result had shown that these indications were porosities which were caused by manufacturing process not by operation service.

• Journal of the Korean institute of surface engineering
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• v.48 no.6
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• pp.260-268
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• 2015

The thermal barrier coating (TBC) for inner wall of liquid-fuel rocket combustor consists of NiCrAlY as bonding layer and $ZrO_2$ as a top layer. In most case, the plasma spray coating is used for TBC process and this process has inherent possibility of cracking due to large difference in thermal expansion coefficients among bonding layer, top layer and metal substrate. In this paper, we suggest crack-free TBC process by using a precise electrodeposition technique. Electrodeposited Ni-P/Cr double layer has similar thermal expansion coefficient to the Cu alloy substrate resulting in superior thermal barrier performance and high temperature oxidation resistance. We studied the effects of phosphorous concentrations (2.12 wt%, 6.97 wt%, and 10.53 wt%) on the annealing behavior ($750^{\circ}C$) of Ni-P samples and Cr double layered electrodeposits. Annealing temperature was simulated by combustion test condition. Also, we conducted SEM/EDS and XRD analysis for Ni-P/Cr samples. The results showed that the band layers between Ni-P and Cr are Ni and Cr, and has no formed with heat treatment. These band layers were solid solution of Cr and Ni which is formed by interdiffusion of both alloy elements. In addition, the P was not found in it. The thickness of band layer was increased with increasing annealing time. We expected that the band layer can improve the adhesion between Cr and Ni-P.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.18 no.2
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• pp.349-355
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• 2017

Bending work using press dies involves bending a flat blank to a desired angle. The bending produces a flange (the bent part) and a web (the unbent part). The bending line will have a bending angle, and there is an inner and outer bending radius. The minimum inner radius size is determined by the material used. When the inner radius size is too small, there will be excess metal welding, which will cause a crack in the outer radius part. The outer bending radius size cannot be controlled by a bending punch and die block. Types of bending include V-bending, U-bending, O-bending, edge bending, twist bending, and crimping. Z-bending involves two bending lines, which are set on the upper side and under surface of the blank, respectively, and upward or downward bending is used. Z-bending is also called crank bending. Z-bending using this type of die structure will produce a standard inner bending radius. The standard size is the minimum bending radius that represents the angle radius of the bending punch. In industry, there is a need for a sharp edge shape with a very small size (R=0.2mm), but that is not possible when using bending punch and die block. The purpose of this research is to meet the need by development.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.11
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• pp.2390-2398
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• 2002

For integrity analysis of nuclear reactor pressure vessel, including the Pressurized thermal shock analysis, the fast and accurate calculation of the stress intensity factor at the crack tip is needed. For this, a simple approximation scheme is developed and the resulting stress intensity factors for axial semi-elliptical cracks in cylindrical vessel under various loading conditions are compared with those of the finite element method and other approximation methods, such as Raju-Newman's equation and ASME Sec. Xl approach. For these, three-dimensional finite-element analyses are performed to obtain the stress intensity factors for various surface cracks with t/R = 0.1. The approximation methods, incorporated in VINTIN (Vessel INTegrity analysis-INner flaws), utilizes the influence coefficients to calculate the stress intensity factor at the crack tip. This method has been compared with other solution methods including 3-D finite clement analysis for internal pressure, cooldown, and pressurized thermal shock loading conditions. The approximation solutions are within $\pm$2.5% of the those of FEA using symmetric model of one-forth of a vessel under pressure loading, and 1-3% higher under pressurized thermal shock condition. The analysis results confirm that the VINTIN method provides sufficiently accurate stress intensity factor values for axial semi-elliptical flaws on the surface of the reactor pressure vessel.