• Korean Journal of Materials Research
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• v.22 no.2
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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.

• Journal of the Korean Society for Precision Engineering
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• v.13 no.3
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• pp.110-122
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• 1996

Finite element analysis tool was developed to analyze the casting process. Generally, casting process consists of mold filling and solidification. Both filling and solidication process were simulated simultaneously to investigate the effects of process variables and to predict the defect. At filling process, thermal coupling was especially considered to investigate thermal history of material during the filling stage. And thermal condition at the final stage of filling is used as the initial conditions in a solidification process for the exact simullation of the actual casting processes. At mold filling process, Lagragian-type finite element method with automatic remeshing scheme was used to find the material flow. A perturbation method with artificial viscosity is adopted to avoid numerical instability in low viscous fluid. At solidification process, enthalpy-based finite element method was used to solove the heat transfer problem with phase change. And elastic stress analysis has been performed to predict the thermal residual stress. Through the FE analysis, solidification time, position of solidus line, liquidus line and thermal residual stress are found. Through the study, the importance of combined analysis has been emphasized. Finite element tools developed in this study will be used process design of casting process and may be basic structure for total CAE system of castings which will be constructed afterward.

• Journal of the Korean Ceramic Society
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• v.36 no.1
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• pp.61-68
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• 1999

To analyze several defects and residual stress in sintering of layer structure materials, multiayer materials with TZP/SUS and ZT/SUS, and bilayer materials with porcelain/alumina and porcelain/Y-TZP were fabricated by sintering method. Multilayer materials prepared by pressureless sintering show the sintering defect such as warping, splitting, cracking originated from the difference of sintering shrinkage between each layer, which could be controlled by the adjustment of number and thickness in interlayer. In tape casting, a certain pressure given during sintering relaxed the sintering defects, specially warping. The residual stress in bilayer was examined with Vickers indentation method. A small tensile stress in porcelain/alumina and a large compressive stress in porcelain/Y-TZP were generated on the porcelain interface due to the thermal expansion mismatch, which affected the strength of bilayer materials. As a consequence, the sintering defects of multilayer materials and the residual stresses of bilayer materials were dominantly influenced on material design and starting material constants.

• Journal of the Korean Society for Heat Treatment
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• v.10 no.3
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• pp.159-164
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• 1997

Non-alloyed and 1.0%Ni alloyed ductile cast iron were cast into the sand mold and metal mold, and finer graphite size was obtained in case of metal mold casting. Direct tempering after casting showed the slight increase of absorbed energy, which is largely due to the relieving of residual stress that is developed during casting. After austempering heat treatment, higher impact energy was obtained in case of metal mold casting than sand mold casting, which is due to the finer graphite size.

• Transactions of the Korean Society of Pressure Vessels and Piping
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• v.11 no.1
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• pp.69-73
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• 2015

The study investigated effects of residual stresses and Charpy impact energy on brittle fractures of the butt weld between the valve and the piping, and of the valve body in nuclear power plants via a linear elastic fracture mechanics approach in the ASME B&PV Code, Sec.XI and finite element analysis. Weld residual stress in a butt weld between close check valve and piping, and residual stress in the valve due to casting process were assumed to be proportional to yield strength of base metal. Operating stresses in the butt weld and the valve body were calculated using approximate engineering formulae and finite element analysis, respectively. Applied stress intensity factors were calculated by assuming postulated cracks with specific sizes and then by substituting the residual stresses and the operating stresses into engineering formulae presented in the ASME B&PV Code, Sec.III. Plane strain fracture toughness was derived by using a correlation between Charpy V-notch impact energy and fracture toughness. Structural integrity of the weld and the body against brittle fracture was assessed by using the applied stress intensity factors, plane strain fracture toughness and the linear elastic fracture mechanics approach. As a result, it was identified that the structural integrity was maintained with decreasing the residual stress levels and increasing the Charpy V-notch impact energy.

• Proceedings of the Korean Society of Tribologists and Lubrication Engineers Conference
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• 1997.10a
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• pp.183-190
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• 1997

The wear behaviors of $Al_2O_3-40%TiO_2$ deposited on casting aluminum alloy(ASTM A356) by plasma spray against SiC ball have been investigated experimentally. Friction and wear tests are carried out at room temperature. The friction coefficient of $Al_2O_3-40%TiO_2$ coating is lower than that of pure $Al_2O_3$ coating(APS). It is found that low friction correspond to low wear and high friction to high wear in the experimental result. The thickness of $Al_2O_3-40%TiO_2$ coatings indicated the existence of the optimal coating thickness. It is found that a voids and porosities of coating surface result in the crack generated. As the tensile stresses in coating increased with the increased friction coefficient. The columnar grain of coating will be fractured to achieve the critical stress. It is found that the cohesive of splats and the porosity of surface play a role in wear characteristics. It is suggested that the mismatch of thermal expansion of substrate and coating play an important role in wear performance. Tensile and compressire under thermo-mechanical stress may be occurred by the mismatch between thermal expansion of substrate and coating. This crack propagation above interface is observed in SEM.

