• Journal of Korea Foundry Society
• /
• v.23 no.5
• /
• pp.276-285
• /
• 2003

In the undercooled melt of $Pd_{40}Cu_{30}Ni_{10}P_{20}$ alloy, the solidification behavior including nucleation and growth of crystals at the micrometer level has been observed in-situ by use of a confocal scanning laser microscope combined with an infrared image furnace. The $Pd_{40}Cu_{30}Ni_{10}P_{20}$ alloy specimens were cooled from the liquid state to glass transition temperature. 575 K, at various cooling late under a helium gas flow. According to the cooling rate, the morphologies of the solidification front are changed among various types, irregular jog like front, columnar dendritic front, cellular grain, star like shape jog and fine grain, etc. The velocities of the solid-liquid interface are measured to be $10^{-5}{\sim}10^{-8}$ m/s which are at least two orders higher than the theoretical crystal growth rates. Combining the morphologies observed in terms of cooling rates and their solidification behaviors, we conclude that phase separation takes place in the undercooled molten $Pd_{40}Cu_{30}Ni_{10}P_{20}$ alloy. The continuous cooling transformation (CCT) diagram was constructed from solidification onset time at various linear cooling conditions with different rate. The CCT diagram suggests that the critical cooling rate for glassy solidification is about 1.5 K/s, which is in agreement with the previous calorimetric findings.

• Journal of the Korean Ceramic Society
• /
• v.39 no.12
• /
• pp.1133-1137
• /
• 2002

The cement for solidification of the toxic waste was fabricated using a mixture of the waste concrete powder and blast furnace slag in the ratio of 1:1 and its hydrate morphology and compressive strength of the sample were evaluated in order to apply to the solidification of the COREX sludge. The X-ray diffraction analysis of the sample which prepared by the addition of 10% Portland cement and hemihydrate showed the presence of $Ca(OH)_2$, ettringite, gel-phase and C-S-H hydrate. Compressive strength of the sample exhibited enough high to use as a solidification cement. The strength of the sample was over 140 kgf/$m^2$ in 7 days in case of solidification of the COREX sludge and the sample possess sufficient morphology for the solidification and stabilization of the waste sludge.

• Journal of Korea Foundry Society
• /
• v.17 no.6
• /
• pp.608-614
• /
• 1997

The effect of mold preheating temperature on the microstructure such as grain size, eutectic silicon morphology was investigated for the Al-7wt%Si-0.3wt%Mg alloy. Microstructural variations have been characterized as a function of Sr addition and cooling rate during solidification. Microstructures were correlated with cooling rate, local solidification time and eutectic nucleation temperature, etc. In this study, Sr addition caused increase of local solidification time, undercooling and reduction of eutectic plateau temperature. In logarithmic scale, local solidification time was in inverse proportion to cooling rate. Eutectic nucleation temperature was in inverse proportion to cooling rate of logarithmic scale. Increasing the cooling rate refined dendrite arm spacing and eutectic silicon. Dendrite arm spacing was logarithmically in inverse proportion to cooling rate. Without modifier addition, eutectic silicon was modified at cooling rate of $7^{\circ}C/s$ or higher.

• Journal of Korea Foundry Society
• /
• v.11 no.1
• /
• pp.54-62
• /
• 1991

A computer program which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of steel castings. The pre-processor is used for mesh generation in a small personal computing system. The modified finite difference method is adopted for the main solidification simulation algorithm. The post -processor graphically presents the simulation results and shows the formation of shrinkage defects. Several experiments on large steel castings in sand mold were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. Several numerical examples for the prediction of shrinkage cavity in large steel casting of SC42 and SCNCrM2 alloys are compared with experimental results. The effect of sleeve and chills on solidification patterns are also studied. Formation of shrinkage defects for the three cases of experimental castings are relatively well predicted by present model.

• Journal of Korean Society of Water and Wastewater
• /
• v.9 no.3
• /
• pp.108-115
• /
• 1995

The feasibility study of using converter slag as a solidifying agent of digested sewage sludge cake has been performed. The availability of converter slag as solidifying agent has been investigated by several trial tests. Based on the trial test results, the optimum mixing ratios of sludge cake and solidification additive are estabilished. Finally the solidification characters of sludge cake are elucidated by SEM and EDS. It is ascertained that converter slag with a small amount of quicklime enhences the solidification. From the result of pH test, overall pH of specimens tends to decrease slowly with curing time. After solidifying specimens had been cured for 7 days, these are water-cured for 24 hours. The weight and strength of all the specimens are nearly the same regardless of the mixed ratios of solidifying agent. The result of leaching tests for four heavy metal ions, Cd, $Cr^{6+}$, Pb and Cu show that the leaching strength becomes below the decision criteria of the specific wastes, respectively. The SEM observation of the delicate structure shows that needlelike crystals appear after solidification which are not observed before. From the EDS analysis, it is found that the main ingredients of needlelike crystals are Ca, Si, Al and O.

