• Journal of Korea Foundry Society
• /
• v.25 no.4
• /
• pp.161-167
• /
• 2005

The experiment of hot dip interaction tests was carried out in order to study the formation behavior of interfacial reaction layer between as-received STD61 hot work tool steel and a commercial pure aluminum melt, Al-xwt.%Fe(x=0.2, 0.5, 0.8 and 1.1) alloys melt and Al-xwt.%Si(x=1.0, 4.0, 7.0 and 10.0) alloys melt, respectively. The results show that the reaction layer, over 300 ${\mu}m$ in thickness, is easily formed by the dissolution of silicon from as-received tool steel. When the iron content in the aluminum alloy is higher than 1.1 wt.%, the thickness of reaction layer decreases below 180 ${\mu}m$ by preventing iron dissolution from the tool steel. The silicon dissolved from tool steel acts as a strong promoter on the formation of reaction layer, but the alloyed silicon in molten aluminum alloys acts as an inhibitor on the formation of reaction layer.

• Journal of the Korean Institute of Electrical and Electronic Material Engineers
• /
• v.20 no.10
• /
• pp.918-923
• /
• 2007

Fuel cell is a modular, high efficient and environmentally energy conversion device, it has become a promising option to replace the conventional fossil fuel based electric power plants. The high temperature fuel cell has conspicuous feature and high potential in being used as an energy converter of various fuel to electricity and heat. Corrosions in molten electrolytes and the electric conductivity across the oxide scale have crucial characteristics. When molten salts are involved, high temperature corrosions become severe. In this sense, corrosions of alloys with molten carbonates have the most severe material problems. Systematic investigation on corrosion behavior of Fe/21Cr/Ti or Al alloy has been done in (62+38)mol% (Li+K)$CO_3$ melt at $650^{\circ}C$ using the electrochemical impedance spectroscopy method. It was found that the corrosion current of these Fe-based alloys decreased with increasing Al or Ti. And Al addition improved the corrosion resistance of this type of specimen and more improvement of corrosion resistance was observed at the specimen added with Al.

• Journal of Electrochemical Science and Technology
• /
• v.11 no.4
• /
• pp.392-398
• /
• 2020

Producing solar grade silicon using an inexpensive method is a key factor in lowering silicon solar cell costs; the direct electrochemical reduction of SiO₂ in molten salt is one of the more promising candidates for manufacturing this silicon. In this study, SiO₂ granules were electrochemically reduced in molten CaCl₂ (850℃) using Ag-Si eutectic droplets that catalyze electrochemical reduction and purify the Si product. When Ag is used as the working electrode, the Ag-Si eutectic mixture is formed naturally during SiO₂ reduction. However, since the Ag-Si eutectic droplets are liquid at 850℃, they are easily lost during the reduction process. To minimize the loss of liquid Ag-Si eutectic droplets, a cylindrical graphite container working electrode was introduced and Ag was added separately to the working electrode along with the SiO₂ granules. The graphite container working electrode successfully prevented the loss of the Ag-Si eutectic droplets during reduction. As a result, the Ag-Si eutectic droplets acted as stable catalysts for the electrochemical reduction of SiO₂, thereby producing one-dimensional Si rods through a mechanism similar to that of vapor-liquid-solid growth.

• Journal of Korea Foundry Society
• /
• v.28 no.3
• /
• pp.119-123
• /
• 2008

Wear test on two die steels for aluminum die casting was carried out by dipping and rotating the specimens into the molten aluminum maintained $680^{\circ}C{\sim}780^{\circ}C$. The rotating speed of the specimen was $4.5rpm{\sim}20.0rpm$. Diffusion layer was formed between the die steel and molten aluminum, and became thicker with dipping time. Wear rate was not proportional with the thickness of the diffusion layer, but was closely related to the density of the diffusion layer. Wear rate was little affected by the kind of die steel and by the microstructure such as martensite, tempered martensite, and pearlite. Specimen with nitrided surface showed good wear resistance, and its wear rate was decreased with increase in the thickness of nitrided layer. While whole surface was worn in heat treated specimens, wear of nitrided specimens was proceeded by pitting partially.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.10a
• /
• pp.279-284
• /
• 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 Korea Foundry Society
• /
• v.31 no.2
• /
• pp.83-86
• /
• 2011

