• 한국주조공학회지
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• 제37권3호
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• pp.71-77
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• 2017

Casting defects produced during the casting process seriously affect the mechanical properties of the resulting products, reduce the performance capabilities of the product, and also result in economic losses. Therefore, this paper mainly investigates the causes of defects and methods by which to reduce these defects stemming from molten metal flows in a runner system of the type widely used in the sand mold casting process. The flow characteristics of a molten alloy are difficult to observe during the actual casting process. For this reason, a water model was used to observe the flow in the casting process, and the flow in each case was recorded using high-speed cameras as part of the experimental process of this study. Several repetitive experiments were performed to improve the accuracy of the experimental results. The traditional casting system was modified according to the design rules proposed by Campbell, and the system was termed flow-adaptive gating system with a water model. Comparing the flow characteristics of traditional and adaptive gating systems with a water model shows that the bubbles in the water in the latter case are reduced more significantly than in the former case. A ceramic filter system was adapted to the flow-adaptive gating system to minimize the instability of the flow during filling, which occurs as the fluid velocity in the runner increases. In additional, the flow behavior with and without the filter system were compared. The water model system in this work was shown to be able to verify that the adaptation of the filter system brings improvements by stabilizing the flow and reducing the amount of bubbles in the runner system. Moreover, using the flow-adaptive runner system with the filter system leads to considerably stable flows in the runner system.

• 보존과학회지
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• 제38권3호
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• pp.234-242
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• 2022

국립춘천박물관 소장 철조석가불좌상(본관 1971)을 기초로 재현실험을 시행하여 분할 주조법을 연구하였다. 불상의 3D 스캔 데이터를 활용해 1/2 모형으로 축소 제작한 후 기존 연구 결과를 토대로 거푸집제작, 주조 등을 실시하여 불상을 제작하였다. 거푸집의 외부는 친모래와 산청토를 3:4의 비율로, 내부는 친모래와 산청토를 1:3의 비율로 배합하여 제작한 다음 불상을 주조하였다. 주조된 철불을 통해 다양한 주조결함을 관찰할 수 있었으며, 원불상과 유사한 형태적인 모습을 볼 수 있었다. 재현된 철불의 표면 관찰 결과 베이닝, 유동불량, 외부수축공, 피하기공, 표면핀홀, 형 어긋남 등의 주조결함을 지니고 있었으며, 이는 철조석가불좌상에서 보이는 주조결함의 특징과 유사하다. 미세조직은 나뭇가지 모양의 Dendrite 조직과 Pearlite 조직이 확인되었으며, Cementite 조직 사이에서 검은색의 Graphite가 관찰되었다. 본 연구는 철불의 전통주조기술과 제작기법을 위한 실험연구로서 고대 대형 주조기술을 알아볼 수 있는 기초데이터로 활용될 것으로 본다.

• 한국주조공학회지
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• 제24권1호
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• pp.52-59
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• 2004

Microstructure and mechanical properties of ductile cast iron were investigated in terms of diameter change of samples that gives rise to modify the microstructure due to different cooling rate in the continuous casting process. The chemical composition used in this study was GCD 400 grade. From the microstructural observation, we have found a large number of graphite with small size in diameter which is comparable to the microstructure of the sample produced by conventional sand casting. The major reason of this would he due to high cooling rate. In the sample with 26 mm in diameter, the microstructure was composed of pearlite, iron carbide, and graphite. In the samples with 60 and 100 mm in diameter, however, we have observed a dissimilar microstructure that consisting of ferrite and graphite. Concerning the mechanical property, the sample with 26 mm in diameter showed higher hardness and strength compared to those samples with 60 and 100 mm in diameter. The result obtained for ductility appeared a reversal. Much more works such as inoculation, process design and chemical composition would be required in order to have a sound product even in a small diameter of samples.

• 한국주조공학회지
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• 제35권2호
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• pp.29-35
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• 2015

In this study, potential defects of ring-type cast products during the mold-filling stage of the casting process were investigated using computer simulation. The main focus was on the effects of runner extension and ingates. During the mold filling the molten metal flowed from the bottom to the top of the mold in two curved paths along the ring-type cavity. The fluid fronts in the two paths did not show the identical velocity during the mold filling stage. This difference in the filling speeds may cause defects such as voids and local contractions. The present model contained virtual fluid detectors at various positions inside the mold. When the molten metal passed those points, the volume of fluid jumped up from zero to one. The moments were measured to compare the speeds of the fluid fronts. We attempted various combinations of runner extensions and ingates to stabilize the flow and then to optimize the casting mold design.

• 한국주조공학회지
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• 제39권5호
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• pp.87-93
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• 2019

The effects of mold materials on the microstructure and tensile properties were investigated to develop a mass production technique of aluminum alloy parts with excellent mechanical properties using a lost foam casting method. The microstructures of the plate-shaped cast alloy showed a tendency to be finer in proportion to the thickness of the plate, and a remarkably fine structure was obtained by applying a steel chill or a ball as a mold material compared to general sand. When a steel ball was used, it was observed that the larger the ball, the finer the cast structure and the better the tensile properties. The microstructure and tensile properties of the cast parts with complex shapes were greatly affected by the gating system, but the positive effects of the steel chill and the steel ball as a mold material were clear.

