• Journal of Technologic Dentistry
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• v.5 no.1
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• pp.13-17
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• 1983

The experimental investication wax performed to study fitness of casting crowns with various investment widely used in Korea. 36 wax patterns were invested and casted according to the regular casting method. The result were as follow : 1. Casting with cristobalite investments of Shofu were seen apart, 0.04mm the tightest space in the linguo and bucco-cervical margin. And the largest deviation, 0.1mm was shown in the central groove 0.1mm was shown in the central groove area of occlusal surface(Jensen Metal) 2. Casting with cristobalite investments of kerr were seen apart, 0.04mm the tightest space in the linguo and bucco-cervical margin And the largest deviation, 0.09 was shown in the central groove area of occlusal surface(Jensen Metal) 3. Casting with Quartz investments of G-C were seen apart, 0.04mm the tightest space in the linguo-cervical margin, And the largest deviation, 0.1mm was shown in the central groove area of occlusal surface(Jensen Metal) 4. Casting with cristobalite investments of shofu were seen apart, 0.01mm the tightest space in the linguo-cervical margin, And the largest deviation, 0.03mm was shown in the central groove of occusal surface(Bo-sung A type gold alloy) 5. Casting with cristobalite investments of kerr showed the best fintness in linguo-cervical margin. And the largest deviation, 0.02mm was shown in the central groove area of occlusal surface(Bosung A type gold alloy) 6. Casting with Quartz investments of G-C were Seen apart, 0.02mm the tightest space in the linguo-cervical margin, And the largest deviation, 0.04mm was shown in the central groove area of occlusal surface(Bo-sung A type gold alloy) 7. Casting with cristobalite investments of shofu were seen apart, 0.01mm the tightest space in the linguo-cervical margin. And the largest deviation, 0.08mm was shown in the buccal cusp area of occlusal surface(Bo-sung B type gold alloy) 8. Casting with cristobalite investments of kerr shown the best fitness in linguo-cervical margin. And the largest deviation, 0.04mm was shown in the central groove atea of occlusal surface(Bosung B type gold alloy) 9. Casting with Quartz investments of G-C were seen apart, 0.03mm the tightest space in the linguo-cervical margin. And the largest deviation, 0.04mm was shown in the central groove area of occlusal surface(Bo-sung B type gold alloy) 10. Casting with cristobalite investments of kerr shown the best fitness and Bo-sung A type gold alloy showed the best fitness.

• Journal of Korea Foundry Society
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• v.20 no.5
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• pp.330-335
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• 2000

Functional metal prototypes are often required in numerous industrial applications. These components are typically needed in the early stage of a project to determine form, fit and function. Recent R/P(Rapid Prototyping) part are made of soft materials such as plastics, wax, paper, these master models cannot be employed durable test in real harsh working environment. Parts by direct metal rapid tooling method, such as laser sintering, by now are hard to get net shape, pores of the green parts of powder casting method must be infiltrated to get proper strength as tool, and new type of 3D direct tooling system combining fabrication welding arc and cutting process is reported. But a system which can build directly 3D parts of high performance functional material as metal park would get long period of system development, massive investment and other serious obstacles, such as patent. In this paper, through the rapid tooling process as silicon rubber molding using R/P master model, and fabricate wax pattern in that silicon rubber mold using vacuum casting method, then we translated the wax patterns to numerous metal tool prototypes by new investment casting process combined conventional investment casting with rapid prototyping & rapid tooling process. With this wax-injection-mold-free investment casting, we developed new investment casting process of fabricating numerous functional metal prototypes from one master model, combined 3-D CAD, R/P and conventional investment casting and tried to expect net shape measuring total dimension shrinkage from R/P pare to metal part.

• Journal of Korea Foundry Society
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• v.25 no.4
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• pp.156-160
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• 2005

There are many factors that influence solidification behavior during continuous casting, e.g. include superheat, casting speed, cooling rate and holding time. However, when melt is stirred by electromagnetic force, there would be some changes in its solidification behavior compared to that of the ordinary casting process. In this study, the billets of A356 alloy with a diameter of 3 inch were fabricated with electromagnetic stirring under various conditions of superheat, casting speed and input voltage of electro magnetic stirring (EMS) device. The microstructure was also investigated under the various casting conditions and electromagnetic input voltages. When increase in input voltage, the microstructure was changed from dendritic to rosette type and finally to spheroidal. With pouring temperature, casting speed and electromagnetic input voltage were $650^{\circ}C$, 100 mm/min and 140 V, respectively, the billet with a diameter of 3 inch, which has a uniform dispersed spheroidal particles in the whole area of billet except for the surface area, was manufactured.

• Journal of Korea Foundry Society
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• v.22 no.4
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• pp.192-199
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• 2002

Dimensional defects of castings are mainly due to the stresses and strains caused by a nonuniform temperature distribution and phase transformation during solidification and cooling, and by mechanical constraint between the mold and casting. It is, however, nearly impossible to trace movements of the casting and mold during solidification and cooling by experimental measurements for castings with complex shape. Two and three dimensional deformation analyses of the casting and the mold were performed using commercial finite element code, MARC. It was possible to calculate deformation and temperature distribution in the casting and mold simultaneously. Cooling curves of the casting obtained by calculation were close to that measured in the field since it was possible to treat latent heat evolution of the casting which could be divided into two parts, primary and eutectic parts. Mold bent inward just after pouring due to the temperature gradient across the mold thickness, and mold returned to its previous position with time. Plastic deformation occurred at the part of the casting where solidification was slow.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.23 no.11 s.170
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• pp.2087-2095
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• 1999

