• Journal of the Korean Ceramic Society
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• v.35 no.4
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• pp.406-412
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• 1998

The reaction bonded alumina ceramics was prepared through the addition of each SiC and ZrO2 powder to the mixture of Al metal powder and Al2O3 The mono sized (3mm) and biodal sized (3mm+5mm) balls were used in attrition milling of Al and starting powders. The milling efficiency of both cases was compared by the analysis of particle size and X-ray diffraction. After the forming and sintering of each powder batchs the weight gains dimensional changes and densities were determined. The specimens were investigated by X-ray diffraction analysis and scanning electron microscope. Bimodal sized balls had better milling effect than single ball size in the milling of Al powder. However in the milling which ceramic powders mono sized the green body during the reaction sintering at 1$600^{\circ}C$ for 5 hour was about 10% The densities attained the values of 92-98% theoretical. The SiC added specimen that was milled with 3mm ball media had 96% theoretical density and dense microstructure.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1995.10a
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• pp.195-198
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• 1995

In Semi-Solid Forging, it is necessary to control the forming variables accurately in order to make near-net-shape products. Generally, the defects of products may occur due to liquid segregation which can be caused by the degree of deformation and condition of friction in Semi-Solid Forging, where the segregation is to be predicted by flow analysis. This paper presents the feasibility of theoretical analysis model using the new yield function which is proposed by Doraivelu et al. to the flow analysis of the semi-solid dendritic Sn-15%Pb alloys instead of adopting the yield criterion of Shima & Oyane which is used by Charreyron and usefulness of the adopted yield function. The distribution of the liquid fraction at various strains in radial direction and the influence of friction are estimated by Upper Bound Method.

• Journal of the Korean Society for Heat Treatment
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• v.27 no.3
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• pp.127-132
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• 2014

The semi-solid metal forming process has been applied to realize a near-net shape fabrication of a high speed tool steel. A complicatedly shaped part out of SKH51 was successfully manufactured by introducing pertinent materials, tooling and processing conditions. A SKH51 billet with globular grains was heated at temperatures between 1300 and $1350^{\circ}C$ using high frequency induction heater to get semi-solid microstructure before high rate injection of mushy metal into a die cavity for the forming process. It was necessary to control the preheating of dies between 300 and $400^{\circ}C$ to maintain the homogeneous microstructure during the semi-solid metal forming process. Significant defects such as pores, high fraction of liquid fraction and segregation could be removed from the part by using air vents.

• Journal of Powder Materials
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• v.5 no.4
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• pp.340-344
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• 1998

Along with the growth of conventional ferrous powder metallurgy (PM), PM of aluminum alloys has been intensively investigated in Japan. Although rapidly solidified aluminum alloy powder was first used in the USA,/sup 1)/ commercialization for consumer market was first realized in Japan./sup 2)/ In order to achieve the viable cost-performance including Near Net Shape (NNS) formability, we developed three processes, powder extrusion, powder forging and sintering. The new powder extrusion process does not use either capsulation or vacuum degassing. The new powder forging does not need lateral flow. The new sintering process does not use liquid phase. The performance achieved by the processes is outstanding mechanical or physical properties that has potential to substitute cast iron, steel, titanium Metal Matrix Composite (MMC) or Ingot Metallurgy (IM) aluminum alloys. Cooperation with customers, powder suppliers and research associations contributed to the advancement of PM aluminum alloys in Japan.

• Transactions of Materials Processing
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• v.14 no.7 s.79
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• pp.587-594
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• 2005

