• Journal of the Korean Society for Precision Engineering
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• v.17 no.8
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• pp.53-59
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• 2000

In this study aluminum casting experiments are carried out to reduce the grain size of a cast preform and to spheriodize its dendritic structure by adding Ti+B and Zr and to modify flaked eutectic silicon by adding Sr, And a finite element simulation is performed to determine an optimal configuration of the cast preform to be used in forging of a compressor piston for an automobile air-conditioner. When 0.15% Ti+B Zr and 0.05% Sr are added respectively into the molten aluminum alloy the finest grain in casting of the preform is obtained. It is confirmed that the optimal configuration of the cast preform predicted by FEM simulation is very useful for forging the compressor piston. After forging the cast preform of the compressor piston. the microstructure and the hardness of the cast preform is compared with those of the cast/forged product.

• Journal of the Korean Society for Precision Engineering
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• v.19 no.1
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• pp.180-185
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• 2002

Aluminum casting/forging process is used to produce an aluminum tie-rod end for the steering system of automobiles. Firstly, casting experiments were carried out to get a good preform for forging the tie-rod end. In the casting experiment, the effects of additives, Ti+B, Zr, Sr, and Mg, on the mechanical properties and the microstructure of a cast preform were investigated. And a finite element analysis was performed to determine an optimal configuration of the cast preform. Lastly, a forging experiment was carried out to make the final product of aluminum tie-rod end by using the above cast preform. In the casting experiments, when 0.2% Ti+B and 0.25% Zr were simultaneously added into molten Al-Si alloy, the highest values of tensile strength and elongation of the cast preform were obtained. When 0.04% Sr were added into the molten aluminum alloy, the finest silicon-structure was observed in the cast preform. The highest hardness was obtained when 0.2% Mg was added. In the forging experiment, It was confirmed that the optimal configuration of a cast preform predicted by FE analysis was very useful. The hardness of a cast/forged product using designed preform was superior to that of required specification.

• Journal of Korea Foundry Society
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• v.36 no.6
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• pp.181-186
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• 2016

The typical microstructure of Al-5%Mg-2%Zn cast alloy mainly consists of an aluminum matrix with a small amount of AlMgZn 2nd phase. The secondary dendrite arm spacing and the grain size of the cast alloy tend to be inversely proportional to the section thickness of casting; however, the tensile properties cannot be said to be clearly related to the cast microstructure. After T6 heat treatment, the tensile strength of the alloy was enhanced significantly. TEM analysis results show that very fine AlMgZn precipitates were formed after the heat treatment. The corrosion resistance, measured according to the corrosion potential, was found to increase slightly after the conducting of heat treatment.

• The Journal of Korean Academy of Prosthodontics
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• v.34 no.3
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• pp.620-631
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• 1996

Bonding of resin to cast alloy has traditionally been provided by mechanical retention. But, chemical bonding methods such as silicoating, tin plating, heat treatment, application of 4-META adhesives, have been developed to overcome the problems of the mechanical bonding methods. Silicoating has been used availaby in fixed prosthodontics, but is also reported to be used in removable prosthodontics. The aim of this study is to measure the tensile bond strength between resin and metal, and compare the effect of the type of metal and the grain size of the aluminum oxide on the bond strength, after metal surface roughening, coating of the opaque resin, and curing of heat-curing resin were performed. The test groups were divided into 4 groups according to the cast alloys and the aluminum oxide particles used. Group 1 : Type 4 gold alloy(DM66) blasted with $$50{\mu}m\;Al_{2}O_3$$ Group 2 : Type 4 gold alloy(DM66) blasted with $$250{\mu}m\;Al_{2}O_3$$, Group 3 : Co-Cr alloy(Nobilium) blasted with $$50{\mu}m\;Al_{2}O_3$$ Group 4 : Co-Cr alloy(Nobilium) blasted with $$250{\mu}m\;Al_{2}O_3$$ * 10 test specimens were made on each group. The specimens were thermocycled, and Instron Universal testing machine was used to measure the tensile bond strength of the finished specimens. The results were as follows : 1. Bond strengths showed that the group of gold alloy blasted with $250{\mu}m$ aluminum oxide particle had higher bond strength, and the group of gold alloy blasted with $50{\mu}m$ aluminum oxide particles had lower bond strength than any of the other groups. 2. Gold alloy had significantly higher bond strength when blasted with $250{\mu}m$ aluminum oxide particles than $50{\mu}m$, but. Co-Cr alloy showed no statistically significant difference between the two particle sizes. 3. When blasted with $50{mu}m$ aluminum oxide particles, Co-Cr alloy showed significantly higher bond strength than gold alloy. And, when blasted with $250{\mu}m$ aluminum oxide particles, gold alloy had significantly higher bond strength than Co-Cr alloy. 4. On the examination of the fractured sites, only the group of Co-Cr alloy blasted with $50{\mu}m$ aluminum oxide particles showed a part of residual opaque resin, but all the samples of the other groups fractured between the resin and the metal.

• Journal of Korea Foundry Society
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• v.41 no.1
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• pp.3-10
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• 2021

In the compound casting between the aluminum alloy and the cast iron, the iron component may be dissolved from the cast iron during the process and mixed into the aluminum melt, thereby forming various iron-containing intermetallic compounds and significantly deteriorating the tensile properties of the aluminum alloy. On the other hand, unlike Fe, which is added as an impurity, Cu is added to improve the mechanical properties of the aluminum alloy. In this study, the change in microstructure and tensile properties of aluminum alloys due to the addition of Fe and Cu was investigated. A large amount of iron-containing compounds such as coarse Al₅FeSi phases were formed when the iron content was 1% or more, and the tensile properties were significantly reduced. In the case of the aluminum alloy to which Cu was added, an Al₂Cu phase was additionally formed and the tensile strength was clearly improved.

