• Journal of the Korean Ceramic Society
• /
• v.40 no.2
• /
• pp.128-131
• /
• 2003

Formation of$B_4C/Al$composite by pressureless infiltration was investigated by lowering wetting angle via surface modification of $B_4C$powder with alumina precursor. Surface modification was confirmed by zeta potential analysis. The$B_4C/Al$composite was prepared by placing an Al 6061 disk on the$B_4C$preform and heating at $1030{\circ}C$/20 min under a flowing argon, but no infiltration took place for a bare $B_4C$ preform even at$1250{\circ}C$/30 min. Analysis of XRD and SEM showed the $Al_3BC$phase besides$B_4C$and Al, but no trace of deteriorative$A1_4C_3$.

• Journal of the Korean Society for Precision Engineering
• /
• v.22 no.11 s.176
• /
• pp.45-50
• /
• 2005

In this study, the casting/forging process was applied in manufacturing a low control arm, in order to prove that application of casting/forging process to Al6061 is likely to get the effect of light weight compared with existing steel products and to reduce the cost of materials. Firstly, In order to set up the optimum casting condition of the forging material, Al6061, casting experiments were carried out by controlling pouring temperature of the aluminum for casting, mold temperature, and pouring time. $700^{\circ}C$ pouring temperature, $300^{\circ}C$ mold temperature and 10-second pouring time were taken into account as the optimum casting conditions. With respect to a hot forging test, it is practiced on the basis of a temperature of materials, strain rate, and reduction rate so as to observe each microstructure and examine strain-stress curve simultaneously; examine tensile test and hardness test; eventually set up the optimum hot forging condition. A hot forging test, tensile test, hardness experiment, and microstructure observation were carried out on condition of $70\%$ reduction rate, $500^{\circ}C$ temperature of materials, and 1 strain rate. As a result of those experiments, 330MPa tensile strength, $16.4\%$ elongation, and 122.8Hv hardness were recorded. In oder to get a sound preform which has no unfitting cavity and less flash, two preforms were proposed on the basis of volume rate of the final product; the optimum volume rate of preform for the low control arm was $115\%$. In conclusion, it is confirmed that using the forging material rather than casting materials in casting/forging process is likely to get more superior mechanical properties. Compared with Al6061, performed by means of general forging, moreover, cast/forged Al6061 can not only stimulate productivity by reducing production processes, but cut down the cost of materials by reusing forging scraps.

• Composites Research
• /
• v.15 no.1
• /
• pp.32-40
• /
• 2002

This study developed fabrication process of $SiC_p/Al$ metal matrix composites as electronic packaging materials by squeeze casting method. The $SiC_p$ preform were fabricated in newly designed preform mold using about 0.8 % of inorganic binder(SiO$_2$) and 5 vol.% of $Al_2O_3$fiber. To infiltrate the molten metal into the preform, fabrication condition such as the temperature and the pressure were selected. Applying the fabrication conditions, heat transfer analysis were preformed using finite element method and thus analyzed the temperature distribution and cooling characteristic during the squeeze casting. For the fabricated composites, impact toughness and thermal expansion coefficient were measured. The metal matrix composites developed in this study have 0.2~0.3 J impact toughness, $8~10 ppm/^{\circ}C$ thermal expansion coefficient and $2.9~3.0g/cm^3$density which is appropriate properties for electronic packaging application.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.34 no.4
• /
• pp.423-430
• /
• 2010

Hot closed-forging process and the die used for forming an automotive flange were analyzed from the viewpoints of heat transfer, grain-flow lines, and stresses to obtain a forged product without defects such as surface cracks, laps, cold shots, and partial filling. The forging process including up-set, pre-forging, final forging and pressing forces was investigated using finite element analysis. The influence of the preform die and the ratio of the heights of the upper die to lower die on the forging process and die were investigated and a die shape ($10^{\circ}$ for the preform die, and 1.5:1 ratio for the final die) suitable to achieve successful forging was determined on the basis of a parametric study. All parametric design requirements such as strength, full filling, and a load limit of 13,000 KN were satisfied for this newly developed flange die. New dies and flanges were fabricated and investigated. Defects such as partial filling and surface cracks were not observed.

• Journal of Korea Foundry Society
• /
• v.13 no.1
• /
• pp.62-70
• /
• 1993

This study presents the effect of applied pressure on the preform deformation during squeeze casting of $Al_2O_3$ short fiber reinforced aluminum alloy (AC8A) metal matrix composites. A preliminary model based on the general beam theory is suggested for the prediction of the preform deformation. Two different commercially available $Al_2O_3$ short fiber (Saffil, Kaowool) were used to study the influence of the fibers on the microstructure and mechanical properties of the squeeze cast $Al/Al_2O_3$ composites. The composites were fabricated with the applied pressure of 75 MPa which was found to be the optimum condition for the squeeze casting of the composites in this study. For the amorphous Kaowool fiber, hard crystalline Mullite phase was formed with heat treatment. Both of amorphous and the crystallized Kaowool fibers were used to fabricate $Al/Al_2O_3$ composites. Microhardness of crystallized Kaowool fiber revealed higher than that of the amorphous Kaowool fiber in the squeeze cast composites. It was also found that the wear resistance of Kaowool fiber reinforced composites increased with the amount of Mullite.