분무성형공정은 급냉응고 및 결정입자 제어에 따른 고품위 소재 개발의 장점과 함께 고밀도 near-net-shape 제품의 제조가 가능한 합금제조기술이다 분무성형체의 미세조직은 적층표면에 도달하는 액적들의 평균 열용량, 즉 고상분율에 의하여 결정되며, 이는 액적의 비행과정에서의 분사가스-액적간의 열전달과 적층표면에서의 열유입과 열유출 속도에 영향을 받는다. 실제 다양한 공정변수들이 복합적으로 미세조직 형성과정에 영향을 미치지만, 균일한 미세조직을 얻기 위하여서는 적층표면에서의 온도와 고상분율을 항상 일정하게 제어하여야만 한다 즉, 적층표면 온도를 분무 성형공정중에 지속적으로 측정하여 이를 공정 제어 시스템에 feedback하여 원하는 적층표면온도를 유지하도록 공정변수를 제어하는 것이 필수적이다. 분무성형에 제조된 성형체는 합금원소의 편석이 없고 미세한 등방성의 결정립으로 이루어진 특징적인 미세조직을 나타낸다 이와 같은 미세조직으로 인하여 분무성형체는 우수한 성형성과 기계가공성을 나타내며, 또한 분무성형-후속가공된 최종 제품은 잉곳주조에 의하여 제조된 것과 비교하여 크게 향상된 기계적 성질을 가진다.

• Transactions of Materials Processing
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• v.10 no.3
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• pp.214-222
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• 2001

The homogeneous distribution of solid region without liquid segregation is important in terms of high quality component during thixoforming process. In closed die semi-solid forging process, liquid segregation is strongly affected by injection velocity than solid fraction because the material has to travel relatively long distance to fill the cavity through a narrow gate. The designed die by computer simulation data was used to thixoforging process. The thixoforming velocity to prediction the liquid segregation had been determined with strain rate associated with multistage velocity control during compression test of semi-solid material. The optimal forging velocity and die temperature were investigated to produce the near-net-shape compressor component. The mechanical properties of thixoformed component were tested with various die and material temperatures before and after heat treatment.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 1997.04a
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• pp.597-601
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• 1997

The technology of Semi-Solid Forging(SSF) has been actively developed to fabricate near-net shape products using light and hardly formable materials. Generally, the SSF process is composed of slug heating,forming,compression holding and ejecting step. After forming step in SSF, the slug is comperssed during a certain holding time in order to be completely filled in the die cavity and be accelerated in solidification rate. This paper presents the analysis of temperature,solid fraction and shrinkage at compression holding step for a cylindrical slug,then predicts the solidification time to obtain the final shaped part. Enthalpy-based finite element analysis is performed to solve the heat transfer problem considering phase change in solidification.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.11 no.1
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• pp.120-126
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• 2002

The near net shape forging of gears offers significant technical and economic advantages ever other forms of manufacture. These potential benefits can however only be realized by careful die design. This paper describes a computer-based methodology fur achieving this. A Visual-BASIC program has been developed on a rule based system that enables optimal design of the dies taking into account the elastic deflections generated in shrink-fitting the die inserts and that caused by the stresses generated in the forging process. The method also enables the profile of the spark erosion electrode to be determined. An example of the application to forging spur gears is given.

• Transactions of the Korean Society of Mechanical Engineers
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• v.18 no.4
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• pp.946-957
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• 1994

In the steel industries, direct rolling process for production of strip from molten metal has been investigated to simplify processes, to minimize energy consumption, and to improve quality of the strip. In this study, two kinds of practicable scale cooling rollers are proposed. And heat transfer analysis of pool region and cooling roller considering flow of molten metal and roll rotation respectively using the finite element method are performed to obtain the proper initial condition and to observe cooling characteristics of cooling roller. From the results, variations of solidification final points and temperature distribution in roller are observed quantitatively according to roll rotation.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.7 s.94
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• pp.1751-1760
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• 1993

The squeeze casting process is considered as an attractive way to form the primary product of near net shape metal matrix composites for wide use in automobile industry. To understand for infiltration limit in squeeze casting processes, the SAFFIL short fiber preform of volume fraction $10%{\sim}23%$ were fabricated by vaccum pumping and speed control press, and the optimal condition for fiber preform fabrication had been experimentally obtained. The composite materials were fabricated by forced infiltration of molten metals such as Al6061, Al7075, pure Al, AC8A, and Al2024. The infiltration distance and deformation of fiber preform are observed, and tensile strength were measured from at the room temperature.