• Journal of Korea Foundry Society
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• v.33 no.2
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• pp.69-74
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• 2013

Silicon (Si) wafer was grown by using direct growth from Si melt and contaminations of wafer during the process were investigated. In our process, BN was coated inside of all graphite parts including crucible in system to prevent carbon contamination. In addition, coated BN layer enhance the wettability, which ensures the favorable shape of grown wafer by proper flow of Si melt in casting mold. As a result, polycrystalline silicon wafer with dimension of $156{\times}156$ mm and thickness of $300{\pm}20$ um was successively obtained. There were, however, severe contaminations such as BN and SiC on surface of the as-grown wafer. While BN powders were easily removed by brushing surface, SiC could not be eliminated. As a result of BN analysis, C source for SiC was from binder contained in BN slurry. Therefore, to eliminate those C sources, additional flushing process was carried out before Si was melted. By adding 3-times flushing processes, SiC was not detected on the surface of as-grown Si wafer. Polycrystalline Si wafer directly grown from Si melt in this study can be applied for the cost-effective Si solar cells.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.27 no.3
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• pp.130-134
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• 2017

In this study, numerical simulation was performed to focus on optimized process condition for obtaining a long-term growth and high quality SiC crystal. It could be optimized by considering the change of fluid and a carbon flow in the Si melt added with 40 % Cr. The Crystal Growth Simulator ($CGSim^{TM}$, STR Group Ltd.) was used as a numerical simulation. It was confirmed that many parameters such as temperature, rotation speed of seed crystal and crucible, and seed position during the crystal growth step had a strong influence on the speed and direction of solution flow for uniform temperature gradient and stable crystal growth. The optimized process condition for the solution growth of SiC crystal was successfully exhibited by adjusting various process parameters in the numerical simulation, which would be helpful for real crystal growth.

• Transactions of Materials Processing
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• v.15 no.1 s.82
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• pp.15-20
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• 2006

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filling difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation for both the conventional molding and the RTR molding processes.

• Journal of Korea Foundry Society
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• v.12 no.1
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• pp.40-50
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• 1992

A computer simulation of mold filling has been performed in order to analyze the fluid flow pattern in a mold cavity since casting defects such as cold shut formation, entrapment of air or gas, and inclusions are closely related to the fluid flow phenomena. The flow of molten metal entering the mold cavity with free surface has been modeled by SMAC(Simplified Marker and Cell) method. Two dimensional analysis was carried out on plate shape castings with two types of gate system. The calculation results were compared with those of water modeling experiments and showed relatively good agreement.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.09a
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• pp.9-12
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• 2005

The rapid thermal response (RTR) molding is a novel process developed to raise the temperature of mold surface rapidly to the polymer melt temperature prior to the injection stage and then cool rapidly to the ejection temperature. The resulting filling process is achieved inside a hot mold cavity by prohibiting formation of frozen layer so as to enable thin wall injection molding without filing difficulty. The present work covers flow simulation of thin wall injection molding using the RTR molding process. In order to take into account the effects of thermal boundary conditions of the RTR mold, coupled analysis with transient heat transfer simulation is suggested and compared with conventional isothermal analysis. The proposed coupled simulation approach based on solid elements provides reliable thin wall flow estimation fur both the conventional molding and the RTR molding processes

• Journal of Korea Foundry Society
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• v.22 no.3
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• pp.109-113
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• 2002