• Applied Chemistry for Engineering
• /
• v.18 no.6
• /
• pp.580-586
• /
• 2007

In this study, 4 directional carbon/carbon composites with different preform architectures were manufactured and their thermophysical properties are studied. Carbon fiber preforms are fabricated with fiber bundles using four different spaces. The density of the fabricated preforms were increased through pressure impregnation and carbonizing process. The increased density of the composites was graphitized at $2300^{\circ}C$. Microstructures of these composite were observed under scanning electron microscope. This was to understand the effect the preform architectures has on the thermophysical properties of carbon/carbon composites. Also, the behavior of thermal conduction and heat expansion was investigated and studied in association with the factors of the reinforced direction of fibers and unit cell of preforms.

• Composites Research
• /
• v.33 no.3
• /
• pp.115-124
• /
• 2020

Laminate composites, especially Carbon fiber-reinforced composites are wide used in various industry such as aerospace and automotive industry due to their high specific strength and specific stiffness. However, the laminate composites has a big disadvantage that delamination occurs because the arrangement of the fibers is all arranged in the in-plane direction, which limits the field of application of the laminate composites. In this study, we first developed a laminate composites T-beam in which π-beam and flat plate were combined and optimized the design parameters through structural analysis and mechanical tests. Afterwards, 3D weave preform T-beam was developed by applying the same design parameters of laminate composites T-beams, and improved mechanical strength was achieved compared to laminated structures. These findings are expected to be applicable to existing laminated composite structures that require increased strength.

• Composites Research
• /
• v.33 no.2
• /
• pp.61-67
• /
• 2020

Preforming is crucial in resin transfer molding process using woven fabric. When shear deformation exceeds the locking angle, wrinkles are generated in the preform, which causes defects in the RTM process. Therefore, in this study, the allowable shear deformation limit of carbon fiber woven fabrics is quantified and the molding characteristics are verified using the actual fabric forming. As a result, the characteristics of creases according to the layer setups have been examined and the results have been discussed. Numerical analyses have been also performed using measured shear properties. These results have been compared with the experimental results.

• Journal of the Korean Ceramic Society
• /
• v.29 no.8
• /
• pp.601-608
• /
• 1992

We investigated the influence of several processes, including the preparation of slurry and preform and the heat-treatment of the preform, on the properties of composites to fabricate the carbon-fiber reinforced glass composites having good mechanical properties. Cerander was determined to be the best binder among Cerander, Rhoplex and Elvacite 2045 by the dipping test and the binder within a preform could be completely eliminatd by burning out the specimen under 10-6 Torr at 400$^{\circ}C$ for more than 1h. The fracture behavior of a composite was largely dependent on the uniformity of carbon-fiber distribution within the composite and the heat-treatment condition of the composite. The higher the glass content, the more difficult to obtain uniform distribution of carbon-fiber. As the hot-pressing temperature increased, the densification process of the composite and the formation of pore due to oxidation of carbon fiber occurred competitively. But, above 1000$^{\circ}C$ the latter played a predominant role. We could fabricated the densest 15 vol.% carbon-fiber-content glass composite having the highest toughness and flexural strength of 250 MPa by hot-pressing under 15 MPa at 900$^{\circ}C$ for 30 min.

• Design & Manufacturing
• /
• v.12 no.3
• /
• pp.5-12
• /
• 2018

Plastic containers which provides the opportunity to reduce transportation costs are lighter and less brittle than glass containers. As a results, efforts to replace glass with plastic are ongoing. The blow molding method is a typical approach in producing plastic containers. Single-stage injection blow molding (ISBM) is one of the blow molding methods. However, the difficulty in controlling the temperature during the injection molding process is considered its main disadvantage. In this study, ISBM process analysis of relatively thick walled containers such as cosmetic containers is carried out. The initial temperature distribution of the preform is deemed to be the most influential factor in the accuracy of blow molding for the thick vessel. In order to accurately predict this, all heat transfer processes of the preform are considered. The validity of this analytical procedure is verified by comparing the cross-sectional thickness with the actual product. Finally, the validated analytical method is used to evaluate the factors affecting the thickness of the final molded part. The ISBM analysis technique for thick walled vessels developed through this study can be used as an effective predictor for preform design and blow process.