• Journal of the Korean Society for Precision Engineering
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• v.18 no.8
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• pp.54-63
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• 2001

Rapid Prototyping(RP) techniques have their unique characteristics according to the working principles: stair-stepped surface of a part due to layer-by-layer stacking, low build speed caused by point-by-point or line-by-line solidification to build one layer, and additional posts processing to improve surface roughness, so high cost is required to introduce and to maintain the RP apparatus. The objective of this study is to develop a new RP process, Variable Lamination Manufacturing by using expandable polystyrene foam sheet as part material(VLM-S), and to design an apparatus for implementation of the process. So, the process parameters and design criterions of the apparatus were defined and the techniques were proposed to satisfy the design criterion. Based on the results, a knob-shape, pyramid shape. and a solid block were fabricated on the apparatus in which unit shape part(USP) was generated for building each layer.

• Journal of Powder Materials
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• v.17 no.3
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• pp.190-196
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• 2010

In this paper, rapid solidified Mg-4.3Zn-0.7Y (at.%) alloy powders were prepared using an inert gas atomizer, followed by a severe plastic deformation technique of high pressure torsion (HPT) for consolidation of the powders. The gas atomized powders were almost spherical in shape, and grain size was as fine as less than $5\;{\mu}m$ due to rapid solidification. Plastic deformation responses during HPT were simulated using the finite element method, which shows in good agreement with the analytical solutions of a strain expression in torsion. Varying the HPT processing temperature from ambient to 473 K, the behavior of powder consolidation, matrix microstructural evolution and mechanical properties of the compacts was investigated. The gas atomized powders were deformed plastically as well as fully densified, resulting in effective grain size refinements and enhanced microhardness values.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.24 no.4
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• pp.158-163
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• 2014

Mineral fiber, or be called mineral wool when it assembles in large amounts, is a kind of wide applied man-made material with excellent thermal and acoustic insulation properties. In this work, mineral fiber was produced via melt spinning method by using iron blast furnace slag as raw material. Two critical experimental parameters for fabrication were investigated: melt pouring temperature and rotating speed of spinning wheels. The mineral fiber produced under the condition of melt pouring temperature $1500^{\circ}C$ and spinning speed 4000 rpm, showed the smoother surface and most quality, while the others had rough surfaces or with heavy shots. In general, mineral fibers with the size in the range of $12{\sim}49{\mu}m$ in diameter and 8~130 mm in length can be fabricated by this method, and the production rate is more than 34 wt.%, which could be up to 57 wt.% at maximum.

• Journal of Advanced Marine Engineering and Technology
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• v.26 no.4
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• pp.464-471
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• 2002

Porosity formation in partial penetration welds by high power lasers is a serious problem in industry. There are two main causes that induce porosity formation. One form of porosity is due to gases (e.g. hydrogen, oxygen) dissolving into the weld pool because of the high temperature and then the rapid solidification traps gases as a bubble in the weld metal. The second problem is voids formed by the keyhole collapsing due to unstable keyhole fluid dynamics. The voids that form at the bottom of the keyhole are relatively large and irregular in shape compared to the gas bubbles; this void formation is the primary concern in this paper. The reduction of voids formed by keyhole collapse is achieved by improving the stability of keyhole. Two methods to improve keyhole stability are discussed in this paper: pulse modulation and beam incident angle. Pulse modulation of the laser beam was performed between 100 Hz and 500 Hz to find out the optimum frequency for the keyhole dynamics. The incident beam angle changed the impact angle of the laser beam to the work surface in a range of 0 to 25 degrees. Glycerin in a semi-solidified state is used as a medium for performing the welding because its transparency allows of visualization of the keyhole.

• Journal of Korea Foundry Society
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• v.27 no.2
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• pp.72-76
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• 2007

Contact materials are widely used as electrical parts. Ag-Cd alloy has a good wear resistance and stable contact resistance. But the Cd exists as coarse oxide in alloy so it have an effect on mechanical properties badly. Moreover, the Cd is an injury material to environment. Nowadays, the use of Cd is strictly restricted. Because of these disadvantage, Ag-Sn-In alloy has been developed. In Ag-Sn-In alloy, the Sn : In ratio affects the internal oxidation properties, such as the formation of the oxide layer on the surface. In this work, we changed and optimized the Sn : In ratio variety for good internal oxidation properties. We have shown that a internal oxidation process did not fully completed when the Sn : In ratio is over 4 : 1 because of the Sn oxide layer at surface. The increase of In decelerates the formation of Sn oxide layer.