Ni-Al based intermetallic compounds of self-propagating high-temperature synthesis (SHS) by the heat of molten aluminum and been coated on the aluminum casting alloy. The effects of the pouring temperature in casting and the thickness of casting substrate on SHS of the coating layer have been investigated. The experimental result showed that the reaction of the coating layer was activated with increasing the pouring temperature in casting and the thickness of casting substrate. However, the aluminum substrate was re-melted by the heat of formation for intermetallic compounds. Then, it was considered that some mechanical or thermal treatments for elemental powder mixtures were required to control the heat of formation for intermetallic compounds in advance.

• Journal of Korea Foundry Society
• /
• v.30 no.1
• /
• pp.5-13
• /
• 2010

This article aims to introduce the synchrotron radiation for its utilization in the casting and solidification fields as an unique tool for observation of real time phenomena of molten metal during solidification. General features of the synchrotron radiation were briefly introduced for readers in the casting and solidification fields, with no background regarding to synchrotron radiation. And basic principles of imaging technologies using synchrotron light for in-situ observation of molten metal were explained together with exemplary research works, which were reported on the casting and solidification fields in recent years. As a practical guide, real time observation of Al-Si casting alloy was introduced with experimental facilities, image acquisition, and processing together with representative results.

• Journal of Surface Science and Engineering
• /
• v.28 no.4
• /
• pp.243-254
• /
• 1995

The fabrication process of Cu-base anode for replacing Ni-base anode of molten carbonate fuel cell was investigated. Electrochemical performance and thermal stability of Cu-base anode were also investigated. Green sheet was prepared by mixing Cu and Ni powder with 1.5wt% methylcellulose and 100wt% water. The pore-size distribution of the Cu-base anode sintered at $800^{\circ}C$ for 30min showed almost uniform pore-size ranging from 4 to 20$\mu\textrm{m}$ and it was considered suitable for MCFC anode. Cu-Ni anode containing between 35 to 50wt% Ni exhibited current density of 111mA/$\textrm{cm}^2$ at 100mV overpotential and it was almost the some value for pure Ni anode. The sintering resistance of Cu-Ni increased with an increase of Ni addition. It was considered that the increase of sintering resistance was due to the decrease of diffusion rate of Cu and Ni with increasing the addition of Ni in Cu-Ni alloy.

• Journal of Surface Science and Engineering
• /
• v.30 no.3
• /
• pp.159-166
• /
• 1997

The metalliding technique was adopted to obtain the diffusion coating of zirconium on AISI 304 Stainless Steel in molten mixed chlorides (32.9wt.%LICl-34.8wt.%NaCl-32.3wt.%). Experiments were carried out in argon gas atmosphere. The electrolytic cell was consisted of a AISI 304 Stainless steel cathode and a consumable zirconium anode. The quality of deposit was analysed by SEM, Optical Microscope, EDS, and also examined by the Micro-Vickers hardness and corrosion tests. Interface of deposit layer was identified as zirconium-iron alloy layer caused by diffusion process at elevated temperatures. The optimum condition for the metalliding was found to be the bath temperature of $550^{\circ}C$, the concentration of $K_2ZrF_6$ ,5wt.%, cathodic current derrent density of 7.0 to 10.0mA/$\textrm{cm}^2$ , and anodic current density of 2.0mA/$\textrm{cm}^2$.

• Journal of Welding and Joining
• /
• v.23 no.5
• /
• pp.30-36
• /
• 2005

In this part, thermal finite element analysis(FEA) is conducted for the experiments in part 1. The molten area of base metals are analyzed by FEA results and compared with experimental ones. Temperature data from FEA results are used to calculate the IMC layer thickness analytically at the interface. IMC layer is established as a function of time and temperature when there is an interaction between solid steel and molten aluminum. The IMC layer thickness is obtained by cumulative computations using the time-temperature data from FEA results.