• Korean Journal of Materials Research
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• v.12 no.12
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• pp.897-903
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• 2002

Morphological evolution and growth mechanism at the solid/liquid interface during solidification were investigated in the Ni-base superalloy GTD111M by directional soldification and quenching(DSQ) technique. The experiments were conducted by changing solidification rate(V) and thermal gradient(G) which are major solidification process variables. High thermal gradient condition could be obtained by increasing the furnace temperature and closely attaching the heating and cooling zones in the Bridgeman type furnace. The dendritic/equiaxed transition was found in the G/V value lower than $0.05$\times$10{^3}^{\circ}C$s/$\textrm{mm}^2$, and the planar interface of the MC-${\gamma}$ eutectic was found under $17 $\times$ 10{^3}^{\circ}C$ s/$\textrm{mm}^2$. It was confirmed that the dendrite spacing depended on the cooling rate(GV), and the primary spacing was affected by the thermal gradient more than solidification rate. The dendrite lengths were decreased as increasing the thermal graditne, and the dendrite tip temperature was close to the liquidus temperature at $50 \mu\textrm{m}$/s.

• Journal of the Korean Ceramic Society
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• v.43 no.7 s.290
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• pp.433-438
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• 2006

In order to examine the working condition of melts in tin bath of float process it was investigated Sn diffusion behavior and solidification rate of melts for alkali-alkaline earth-silica PDP substrate glasses such as commercial CaO rich CS-77 glass, commercial $Al_2O_3$ rich PD-200 glass and self developed $SiO_2$ rich T-series (T-2, T-4, T-6) glasses. In the case of Sn depth and concentration created in glass surface by ion exchange between Sn and alkali, T-series showed lower value than CS-77, especially T-2 is more excellent than PD-200. The solidification rate of melts expressed by cooling time between $log{\eta}=4\;and\;7.6dPa{\cdot}s$ was low for T-series comparing with CS-77 and PD-200. Therefore, it was concluded that T-series is desirable considering forming condition in the tin bath of the float process.

• Korean Chemical Engineering Research
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• v.50 no.1
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• pp.61-65
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• 2012

The onset of convection in a mushy layer is analyzed by using linear stability theory in time-dependent solidification of a binary melt. A simplified model of a near-eutectic mush, in which the mush is assumed to be a porous block, is used and the propagation theory is applied to determine the critical conditions for the onset of convection. The present critical Rayleigh number is higher than the existing experimental result and also theoretical results obtained by considering the mushy layer with an overlying liquid layer. The constant pressure (permeable) condition applied on the mush-liquid interface produces a lower critical Rayleigh number, which is closer to the experimental results of aqueous ammonium chloride solution, compared with the impermeable condition.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.36 no.4
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• pp.71-76
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• 2013

For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_DX2E, Computer Aided Engineering (CAE) simulation was performed with two layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with two models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflow. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• 한국전산유체공학회:학술대회논문집
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• 2009.04a
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• pp.355-362
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• 2009

Most material of engineering interest undergoes solidification process from liquid to solid state. Identifying the underlying mechanism during solidification process is essential to determine the microstructure of material which governs the physical properties of final product. In this paper, we expand our previous two-dimensional numerical technique to three-dimensional simulation for computing dendritic solidification process with fluid convection. We used Level Contour Reconstruction Method to track the moving liquid-solid interface and Sharp Interface Technique to correctly implement phase changing boundary condition. Three-dimensional results showed clear difference compared to two-dimensional simulation on tip growth rate and velocity.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.21 no.1
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• pp.57-67
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• 1997

The solidification process of Al 4.5%Cu alloy is numerically studied in the presence of contact resistance between mold and cast. Natural convection is considered in the liquid and mushy regions. The porosity approach is applied to the mushy zone modeling and linear variation of the solid fraction on the temperature is assumed. Results show that the mushy region is wider in the case with a contact resistance compared to the perfect contact condition. The temperature of the cast with a temporal variation in the contact heat transfer coefficient changes very rapidly in the early stage of the casting process compared to that with constant contact heat transfer coefficient.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.33 no.7
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• pp.469-476
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• 2009

Most material of engineering interest undergoes solidification process from liquid state. Identifying the underlying mechanism during solidification process is essential to determine the microstructure of material thus the physical properties of final product. In this paper, effect of fluid convection on the dendrite solidification morphology is studied using Level Contour Reconstruction Method. Sharp interface technique is used to implement correct boundary condition for moving solid interface. The results showed good agreement with exact boundary integral solution and compared well with other numerical techniques. Effects of Peclet number and undercooling on growth of dendrite tip of both single and multiple seeds have been also investigated.

• Journal of Korea Foundry Society
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• v.19 no.6
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• pp.472-483
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• 1999

The effects of rapid solidification and Cr addition to the microstructure variations of the rapid solidified Ti-48Al-xCr(X = 2,4,6) alloys have been investigated using X-ray diffractometry, optical microscopy, scanning electron microscopy and transmission electron microscopy. The segregated coarse ${\gamma}$ phase was eliminated and the microstructure was refined by rapid solidification of the cooling rate of $10^4-10^6\;^{\circ}C/sec$. The lattice parameters and tetragonality of ${\gamma}$ phase decrease with the increase Cr content and by the rapid solidification. Non-equilibrium phase ${\alpha}$ remains at room temperature condition, which would be resulted from the restriction of phase transformation ${\alpha}$ to ${\alpha}_2+{\gamma}$.

• Journal of Welding and Joining
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• v.17 no.5
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• pp.47-54
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• 1999

It is well known that solidification cracking often occurs in welds of root pass for one-side welding under the conditions of high welding currents and speeds. In this study, the solidification in 590MPa class steel for pressure vessels SPPV490 was investigated by using flux-cored arc welding(FCAW) with 4 types of welding wires and welding conditions of 200∼280A and 2.8∼ 4.2mm/sec. In order to compared the result of cracking in SPPV490, 0.2%C steel for welded structure of SWS400 and 0.45%C steel for machine structural SM45C were also used as base metals. As the results, all the cracks formed in some welding conditions were observed near the center of weld bead. The solidification cracks were generally initiated near the upper surface of bead and propagated toward the inner part. The solidification cracking generally increased with welding current and welding speed in the same base metal and welding material. In cracking susceptibility, SPPV490 showed higher cracking susceptibility than SWS400 in all welding conditions and welding materials. It was considered that cracking susceptibility could not be evaluated with the hardness of weld metals. The cracking ratio increased with decreasing of a/b(a and b; the width of the upper surface and the back surface of the bead) as shape factor of bead. The cracking tendency with shape factor of bead was extended under the condition of higher welding currents.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.20 no.11
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• pp.3655-3665
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• 1996

An analytical solution is presented for the conduction-dominated solidification of a binary mixture in a semi-infinite medium. The present approach differs from that of other solution by these four characteristics. (1) Solid fraction is determined from the phase diagram, (2) thermophysical properties in mushy zone are weighted according to the local solid fraction, (3) non-equilibrium solidification can be simulated and (4) the cooling condition of under-eutectic temperature can be simulated. Up to now, almost all analyses are based on the assumption of constant properties in mushy zone and solid fraction linearly with temperature or length. The validation for these assumptions, however, shows that serious error is found except some special cases. The influence of microscopic model on the macroscopic temperature profile is very small and can be ignored. But the solid fraction and average solid concentration which directly influence the quality of materials are drastically changed by the microscopic models. An approximate solution using the method of weighted residuals is also introduced and shows good agreement with the analytical solution. All calculations are performed for NH$_{4}$Cl-H$_{2}$O and Al-Cu system.