• Journal of Korea Foundry Society
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• v.26 no.3
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• pp.123-128
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• 2006

Mechanical and thermal properties of spray-cast hypereutectic Al-20wt.%Si-xwt.%Fe alloys (x=0, 1, 3, 5) were investigated. After the spray-casting, hot extrusion was performed at $400^{\circ}C$. Intermetallic compound (${\beta}-Al_5FeSi$) and primary Si are observed in the spray-cast aluminum alloys. The size of primary Si and intermetallic compound of the spray-aluminum alloys became finer and more uniformly distributed than that of the permanent mold cast ones. Ultimate tensile strength of the spray-cast aluminum alloys increased by increasing Fe contents, but that of the permanent mold cast aluminum alloys decreased by increasing Fe contents possibly due to increased amount of coarse intermatallic compound. The coefficient of thermal expansion (CTEs) of the aluminum alloys became lower with finer primary Si and intermetallic compound, and this is attributed to the increased amount of interfacial area between the aluminum matrix and the phases of finer Si and intermetallic compound.

• Proceedings of the Korea Committee for Ocean Resources and Engineering Conference
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• 2002.10a
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• pp.312-317
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• 2002

A experimental try was conducted for the purpose of establishment of the cast iron modification by the metal spray method. The friction and wear resistance properties of the metal sprayed cast iron surface were evaluated. The application experiment for the cast iron modification by the metal spray method was conducted in order to develope the restoring method of the scrapped cast iron cylinder liner of the marine engine.

• Journal of Korea Foundry Society
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• v.28 no.4
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• pp.179-183
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• 2008

Mechanical properties of the spray-cast Al 6061 alloy with variation of Mg/Si addition were investigated. After spray-cast, hot extrusion was performed at $460^{\circ}C$ then followed ageing treatment to the T6 condition. SEM, EDX, and XRD were used to characterize a ${\beta}(Mg_{2}Si)$ precipitate. The amount of ${\beta}$ precipitate was calculated from the XRD measurements. Hardness, ultimate tensile strength and elongation were tested then compared with those of the Al 6061 alloys made by ingot metallurgy (I/M) and powder metallurgy (P/M). The ultimate tensile strength and elongation of the spray-cast Al 6061 alloy were 318MPa and 16.5%, respectively. These properties were improved in the 2.2 wt%Mg and 1.3wt%Si addition up to 349MPa of UTS and 12.5% of elongation, mainly due to increased amount of a fine supersaturated ${\beta}(Mg_{2}Si)$ precipitate.

• Journal of Powder Materials
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• v.17 no.6
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• pp.470-476
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• 2010

In this study, Cu-10Sn and Cu-10Sn-2Ni-0.2Si alloys have been manufactured by spray casting in order to achieve a fine scale microstructure and high tensile strength, and investigated in terms of microstructural evolution, aging characteristics and tensile properties. Spray cast alloys had a much lower microhardness than continuous cast billet because of an improved homogenization and an extended Sn solid solubility. Spray cast Cu-Sn-Ni-Si alloy was characterized by an equiaxed grain microstructure with a small-sized (Ni, Si)-rich precipitates. Cold rolling of Cu-Sn-Ni-Si alloy increased a tensile strength to 1220 MPa, but subsequent ageing treatment reduced a ultimate tensile strength to 780 MPa with an elongation of 18%.

• Journal of Korea Foundry Society
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• v.13 no.5
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• pp.476-483
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• 1993

The influence of substrate materials on the degree of basal porosity during spray casting process has been investigated. Different conditions of droplet spreading on the substrate were induced by varying the substrate material. Flat sections of cast iron and aluminum have been spray deposited via spray casting process onto an aluminum substrate, a low carbon steel substrate, and an alumina based refractory substrate. Results for cast iron and aluminum sprayed onto the aluminum substrate showed significant improvements in the surface condition and degree of basal porosity with evidence of substrate deformation that round pits ranging from $5{\mu}m$ to $20{\mu}m$ in diameter are distributed on the surface of aluminum substrate. The lowest level of porosity was developed in alumina based refractory material. Several mechanisms for porosity formation were discussed with droplet impact pressure and droplet spreading. Adopting a spray cutting mechanism for removing the periphery of spray cone, porosity level was remarkably decreased.

• Journal of Korea Foundry Society
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• v.17 no.4
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• pp.365-370
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• 1997

The effects of changes in microstructure of Si phase on the thermal expansion coefficients(CTEs) and tensile properties of the hypereutectic Al-Si foundry alloy(A390) were investigated experimentally. Specimens were prepared by various fabrication processes, such as a permanent mold casting, a squeeze casting and a spray casting process, and subsequently hot-extruded. CTEs of the spray-cast specimen were found to be about 10% lower than those of the permanent mold-cast specimen, and the CTEs of the hypereutectic Al-Si alloy(A390) were changed proportionally with the size of Si phase. Ultimate tensile strength of the spray-cast and hot-extruded specimen was dramatically improved about 100% with improved elongation, compared to that of permanent mold-cast specimen. These improvements are mainly attributed to the reduction in size and aspect ratio of the brittle Si phase, and the elimination of the microvoids/porosities formed during casting.