• Korean Chemical Engineering Research
• /
• v.52 no.2
• /
• pp.199-204
• /
• 2014

In binary solidification compositional convection in a porous mushy layer influences the quality of the final products. We consider the mushy layer solidifying from below with a constant solidification velocity. The disturbance equations for the mushy layer are derived using linear stability theory. The basic-state temperature fields and the distribution of the porosity in the mushy layer are investigated numerically. When the superheat is large, the thickness of the mushy layer is relatively small compared to the thickness of the thermal boundary layer. With decreasing the superheat the critical Rayleigh number based on the thickness of the mushy layer increases and the mushy layer becomes stable to the compositional convection. The critical Rayleigh number obtained from the continuity conditions of temperature and heat flux at the mush-liquid interface is smaller than that from the isothermal condition at the upper boundary of the mushy layer.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.18 no.7
• /
• pp.1818-1832
• /
• 1994

Transport process during solidification of an AI-CU alloy in a vertical annular mold of which inner wall is cooled is numerically simulated. A model which can take account of local density dependence on the solute concentration is established and incorperated in the analysis. Results show that thermally and solutally induced convections are developed in sequence, so that there is little interaction between them. Thermal convection effectively removes the initial superheat from the melt and vanishes as solidification proceeds from the cooling wall. On the other hand, solutal convection which is developed later over the meshy and the pure liquid regions leads to large-scale redistribution of the consituents. The degree of the initial superheating hardly affects overall solidification behavior except the early stage of the process, when the cooling rate is kept constant. Macrosegregation is reduced remarkably with increasing cooling rate, because not only the liquidus interface advances so quickly that time available for the solute transport is not enough, but also the interdendritic flow is strongly damped by rapid crystal growth within the mushy region.

• Journal of Korea Foundry Society
• /
• v.18 no.3
• /
• pp.283-288
• /
• 1998

Interest in rapid solidification of magnesium alloys stems from the fact that conventional ingot metallurgy alloys exhibit poor strength, ductility, and corrosion resistance. Such properties can be improved by microstructural refinement via rapid solidification processing. In this study, Mg-Zn alloys have been produced as continuous strips by melt overflow technique. In order to evaluate the influence of additional elements on the grain refinement and mechanical properties, Th and Zr were added in rapidly solidified Mg-5wt%Zn alloy. Then the microstructual observations were undertaken with the objective of evaluating the grain refinement as function of the cooling rate and the additional elements. The tremendous increase in hardness of Mg-Zn base alloys was mainly due to the refinement of the grain structure by the effect of rapid solidification and alloying elements. The formation of intermetallic phases on the grain boundaries may have a positive effect on the corroion resistance. Therefore, despite competition from many other developments, the rapid solidification processing of magnesium alloys emerges as a valuable method to develop superior and commercially acceptable magnesium alloys.

• Journal of Korea Foundry Society
• /
• v.13 no.3
• /
• pp.268-275
• /
• 1993

In gravity die casting, die cooling systems are frequently employed with water cooling to remove the heat of the solidifying metal. Thermal modeling is an important technique in mold design for improving the productivity of the process. Computer simulation system which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of cyclic gravity die casting. The pre-processor is used for mesh generation in a PC system. The modified finite difference method is adopted for the main solidification simulation algorithm during all the casting cycles. The post-processor graphically presents the simulation results. Several experiments in automotive cast piston were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. The effects of cycle number on solidification pattern are also studied. Several experimental results for the prediction of shrinkage defects are compared with calculated results.

• Journal of Power System Engineering
• /
• v.19 no.3
• /
• pp.69-74
• /
• 2015

Check valves used in vessels include shock-release function on piping system, aside from basic back flow prevention. However, proper and enough protection of system is not obtainable due to use of high-pressure and bulk fluids, resulting from enlargement of vessels. In this study, casting analysis of check valves protecting systems in flow path from water hammering or back flow is conducted, using Z-CAST program. Also, molten metal filling, flow analysis, solidification analysis and shrinkage cavity analysis are conducted. The main results are as following. Regarding filling of each risering, molten metal showed stable supply condition without being isolated. It was identified that the final solidification exists on risering, but shrinkage cavity possibly might happens at the point of isolation solidification.