• Transactions of Materials Processing
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• v.16 no.3 s.93
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• pp.178-186
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• 2007

Rheo-forging process of aluminum alloy is suitable for large parts of net shape without defects and excellent mechanical properties in comparison with conventional die casting and forging process. To control the microstructure of the product with high mechanical properties in rheo-forming, solid fraction is required to prevent porosity and liquid segregation. Therefore, in rheo-forging process, die shape, pressure type and solid fraction are very important parameters. The defects such as porosity, liquid segregation and unfitting phenomena occur during rheo-forging process. To prevent these defects, mechanical properties and microstructure analysis of samples versus the change of pressure are carried out and the problem and its solutions are proposed. Also, the mechanical properties versus various pressures were compared with and without heat treatment. The alloys used for rheo-forming are A356 and 2024 aluminum alloy. The rheology material is fabricated by electromagnetic process with controlling current and stirring time.

• Journal of Korea Foundry Society
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• v.33 no.5
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• pp.210-214
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• 2013

Recently, the automotive industry has replaced cast iron to lightweight materials like aluminum for engine efficiency of automobiles and an emission control by government. In this paper we studied two auto parts manufacturing methods using an alloy of A356. That is gravity casting and H-NCM Rheo-diecasting forging. We analyzed the microstructure and mechanical properties for this method. In Microstructure analysis results, H-NCM Rheo-diecasting forging has more finer microstrucre and better forging effect. Resulting in better mechanical properties than gravity forging.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.10a
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• pp.371-374
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• 2009

Die casting process has been used widely for complex automotive products such as the knuckle, arm and etc. Generally, a part fabricated by casting has limited strength due to manufacturing defects by origin such as the dendrite structure and segregation. As an attempt to offer a solution to these problems, forging has been used as an alternative process. However, the forging process provides limited formability for complex shape products. Rheo-forging of metal offers not only superior mechanical strength but also requires significantly lower machine loads than solid forming processes. This paper presents the results of an A356 aluminum alloy sample, which were obtained by experiment and by simulation using DEFORM 3D. Samples of metal parts were subsequently fabricated by using hydraulic press machinery.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.135-138
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• 2007

A semi-solid forming processing has been developed for manufacturing near net-shape components. The semi-solid forming has two methods. One is thixo-forming with reheating prepared billet, the other is rheo- forming with cooled melt until semi-solid state. In indirect forging processing, this experiment used aluminum rheology materials by electromagnetic stirring system. Rheology material is made by A16061. An experiment has variation factors which are pressure, solid-fraction, stirring current and stirring time. Forged samples are found microstructures and mechanical properties. Forged samples are accomplished heat treatment T6 for high mechanical properties.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2001.05a
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• pp.124-128
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• 2001

Two-dimensional solidification analysis during rheology forming process of semi-solid aluminum ahoy has been studied Two-phase fluid flow model to investigate the velocity field and temperature distribution is proposed. The unposed mathematical model is applied to the die shape of the two type. To calculate the velocities and temperature fields during rheology forming process, the each governing equation correspondent to the liquid and solid region are adapted. Theoretical model on the basis of the two-phase flow model is the mixture rule of solid and liquid phases. This approach is based on the liquid and solid viscosity.

• Transactions of Materials Processing
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• v.15 no.5 s.86
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• pp.395-401
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• 2006

It is reported that semi-solid forming process takes many advantages over the conventional forming process, such as a long die life, good mechanical properties and energy saves. It is important to predict the deformation behavior for optimization of the forging process with semi-solid materials and to control liquid segregation for mechanical properties of materials. But rheology material has thixotropic, pseudo-plastic and shear-thinning characteristics. So, it is difficult for a numerical simulation of the rheology process to be performed because complicated processes such as the filling to include the state of the free surface and solidification in the phase transformation must be considered. General plastic or fluid dynamic analysis is not suitable for the analysis of the rheology material behavior. Recently, molecular dynamics is used for the behavior analysis of the rheology material and turned out to be suitable among several methods. In this study, molecular dynamics simulation was performed for the control of liquid segregation, forming velocity, and viscosity in compression experiment as a part of study on the analysis of rheology forming process.

• Transactions of Materials Processing
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• v.16 no.6
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• pp.443-446
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• 2007

The semi-solid process has been developed near net-shape components for kinds of methods. Thixo-forming with reheating prepared billet and rheo-forming with cooled melt until semi-solid state. Material is applied electromagnetic stirring system to slurry with aluminum 6061 alloy. An experiment has variation factors which are pressure, solid-fraction, stirring current and stirring time. The mechanical properties are compared to forge sample with to apply heat treatment T6. This study is researched function a virtual pressure and fine shape zone. Optimum pressure is found to prevent defect of porosity.

• Transactions of the Korean Society of Automotive Engineers
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• v.16 no.6
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• pp.58-64
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• 2008

An aluminum radius rod using rheo-forging method has been developed for heavy commercial vehicles to decrease vehicle unsprung weight. To design the shape of the rod, structural simulations are performed using two load cases. To evaluate durability performance of the rods, a test system which has simultaneous 3 axes actuating system is developed. And 3 axes durability test conditions are established based on vehicle field tests. Using the test systems and the conditions, the durability test is carried out and the rods have passed the test conditions of 700,000 cycles. The weight of a developed aluminum radius rod is 4.2kg and it was drastically reduced by 48.8 percent in comparison with the weight of a steel radius rod.