• Korean Journal of Materials Research
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• v.31 no.3
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• pp.156-161
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• 2021

Cr-Si based alloys are not only excellent in corrosion resistance at high temperatures, but also have good wear resistance due to the formation of Cr3Si phase, therefore they are promising as metallic coating materials. Aluminum is often added to Cr-Si alloys to improve the oxidation resistance through which stable alumina surface film is formed. On the other hand, due to the addition of aluminum, various Al-containing phases may be formed and may negatively affect the heat resistance of the Cr-Si-Al alloys, so detailed investigation is required. In this study, two Cr-Si-Al alloys (high-Si & high-Al) were prepared in the form of cast ingots through a vacuum arc melting process and the microstructural changes after high temperature heating process were investigated. In the case of the cast high-Si alloy, a considerable amount of Cr3Si phase was formed, and its hardness was significantly higher than that of the cast high-Al alloy. Also, Al-rich phases (with the high Al/Cr ratio) were not found much compared to the high-Al alloy. Meanwhile, it was observed that the amount of the Al-rich phases reduced by the annealing heat treatment for both alloys. In the case of the high temperature heating at 1,400 ℃, no significant microstructural change was observed in the high Si alloy, but a little more coarse and segregated AlCr phases were found in the high Al alloy compared to the cast state.

• Journal of Korea Foundry Society
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• v.39 no.5
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• pp.87-93
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• 2019

The effects of mold materials on the microstructure and tensile properties were investigated to develop a mass production technique of aluminum alloy parts with excellent mechanical properties using a lost foam casting method. The microstructures of the plate-shaped cast alloy showed a tendency to be finer in proportion to the thickness of the plate, and a remarkably fine structure was obtained by applying a steel chill or a ball as a mold material compared to general sand. When a steel ball was used, it was observed that the larger the ball, the finer the cast structure and the better the tensile properties. The microstructure and tensile properties of the cast parts with complex shapes were greatly affected by the gating system, but the positive effects of the steel chill and the steel ball as a mold material were clear.

• Journal of Korea Foundry Society
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• v.16 no.2
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• pp.149-157
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• 1996

Several aluminum based alloys were fabricated by a twin roll strip casting mill. As-cast microstructures and microsegregations of these aluminum alloys were investigated by means of optical microscope, scanning electron microscope and electron probe micro analysis. Clear distinction on microsegregation among the alloy systems was observed, that is, A1235 and A8011 alloys showed diffused segregation in the middle of the strip, while A3003 and A5086 alloys revealed a centerline segregation consisted of lamellar structure. Above center line segregation was resulted from enrichment of the alloying elements such as Mn, Fe, Cu, Si and eutictic reaction in central region of the alloy strip.

• Journal of Korea Foundry Society
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• v.11 no.3
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• pp.208-216
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• 1991

The solidification behavior of the squeeze cast composites of aluminum alloys reinforced with boron fiber($100{\mu}m$) and silicon carbide fibers($140{\mu}m$ and $15{\mu}m$) were investigated. Al-4.5wt%Cu and Al-l0wt%Mg were chosen for the matrix phase of the composites. In the squeeze cast specimen with high thermal difference between fiber and melt, the average secondary dendrite arm spacing(DAS) in reinforced alloy is smaller than that in unreinforced alloy. It was also observed that primary ${\alpha}$ and non-equilibrium eutectic, which seems to be penetrated and solidified at the final stage of the solidification of the matrix, are irregularly distributed around fibers. It is considered that cold fibers serve as heterogeneous nucleation site. While in the remelted and resolidified specimen without temperature difference, the DAS was not changed with reinforcement and microstructure reveals non-equilibrium eutectic with relatively uniform thickness around fibers. It might be evident the nucleation starts at interfiber region. Microsegregation decreases with the decrease in cooling rate and with reinforcement in the as-squeeze cast specimen. Al-10wt% Mg alloy shows less microsegregation than Al-4.5wt%Cu alloy.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.9
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• pp.41-47
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• 1999

The scale of dendritic structure of a cast preform plays a key role in determining the mechanical properties of cast/forged products. In this study, casting experiments are carried out to reduce dendrite arm spacing (DAS) to smaller than 20 ${\mu}$m by increasing cooling rate of the mold and then to spheriodize dendritic structures by addition of alloying elements such as Zr and Ti-B. From the casting experiments, appropriate casting conditions for producing the cast preform of a motorcycle connecting rod are obtained. To obtain fine microstructures of the cast preform, mold temperature must set to be low whilst cooling rate being high. When cooling rate is 10 $^{\circ}C$/s, the size of DAS is 17.4 ${\mu}$m. And the degree of spheriodization of a grain in the cast preform is described by aspect ratio, which is defined as the ratio of major and minor radii of an elliptical grain. When 0.5% Zr and 0.24 % Ti+B are added to the molten aluminum alloy, the best aspect-ratio 0.75 is obtained. After forging the cast preform of a motorcycle connecting rod, the microstructure and mechanical properties of the cast preform are compared with those of the cast/forged product. Cast/forged products are superior in microstructure and in mechanical properties such as ultimate strength, elongation, and hardness.