• The Journal of Korean Academy of Prosthodontics
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• v.35 no.4
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• pp.706-718
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• 1997

Ceramometal crowns are common restorations in fixed prosthodontics because of their casting accuracy, the high strength properties of the metal, and the cosmetic appearance of porcelain. However, deterioration of the initial fit of the metal coping has been observed after the porcelain firing cycle. The distortion due to repeated firing makes it difficult to fit crown margin and elicits microleakage. The major causes of distortion are the residual stress that accumulate during wax-up, casting, cold work and the induced stress caused by the mismatch of porcelain-metal thermal contraction. This study examined the marginal fit changes of metal copings in relation to repeated firing and the effects of heat treatment that reduce the distortion resulted from residual stress. The marginal changes of the copings that were treated with conventional method and those treated with heat before repeated firing, were evaluated. The metal die which represented preparations of a maxillary central incisor was fabricated, and 45 wax patterns were cast with nonprecious metal alloys. The heat treatment of each group was performed as follows. Group 1(control) : Casting - Devesting - Cold work - Firing Group 2 : Casting - Heat treatment - Devesting - Cold work - Firing Group 3 : Casting - Devesting - Cold work - Reinvesting - Heat treatment - Devesting - Firing The copings were fired 3 times. After each firing, the marginal fit changes were measured with inverted metallurgical microscope at the 4 reference points located at labial, lingual, and both proximal surface. Measurements were compared, and statistically analyzed. The results were as follows ; 1. In all groups, the highest value of marginal fit changes of the copings studied were found after the first firing cycle. 2. When the distortion of each experimental group at the first firing cycle were compared, group 1 exhibited the greatest changes($20-27{\mu}m$), followed by group 2($9-13{\mu}m$), and group 3($8-10{\mu}m$). 3. The copings treated with heat before devesting(group 2) revealed significantly smaller marginal fit changes than the copings treated with conventional method(group 1). (p<0.01) 4. The copings treated with heat after reinvesting(group 3) revealed significantly smaller marginal fit changes than the copings treated with conventional method(group 1). (p<0.01) 5. No siginificant differences in marginal fit changes were found between the copings treated with heat before devesting(group 2) and the copings treated with heat after reinvesting(group 3). (p>0.01)

• The Journal of Korean Academy of Prosthodontics
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• v.27 no.2
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• pp.53-78
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• 1989

This study was taken to observe the changes of the residual stress in the alloy and to measure 3 dimensional distortions of the long span ceramo-metal bridge. The materials used in this study were Pors-on 4 (Pd-Ag alloy), and Ceramco and Vita VMK 68 powders. The residual stress of the alloy was measured on the six specimens (dia. 8m/m) by the X-ray diffraction stress analyzer according to the kind of ceramic powder and different measuring stages. And, for the measurement of the distortions, fifteen specimens of the anterior 8-unit ceramo-metal brige were fabricated and subjected to the 3-D coordinate measuring machine. Variables included the 2 kinds of a ceramic powder and the presence or absence of a splint bar at the cast metal framework. The measuring stages in both were after casting, after degassing and after glazing. The following conclusions were obtained : 1. The residual stress of the alloy showed increasing tendency for the tension by the ceramic fusing, but there was not significance. 2. The tendency of the distortions in the cast metal frameworks were decrease of the width, the anterior displacement and sagging. 3. The amount of the distortions at the degassing stage were greater than that at the ceramic fusing stage. 4. The splint bar was effective to control the distortion only at ceramic fusing stage. 5. The sagging distortion in the Ceramco firing were even through all measuring stages, but in the Vita firing, pronounced at degassing stage.

• Journal of Korea Foundry Society
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• v.38 no.1
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• pp.9-15
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• 2018

Electromagnetic continuous casting (EMCC) was used to fabricate Ti-6Al-4V alloys with properties suitable for medical applications. Ti-6Al-4V alloy ingots fabricated by EMCC were subjected to heat treatment, such as residual stress removing (RRS), furnace cooling after solution treatment (ST-FC) and water-cooling after solution treatment (ST-WC), in order to obtain characteristics suitable for the standard. After component analysis, the microstructure and mechanical properties (tensile strength and elongation) were evaluated by ICP, gas analysis, OM, SEM, a Rockwell hardness tester and universal testing machine. The Ti-6Al-4V alloy ingot fabricated by EMCC was fabricated without segregation, and the lamellar structure was observed in the RRS and ST-FC specimens. The ST-WC specimen showed only martensite structure. As a result of evaluating the mechanical properties based on the microstructure results, we found that the water-cooled heat treatment condition after the solution treatment was most suitable for the Ti-6Al-4V ELI standard.

• Korean Journal of Materials Research
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• v.8 no.11
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• pp.993-998
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• 1998

In this study TiNi/A16061 shape memory composite is introduced as one of new material using a shape memory alloy. High tensile strength of composite due to compressive residual stress in matrix by the shape memory effect of TiNi fiber can be produced. This composite can remove the tensile residual stress by the difference of coefficients of thermal expansion between fiber and matrix. one of the significant weak point of metal matrix composite. In this paper, shape memory composites are made by squeeze casting. And then, microstructure and fatigue properties of the composites by shape memory effect above inverse transformation temperature A, of TiNi alloy are discussed. The results of the fatigue crack control properties of TiNi/A16061 shape memory composite by a squeeze casting are summarized as follows the effect of fatigue crack propagation control at 363K increases according to the increase of volume fraction and prestrain in composites.