• 한국재료학회지
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• 제12권5호
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• pp.398-406
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• 2002

VAR process is required to control its various operating parameters. Heat transfer simulation has been accomplished to understand development of solidification micro and macro-structures during VAR process in Ti alloys. Optimum VAR process parameters could be also estimated in this study. It was found that macro-structures were closely related to the shape and depth of liquid pool, and solidification parameters, such as temperature gradient, heat flux, solid fraction. The cooling rates were higher at bottom, top, and center part respectively. As cooling rates increased, the $\alpha$ phase decreased in length, width and fraction. In order to evaluate which parameter affects the result of heat transfer calculation most sensitively, the sensitivities of input parameters to the simulation result were examined. The pool depth and cooling rate showed more sensitive to the temperature of the molten metal, heat transfer coefficient, and liquidus respectively. Also, these thermal properties became more sensitive at higher temperatures.

• 한국재료학회지
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• 제22권2호
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• pp.82-85
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• 2012

The effect of the alloy systems Al-Mg alloy and Al-Si alloy in this study on the characteristics of die-casting were investigated using solidification simulation software (MAGMAsoft). Generally, it is well known that the casting characteristics of Al-Mg based alloys, such as the fluidity, feedability and die soldering behaviors, are inferior to those of Al-Si based alloys. However, the simulation results of this study showed that the filling pattern behaviors of both the Al-Mg and Al-Si alloys were found to be very similar, whereas the Al-Mg alloy had higher residual stress and greater distortion as generated due to solidification with a larger amount of volumetric shrinkage compared to the Al-Si alloy. The Al-Mg alloy exhibited very high relative numbers of stress-concentrated regions, especially near the rib areas. Owing to the residual stress and distortion, defects were evident in the Al-Mg alloy in the areas predicted by the simulation. However, there were no visible defects observed in the Al-Si alloy. This suggests that an adequate die temperature and casting process optimization are necessary to control and minimize defects when die casting the Al-Mg alloy. A Tatur test was conducted to observe the shrinkage characteristics of the aluminum alloys. The result showed that hot tearing or hot cracking occurred during the solidification of the Al-Mg alloy due to the large amount of shrinkage.

• 한국재료학회지
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• 제12권12호
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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 Advanced Marine Engineering and Technology
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• 제28권2호
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• pp.361-366
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• 2004

The die casting process was used to manufacture an automotive alternator housing. Generally automobile parts are required to be light and have high strength. The control of casting defects is important but has usually been depended only on the experience of the foundry engineer. Therefore simulations have been carried out on the die casting process of alternator housing. In this paper. we investigated the characteristics of the die casted alternator housing with the HPDC(High Pressure Die Casting) process. We presented the results of filling behavior and solidification process of the cast, The analysis results obtained from the filling behavior and solidification of cast agreed with test results.

• 한국주조공학회지
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• 제40권2호
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• pp.34-42
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• 2020

The effects of the initial balancing pressure, filling pressure and maximum build-up pressure on the casting characteristics of the thick-wall thickness casting during the counter-pressure casting process were investigated. Water model experiment and a computer simulation were carried out to evaluate the characteristics during the filling and solidification stages in counter-pressure casting (CPC); as a reference, the low-pressure casting (LPC) process was used. The average dendrite cell size decreased with an increase in the solidification rate and maximum build-up pressure. A turbulent flow occurred during the filling stage of the LPC process, resulting in the formation of inner gas, while a lamellar flow pattern dominated during the CPC process and was more evident with an increase in the initial balancing pressure, improving the mechanical properties of the castings.

• Journal of Welding and Joining
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• 제18권4호
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• pp.55-63
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• 2000

This paper presents a study of the solder bumping process. The theoretical model, based on the variational principle instead of solving the Navier-Stokes equation with moving boundaries, was developed to considered the energy dissipation in semi-solid phase and the approximate solidification time of the molten metal droplet. The simulation results revealed that the developed model could reasonably describe the collision behavior of molten metal with solid surface. Simulations were made with variation of initial droplet temperature, substrate metal and initial substrate temerature.

• 한국표면공학회지
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• 제33권5호
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• pp.381-386
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• 2000

It was found that colloidal silica sprayed to the galvanized steel sheet apparently made the molten zinc layer solidified to be the randomly oriented fine grains. Its spraying effect was also little affected by steel temperature that had been considered as one of the major operating factors in this process. From the results of surface analysis, it is considered that aluminum dissolved in coating layer reduces silica to silicon by the oxidation-reduction reaction, and that the reduced silicon acts as a more effective nucleus in solidification reaction than phosphate salt, siica and alumina.

• 한국분말재료학회지
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• 제3권4호
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• pp.253-259
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• 1996

The efficiency of thermoelectric devices for different applications is known to depend on the thermoelectric effectiveness of the material which tends to grow with the increase of its chemical homogeneity. Thus an important goal for thermal devices is to obtain chemically homogeneous solid solutions. In this work, the new process with rapid solidification (melt spinning method) followed by hot pressing was investigated to produce homogeneous material. Characteristics of the material were examined with HRD, SEM, EPMA-line scan and bending test. Property variations of the materials were investigated as a function of variables, such as dopant ${CdCl}_{2}$ quantity and hot pressing temperature. Quenched ribbons are very brittle and consist of homogeneous $Bi_2Te_3$, ${Bi}_{2}{Se}_{3}$ solid solutions. When the process parameters were optimized, the maximum figure of merit was 2.038$\times$$10^{-3}K^{-4}. The bending strength of the material hot pressed at 50$0^{\circ}C$ was 8.2 kgf/${mm}^2$.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2000년도 추계학술대회 논문집
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• pp.185-190
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• 2000

Die design by computer simulation has some advantages compared with the conventional method which has performed by designer's experiences and trials and errors. The die filling and solidification process of thixoforming process were simulated by MAGMAsoft/thixo module. First of all, thixoforming die design was applied to previously geometry shape. The value of pressure distribution shows high and uniform as the gate diameter is 18mm. Designed gating system considering the deformation of die and product was suggested by the filling simulation. Gate velocity(7.25m/s) of designed gating system shows that propriety to semi-solid metal working process and CAE results were in good agreement with experimental results.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 1995년도 제2회 단조심포지엄 단조기술의 진보
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• pp.25-34
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• 1995

Large-scale low-alloy steel shafts, used in the manufacture of steam turbine, are produced by ingot making, forging and heat treatemtn processes. The numerical analysis techniques are introduced to analyze and design the working conditions in each process. The solidification of a steel ingot is studied through the finite element method. The open die press forging and quenching process are simulated by viscoplastic and elastic-plastic finite element method, respectively. Thus numerical analysis techniques are very useful tools to study favorable working conditions for better and more desirable product quality.