A good fluidity of high strength Al-alloys is required to cast thin wall castings needed to reduce the weight of cast parts. The fluidity, measured as the length to which the metal flows in a standard channel, is affected by many factors, such as the pouring temperature, solidification type of the alloy, the channel thickness, melt head, mold materials and temperature, coating etc. Therefore the experimentally measured fluidity scatters very much and makes it difficult to estimate the fluidity of a melt with a few measurements. The effect of Ti content and grain refinement on the fluidity of high strength aluminum alloy was investigated with a test casting with 8 thin flow channels to reduce the scattering of the fluidity results. The fluidity of Al-4.8%Cu-0.6%Mn Al-6.2%Zn-1.6%Mg-1.0%Cu and well-known commercial aluminum alloy, A356 was tested. Initial content of Ti was varied from 0 to 0.2wt% and Al-5Ti-B master alloy was added for grain refinement. The flow length varied linearly with superheat. By adding Ti and Al-5Ti-B, the fluidity increased. The grain size decreased by adding grain refiner at the same time. The fluidity depended on the degree of grain refinement. The fluidity of the alloy solidifying in mushy type is improved by grain refinement, because grain refinement increases the solid fraction at the time of flow stoppage.

• The Korean Journal of Rheology
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• v.11 no.2
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• pp.153-158
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• 1999

An improved method to predict preferred direction of gas in gas assisted injection molding processes is introduced. Resistance of resin flow is defined and this resistance of resin flow is not directly related to the resistance of gas flow. Pressure drop requirement was believed to be proportional to the resistance to gas flow in our previous work. Instead of using the pressure drop requirement, velocity of resin should be compared to predict the gas flow direction. This method predicts the gas flow direction from the knowledge of process variables such as resin flow length, cross section area of cavity, melt temperature, and short shot. A simulation package was used to confirm the method.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.5
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• pp.657-665
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• 2003

Several interesting results were obtained from the flow visualization experiment in the accompanying paper, Part I. in the present study, Part II, a numerical study has been carried out to explain the detailed flow phenomena in micro-channel filling process. Hele-Shaw flow approximation was applied to the micro-channel geometry based on the small characteristic length. And surface tension effect has been introduced on the flow front as the boundary condition with the help of a dynamic contact angle concept between the melt front and the wall. A dimensional analysis for numerical results was carried out and a strong relationship between dimensionless pressure and Capillary number is obtained. The numerical analysis results are compared with the flow visualization experimental observations. And the numerical system developed in the present study seems to be able to predict the interesting micro-channel filling flow characteristics observed from experiments.

• Nuclear Engineering and Technology
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• v.54 no.1
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• pp.72-83
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• 2022

This paper presents a numerical investigation of two-phase natural circulation flows established when external reactor vessel cooling is applied to a severe accident of the APR1400 reactor for the in-vessel retention of the core melt. The coolability limit due to external reactor vessel cooling is associated with the natural circulation flow rate around the lower head of the reactor vessel. For an elaborate prediction of the natural circulation flow rate using a thermal-hydraulic system code, MARS-KS1.5, a three-dimensional computational fluid dynamics (CFD) simulation is conducted to estimate the flow rate and pressure distribution of a liquid-state coolant at the brink of significant void generation. The CFD calculation results are used to determine the loss coefficient at major flow junctions, where substantial pressure losses are expected, in the nodalization scheme of the MARS-KS code such that the single-phase flow rate is the same as that predicted via CFD simulations. Subsequently, the MARS-KS analysis is performed for the two-phase natural circulation regime, and the transient behavior of the main thermal-hydraulic variables is investigated.

• Proceedings of the KSME Conference
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• 2007.05b
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• pp.3062-3067
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• 2007

HVOF thermal spray guns are now being widely used to produce protective coatings, on the surfaces of engineering components. HVOF technology employs a combustion process to heat the gas flow and melt the coating materials which are particles of metals, alloys or cermets. Particle flow which is accelerated to high velocities and combustion gas stream are deposited on a substrate. In order to obtain good quality coatings, the analysis of torch design must be performed. The reason is that the design parameters of torch influence gas dynamic behaviors. In this study, numerical analysis is performed to predict the gas dynamic behaviors in a HVOF thermal spray gun with various torch shapes. The CFD model is used to deduce the effect of changes in nozzle geometry on gas dynamics. Using a commercial code, FLUENT which uses Finite Volume Method and SIMPLE algorithm, governing equations have been solved for the pressure, velocity and temperature distributions in the HVOF thermal spray torch.