• Journal of Korea Foundry Society
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• v.22 no.3
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• pp.137-143
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• 2002

Silica sand, zircon sand, and steel shots were used as mold packing materials in lost foam casting of the aluminum alloy bar. Vibration acceleration in three directions and temperatures in the casting and mold were measured, and packing and cooling characteristics of these materials were investigated. Packing densities increased with increase in vibration magnitude and time, and were $1.41{\sim}1.49g/cm^2$ for silica sand, $2.54{\sim}2.86g/cm^2$ for zircon sand, and $3.92{\sim}4.52g/cm^2$ for steel shots. Sound castings were obtained only without evacuation of the flask during pouring. Solidification time became faster in order of silica sand, zircon sand and steel shot packing because steel shot has the highest cooling capacity of them. Solidification time of steel shot packing was shortened to about 1/2 of silica sand packing. Cooling capacity of sand mold was generally evaluated by heat diffusivity of the mold, however could be simply evaluated with specific heat per unit volume of the packing material in lost foam casting.

• Transactions of Materials Processing
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• v.3 no.1
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• pp.63-83
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• 1994

In this paper, the slab method have been applied to investigate the strip casting process in which hot coil is produced from molten steel directly. In the twin roll strip casting process, molten steel supplied by the nozzle cools and solidifies due to the heat extraction effect of the rolls and hot rolling of the solidified shell takes place simultaneously. The analysis of hot rolling has been carried out by using the existing results of solidification analysis for the twin roll strip casting process. The current slab method provides basic design data such as roll separation force, rolling torque, rolling power as well as end dam separation force which are required to design strip caster. The effect of friction on the basic process parameters are investigated also. It is shown that the use of appropriate friction coefficient is important and that the characteristics of hot rolling in the twin-roll strip casting process is quite different from the conventional hot rolling processes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.04a
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• pp.111-114
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• 2009

Production of rolled steel has been growing partly supported by the advancement of rolls and rolling mills. Aiming at the further improvement in roll performance, various new techniques such as centrifugal casting, double poured casting cast steel, special build-up making, etc. have been introduced in the field of roll manufacture in these several years. The present paper describes the development of horizontal cast rolls(sleeve and indefinite chilled roll) made by Hyundai Steel and the results of mill tests. The developed roils are contributing the improvement of final products.

• Journal of Korea Foundry Society
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• v.25 no.6
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• pp.259-264
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• 2005

The copper clad steel wire is used extensively as lead wires of electronic components such as capacitors, diodes and glass sealing lamp because the wire combines the strength and low thermal expansion characteristic of Fe-Ni steel with the conductivity and corrosion resistance of copper. In order to fabricate the copper clad steel wire, several processes including electro-plating, tubecladding extrusion process and dip forming process have been introduced and applied. The electroplating process for the production of copper clad steel wire shows poor productivity and induces environmental load generation such as electroplating solution. The dip forming process is suitable to mass production of copper clad steel such as trolley wire. and need expensive manufacturing facilities. The present paper describes the improvement of the conventional continuous casting process to fabricate copper clad steel wire, which its core metal is low thermal expansion Fe-Ni alloy and its sheath material is copper. In particular, the formation of intermetallic compound at interface between core and sheath was investigated in order to introduce optimum continuous casting process parameter for fabrication of copper clad steel wire with higher electrical conductivity. The mechanical strength of copper clad steel wire was also investigated through wiredrawing process with of 95% in total reduction ratio.

• Journal of Korea Foundry Society
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• v.23 no.2
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• pp.86-93
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• 2003

It has been a major concern in the foundry that steel castings manufactured by the evaporative pattern casting process encounter the carbon pick-up problem. A carbon rich layer at the evaporative pattern cast surface is a result of interactions between the gaseous products from foamed polystyrene and the molten metal. The carburized layer with a high hardness makes it difficult to machine the casting. In this study, the influence of the density of EPS pattern and coatings on carbon pick-up phenomena of S25C and S45C commercial carbon cast steel were investigated. As the density of EPS pattern is increased, the carbon concentration of decomposed pattern is increased and the thickness of carburized layer at the surface of steel castings is increased. Also as the density of coatings is increased, the permeability of coatings is decreased and the thickness of carburized layer at the surface of steel castings is increased. S25C steel which has lower original carbon content compared to S45C steel exhibited severe carburization.