• Journal of the Korean Society for Heat Treatment
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• v.20 no.6
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• pp.299-305
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• 2007

The effect of spray deposition of oxide particles on oxidation behaviors of as-cast Mo-14.2Si-9.6B (at%) alloys at $1200^{\circ}C$ up to for 100 hrs has been investigated. Various oxide powders are utilized to make coatings by spray deposition, including $SiO_2,\;TiO_2,\;ZrO_2,\;HfO_2$ and $La_2O_3$. It is demonstrated that the oxidation resistance of the cast Mo-Si-B alloy can be significantly improved by coating with those oxide particles. The growth of the oxide layer is reduced for the oxide particle coated Mo-Si-B alloy. Especially, for the alloy with $ZrO_2$ coating, the thickness of oxide layer becomes only one fifth of that of uncoated alloys when exposed to in air for 100 hrs. The reduction of oxide scale growth of the cast Mo-Si-B alloy due to oxide particle coatings are discussed in terms of the change of viscosity of glassy oxide phases that form during oxidation at high temperature.

• Journal of Korea Foundry Society
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• v.17 no.5
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• pp.494-501
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• 1997

In order to manufacture large rod preforms of 2014 Al alloy with a good mechanical property by spray forming method, it was spray-formed at a droplet temperature of $715^{\circ}C$, a droplet flight distance of 400mm, and a spraying angle of $35^{\circ}$. The rod preforms were extruded at $397^{\circ}C$ with the die temperature of $420^{\circ}C$ under the hot extrusion ratio 21:1 and T6 heat treatment was performed. The 2014 Al alloys cast by hot top process were also extruded and heat-treated at the same condition as a reference material. Microstructural observation and tensile test were carried out to investigate the effects of extrusion on microstructure and mechanical property of spray-formed Al alloy. Spray-formed Al alloys had many porosities due to inappropriate process conditions such as long droplet flight distance and low droplet temperature but have fine equiaxed grain. These porosities were reduced with decreasing in grain size by hot extrusion. Ultimate tensile strength and yield strength of spray formed-extruded 2014 Al alloy were inferior to those of the normal cast-extruded 2014 Al alloy, but elongations were superior. The control of porosity was important to get spray formed preform with a good mechanical property.

• Journal of Korea Foundry Society
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• v.14 no.6
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• pp.530-540
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• 1994

Aluminium-silicon alloy(JIS AC8A) matrix composites reinforced with SiC particles were fabricated by spray-cast forming process, and the microstructure of powders and preforms produced were studied by using an optical and scanning electron microscopy. SiC particles were co-sprayed by mixed phase injection method during the spray casting process. Most of the composite powders formed by this mixed phase injection method exhibit morphology of particle-embedded type, and some exhibits the morphology of particle attached type due to additional attachment of the SiC particles on the surface of the powders in flight. The preforms deposited were resulted in dispersed type microstructure. The pre-solidified droplets and the deposited preform of SiC-reinforced aluminium alloy exhibit finer equiaxed grain size than that of unreinforced aluminium alloy. Eutectic silicons of granular type are crystallized at the corner of the aluminum grains in the preforms deposited, and some SiC particles seem to act as nucleation sites for primary/eutectic silicon during solidification. Such primary/eutectic silicons seem to retard grain growth during the continued spray casting process. It is envisaged from the microstructural observations for the deposited preform that the resultant distribution of SiC injected particles in the Al-Si microsturcture is affected by the amount of liquid phase in the top part of the preform and by the solidification rate of the preform deposited.

• Journal of Korea Foundry Society
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• v.34 no.2
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• pp.60-66
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• 2014

A Zr-based amorphous alloy specimen was produced by vacuum die casting process. The salt spray test was carried out using the specimens in the as-cast, $Al_2O_3$ and $ZrO_2$ particle blasted state. Using these specimens, the SEM-EDX and XRD analyses, DSC measurement and bending strength test were conducted. After the salt spray test, the specimens were not experienced phase change and thermal characteristics of the alloys were remained unchanged. In the as-cast specimen, corrosion products were not observed. However, in the $Al_2O_3$ particle blasted specimen, pitting corrosion occurred and the detected corrosion products were $ZrCl_2$ and $NaZrO_3$. Due to the salt spray test, bending strength of the $Al_2O_3$ blasted specimens showed about 100 MPa lower strength than the other specimens. The bending fracture surface was vein pattern which was shown typically in the amorphous alloys.