One of the main causes of unwanted dimensional changes in precision metal mold casting parts is excessive and irregular residual stresses induced by temperature gradients and plastic deformation in the solidifying shell. Residual stresses can also cause stress cracking, and lower the fatigue life and fracture strength of the casting parts. In the present study, aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling units was designed and the casting specimens were produced to quantify the effects of different cooling conditions on the development of residual stresses. The layer removal method was used to measure the biaxial residual stresses in casting specimens produced from the experiments. The experimental results agreed with Tien-Richmond's theoretical model for thermal stress development for the solidifying metal plate.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.20 no.5
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• pp.541-546
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• 2011

This study was numerically investigated on thermal deformation of AC4C and AC7A aluminum alloy casting material for manufacturing the automobile tire mold. The metal casting device was used in order to manufacture the mold product of automobile tire at the actual industrial field. The temperature distribution and the cooling time of these materials were numerically calculated by finite element analysis. Thermal deformation with stress distribution was also calculated form the temperature distribution results. The thermal deformation was closely related to the temperature difference between the surface and inside of the casting. As shown by numerical analysis result, the thermal deformation of AC7A casting material became higher than AC4C casting material. In addition, the results of displacement and stress distributions appeared to be larger at the center parts of casting than on its sides because of the shrinkage caused by the cooling speed difference.

• Journal of Technologic Dentistry
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• v.21 no.1
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• pp.87-96
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• 1999

In order to examine the influence of sprue(used to make crown supplements) on casting, 3 kinds of sprue materials(wax, wood, plastic) and 3 types of sprue(round, square, triangle) were made and buried and cast, then the comparison and analysis of casting characters among sprue materials and among sprue type show the following results : 1. The comparison of casting characters in accordance with sprue materials shows wax sprue of 83.3%, wood sprue 81.3%, and plastic sprue of 80.7%, Wax sprue was the bast materials for casting, However there was no statistically significant difference of casting characters among was, plastic and wood. 2. The comparison of casting in accordance with sprue types shows square sprue of 94.0%, round sprue of 86.9% and triangle sprue of 84.2%. square sprue had a best casting character. 3. When a ring cast using wood sprue was classified from burying materials. its cutting of casting body and sprue indicated much more than any other sprue material. It seems to be caused by the influence of wood residuals and carbon occurrence.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.10a
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• pp.279-284
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• 2005

The casting defects that are caused by molten metal were cold shut formation, entrapment of air, gas, and inclusion. But the control of casting defects has been based on the experience of the foundry engineers. In this thesis, the computer simulation analyzed the flow of molten metal. The quantitative analyses which proposed the effective mold design was executed Flow patterns of 0.15-0.16m/s molten metal in 15 mm thin plate casting were investigated in order to optimize die-casting process. As increasing ingate velocity in thin plate casting, cold shot was decreased. The parameters of runner shape that affected on the optimized conditions that was calculated with simple equation were investigated. These die casting process control techniques of automobile valve body mid-plate have achieved good agreement with the experimental data of tensile strength, hardness test, and material structure photographies satisfactory results.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.11 s.176
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• pp.45-50
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• 2005

In this study, the casting/forging process was applied in manufacturing a low control arm, in order to prove that application of casting/forging process to Al6061 is likely to get the effect of light weight compared with existing steel products and to reduce the cost of materials. Firstly, In order to set up the optimum casting condition of the forging material, Al6061, casting experiments were carried out by controlling pouring temperature of the aluminum for casting, mold temperature, and pouring time. $700^{\circ}C$ pouring temperature, $300^{\circ}C$ mold temperature and 10-second pouring time were taken into account as the optimum casting conditions. With respect to a hot forging test, it is practiced on the basis of a temperature of materials, strain rate, and reduction rate so as to observe each microstructure and examine strain-stress curve simultaneously; examine tensile test and hardness test; eventually set up the optimum hot forging condition. A hot forging test, tensile test, hardness experiment, and microstructure observation were carried out on condition of $70\%$ reduction rate, $500^{\circ}C$ temperature of materials, and 1 strain rate. As a result of those experiments, 330MPa tensile strength, $16.4\%$ elongation, and 122.8Hv hardness were recorded. In oder to get a sound preform which has no unfitting cavity and less flash, two preforms were proposed on the basis of volume rate of the final product; the optimum volume rate of preform for the low control arm was $115\%$. In conclusion, it is confirmed that using the forging material rather than casting materials in casting/forging process is likely to get more superior mechanical properties. Compared with Al6061, performed by means of general forging, moreover, cast/forged Al6061 can not only stimulate productivity by reducing production processes, but cut down the cost of materials by reusing forging scraps.

• Journal of Technologic Dentistry
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• v.25 no.1
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• pp.9-20
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• 2003

Using a nickel-chrome casting alloy called 'Rexillium V' which is also available as base metal alloy for dental ceramic crown, 4 types of mixtures(A, B, C, D) with old and new metal were prepared for cyclic casting. The results of cyclic casting can be outlined as follows: 1. For Vickers hardness after casting, specimen A and D tended to have lower hardness in the course of cyclic casting, while specimen B and C tended to higher hardness. 2. The results of X-ray diffraction analysis showed that major crystal phase contained nickelchrome compounds and carbide. 3. The observation results of SEM photographs after cyclic casting show that there was a significant tendency to have similar structures among experimental groups. 4. The results of EDX analysis after cyclic casting showed that there were little differences in chemical composition between parent metal and base metal alloy. Although industrial nickel-chrome cast alloy did not show any significant change in material properties even through cyclic casting over several times, it is recommended that more there be more in-depth studies on how to detect any potential corrosion, discoloration and toxication of dental ceramic crown implanted in patient's oral cavity.