• 대한기계학회논문집A
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• 제21권9호
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• pp.1491-1497
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• 1997

The purpose of this research is to improve the surface roughness of cast-iron pipe porduced by the centrifugal casting. A twin-fluid atomizer of mold-wash slurry is designed for this project. New atomizer is equipped with the existing manufacturing facility to produce pipes. Cast-iron pipes (.cent.125*L3000mm) are produced and the surface roughnesses of those are analysed by UBM. The average surface roughness of new products is 6.7.mu.m while the old products of sand-resin coating method have 17.0.mu.m of average surface roughness. The surface roughness of cast-iron pipe is improved very much than before.

• 한국주조공학회지
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• 제7권2호
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• pp.122-132
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• 1987

Full mold casting process is a new technique offering numerous advantages and promising possibilities. The present study is aimed to bring out the results of experiments carried out to study the effect of pattern coatings on the solidification of 99.5% pure aluminum plate-shaped castings in the various sand molds and the thermal behavior of the molds. The results of the investigation indicate that (i) with increase in pattern coating thickness, the relative chilling power decreases gradually for silica and increases for zircon coating, and (ii) the application of a pattern coating significantly reduces the maximum interface temperature by the mold which is more pronounced in the case of thinner mold wall. The investigation also indicates that Chvorinov's rule is not found to be valid for the casting in the full mold, with or without pattern coating. Therefore in full mold process, the pattern coating thickness will be a very important parameter in the study of thermal behavior.

• 박물관보존과학
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• 제15권
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• pp.4-25
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• 2014

국립춘천박물관이 소장하고 있는 수다사지 청동금고는 1987년 강원도 평창군 진부면 수항리에서 발견되었다. 금고 표면에, 제작 당시의 주조 결함과 보수 흔적이 다수 발견되어 제작 기법을 유추하기에 용이한 중요 자료이다. 본 연구에서는 금고의 성분, 주형과 채플릿^{Chaplet, 형지(型持), 코어받침쇠}의 위치, 결함의 원인 등을 과학적으로 조사하여 주조 기법과 당대의 보수 방식을 추정해 보았다. 성분 분석 결과, 금고의 주성분은 구리 71.6wt%, 주석 18.2wt%, 납 7.2wt%로 3원계 청동합금이며 비소·안티몬이 각각 약 1wt%씩 검출되었다. 주조 시 주형을 고정하기 위하여 사용한 채플릿의 성분은 납 함량이 금고보다 더 높으며, 제작 후 구멍을 메우기 위해 사용된 땜납의 성분은 납 함량이 가장 높게 나타났다. 주조 분할선을 토대로 표면 상태를 관찰한 결과 사형주조 ^砂型鑄造로 제작되었을 가능성이 높았으며, 표면 관찰 및 방사선투과조사로 냉접^{Cold shut}이나 표면 주름^{Surface Folds}, 미스런^Misrun, 채플릿 주변의 기공^{Blowholes Adjacent to Chaplets} 등의 주조결함을 확인하고 발생 원인을 추정하였다. 보수된 부분은 제작 당시의 주조 결함인 구멍이 생긴 부위를 메우기 위하여 연납을 사용한 땜질보수 ^{Soldered-in Repair}를 하였다.

• 한국콘크리트학회:학술대회논문집
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• 한국콘크리트학회 2001년도 가을 학술발표회 논문집
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• pp.79-84
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• 2001

Because the WFS(Waste Foundry Sand), by-product of a casting factory, is generally a smaller particle than a fine aggregate, it has a bad influence on quality of concrete. Especially, the grading of aggregate is a very important factor in the case of concrete-based products having low water cement ratio manufactured by vibration and pressing method. Therefore, it is necessary to use WFS with the suitable grading of aggregate that it don't has a bad Influence on the quality of concrete-based products. This study investigated the suitable using proportion of WFS by means of the composition method of aggregate suggested by Driscoll. The results showed that it was desirable to use 10% of WFS since higher strength was developed with that amount.

• 한국안전학회지
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• 제11권1호
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• pp.3-10
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• 1996

The mechanical properties and fatigue crack growth rate fracture toughness of permanent mould cast austempered gray cast iron(AGI) were compared to those of sand cast AGI. Specimens prepared for tensile, impact and fatigue test were austenitized at $900^{\circ}C$ and austempered at $270^{\circ}C$, $320^{\circ}C$, $370^{\circ}C$ and $420^{\circ}C$ for 1 hour. The strength, impact and fatigue crack propagation behavior of permanent mold cast AGI were found to be superior to those of sand cast AGI. Maximum values in tensile strength, BHN, Charpy impact energy, were obtained at the austempering temperature of $270^{\circ}C$. Samely, the slowest fatigue crack growth rate was appeared at the austempering temperature of $270^{\circ}C$. But ductility of AGI was not improved by permanent mould casting.