• Journal of the Korean Society for Heat Treatment
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• v.12 no.4
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• pp.320-326
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• 1999

In rapidly solidified $Al_{92-x}Nd_8$(Cu,Ag)x ($0{\leq}X{\leq}10at%$) alloys, amorphous single phases were obtained in the ranges of $Oat%{\leq}X{\leq}4at%$ for Al-Nd-Cu system and $Oat%{\leq}X{\leq}6at%$ for Al-Nd-Ag system, respectively. Mesoscopic structures consisted of amorphous and crystalline phases were formed above solute ranges. It was founded that the mesoscopic structures were also formed near 1st exothermic peak on DSC curve by aging in amorphous single phase alloys. For example, amorphous $Al_{92-x}Nd_8$(Cu,Ag)x (X=2.4at%) alloys containing nanoscale Al particles and compounds, i.e., mesoscopic structure, exhibited higher tensile fracture strength(${\sigma}_f$) than those of amorphous single phase alloys with the same composition. The ${\sigma}_f$ showed a maximum value in the $V_f$ ranges of 10~15%. The reason is presumed that the nanoscale precipitates which have higher mechanical strength compared with the amorphous phase with the same composition act as an effective resistance to shear deformation of the amorphous matrix.

• Journal of Powder Materials
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• v.3 no.4
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• pp.271-278
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• 1996

In this study, the effect of the transition elements on the microstructure and mechanical properties of rapidly solidified Al-Mg-X alloys was investigated. As a result of the rapid solidification processing, fine equiaxed grains with a mean diameter of 2 $\mu$m were observed in these alloys. Many fine particles were found to be distributed rather homogeneously throughout the matrix with relatively large particles occasionally at grain boundaries. The ultimate tensile strengths of Al-Mg-X alloys were found to decrease rather remarkably at 150 $^{\circ}C$ without the gain of the ductility at 150 $^{\circ}C$, which may result from segregation of $\beta$ ($Al_{3}Mg_{2}$) precipitates. Fine dimples were observed on the fracture surfaces for all alloy systems and the variation of the size and shape of dimples was not observed upon alloy systems. The ductility at 530 $^{\circ}C$ was found to be ~100%, suggesting that grain boundary sliding did not contribute to ductiliy despite he grain size stabilization. The absence of superplastic behavior may be associated with low boundary misorientation in rapidly solidified Al-Mg-X alloys.

• Journal of the Korean Magnetics Society
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• v.4 no.2
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• pp.126-129
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• 1994

In order to invetigate the effect of Pr additive on the magnetostriction of amorphous Fe-B alloys, amorphous $Fe_{86-x}B_{14}Pr_{x}(2{\leq}x{\leq}8\;at.%)$ alloys were prepared by a rapid solidification process. As the Pr content increased in the as-prepared amorphous $Fe_{84}B_{14}Pr_{2}$ alloy annealed at $300^{\circ}C$ for 2 hr increased to 70 ppm. Ac power loss and permeability$(f=50\;kHz,\;B_{m}=0.1\;T)$ of the annealed amorphous $Fe_{84}B_{14}Pr_{2}$ alloy were 15 W/kg and $5.5{\times}10^{3}$, respectively.

• Journal of Korea Foundry Society
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• v.8 no.4
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• pp.446-452
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• 1988

To obtain detailed information on the metastable and the equilibrium phases in rapidly solidified Al-(Fe,Ce) alloys, analysis of X-ray diffraction pattern has been carried out. It has been found that the metastable phase formed in Al-Fe alloys including up to 6wt%Fe is $Al_6Fe$ and the equilibrium phase is $Al_3Fe$. Any X-ray diffraction peak corresponding to the equilibrium phase $Al_{13}Fe_4$ has not been observed during aging. In Al-4wt%Fe alloy, which is ribbon shape with thickness less than $70\;{\mu}m$, aged at $400^{\circ}C$ for 1h after rapid solidification, unidentified phase has been found. In Al-4wt%Ce alloy, only X-ray diffraction peak corresponding to the equilibrium phase, $Al_4Ce$ has been observed. It has been found that the metastable phase Formed in Al-Fe-Ce alloys including up to 6wt% Fe and 4wt% Ce is $Al_6Fe$ and the equilibrium phases are $Al_3Fe$ and $Al_{10}CeFe_2$.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2000.05a
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• pp.771-774
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• 2000

RP techniques have inherent disadvantages caused by their working principles: stair-stepped surface of parts due to layer-by-layer stacking of layers, low build speed caused by line-by-line solidification to finish one layer, and post processing to improve surface finish, etc. The objective of this study is to propose a new RP technique, variable deposition manufacturing (VDM), which can make up for the disadvantages of the existing RP techniques, and to develop an apparatus to implement the technique. The proposed process can greatly reduce the building time and improve the surface finish of parts generated. The experiments are carried out to obtain the range of temperature of molten material to maintain its fluidity and to investigate the effect of gas cooling on the preservation of the slopes. Based on the results, some simple shapes such as a line-shape. an S-shape, and a circle-shape were fabricated from Ethylene Vinyl Acetatecopolymer (EVA). In order to examine the applicability of VDM to more general shapes, a tensile specimen and a yo-yo shape were manufactured by the proposed RP method using EVA material as the first trial approach. The present basic study has shown the possibility of a practicable utilization of the proposed VDM process to prototyping of a general three-dimensional shape.