• Journal of Korea Foundry Society
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• v.17 no.5
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• pp.465-471
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• 1997

An integrated computer program consisting of a pre-processor, main solver, and post-processor was developed for the design of large steel castings. The pre-processor, based on the AutoCAD, enables the user to produce approval drawings, casting design drawings and mesh diagrams in sequence using a personal computer. In the main solver, two numerical models were employed; one models the fluid flow during mold filling, and the other models the heat transfer and solidification. The post-processor can be used to present simulation results such as flow pattern, mold filling sequences, solidification times, temperature gradients and location of shrinkage defects by color graphics. In order to validate the applicability of the present integrated program, a series of experiments on simple-shaped steel castings were carried out. After the validation of the present model, it was applied to the casting design of the large steel anchor of an SC42 alloy. Various solidification parameters such as a temperature distribution and a solidification time in the casting and the mold were compared with those obtained experimentally. Simulated results predicting shrinkage defects were in good agreement with those obtained experimentally. It was found that the present method can be successfully applied to the quantitative casting design for complex-shaped large steel castings.

• Korean Journal of Materials Research
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• v.13 no.3
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• pp.137-143
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• 2003

The air gap between the metal and mold, formed by shrinkage during solidification, causes surface and subsurface cracks in the continuous casting process. Molten crack on the surface might also occur due to improper heat transfer between them. In order to compensate the air gap in mold design, the thermal contraction is an essential factor. In this study, the thermal contraction and expansion behaviors were examined from the ($\alpha$ and pearlite)/${\gamma}$ to ${\gamma}$/$\delta$ transformations in continuous casting steels by the commercial dilatometer and the self- assembled dilatometer with laser distance measurement. It was found that the thermal contraction and expansion behaviors were very dependant on the phase transformation of the ${\gamma}$/$\delta$ as well as ($\alpha$ and pearlite)/${\gamma}$. The sudden volume change from $\delta$ to ${\gamma}$ which might cause cracks in the continuous casting process, was observed on cooling just below the melting temperature by the self-assembled dilatometer.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.03a
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• pp.138-143
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• 1998

The continuous casting process has been adopted increasingly in recent years to save both energy and labor. It has experienced a rapid development in the production of semi-finished steel products, replacing the conventional route of ingot casting plus rolling. To achieve this good merit, however, more studies about a heat transfer mechanism between roll and slab are needed. So this paper shows the results of the deformation behavior of steel cast slabs, which are about the solidification and heat transfer. This study is used to prevent internal cracks of a slab in a bending and unbending zone. The value of moving strand shell bulging between two supporting rollers under ferrostatic pressure and slab-self weight has been computed in terms of creep and elastic-plasticity. The high strand distributions in solidified shell undergoes a series of bulging are calculated with boundary condition a very closed to continuous steel cast slabs productions.

• Journal of the Society of Naval Architects of Korea
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• v.45 no.4
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• pp.426-431
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• 2008

The high-strength low-alloy(HSLA) steels have low carbon contents($0.05{\sim}0.25%$ C) in order to produce adequate formability and weldability, and they have manganese contents up to 1.7%. Small quantities of silicon, chromium, nickel, copper, aluminum, molybdenum are used in various combinations. The results contained in this paper can provide the valuable information on the development of $-40^{\circ}C$ low temperature HSLA. Furthermore, the present experimental data will provide important database for casting steel materials of the offshore structure.

• Journal of Korea Foundry Society
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• v.10 no.2
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• pp.110-115
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• 1990