• Design & Manufacturing
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• v.11 no.1
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• pp.30-33
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• 2017

In this study, the mold technology for manufacturing of porous implant was investigated. Firstly, we considered the concept of insert molding technology with 3D printing of porous inert part. The part on implant was designed in the end region of the implant. And then main implant bodies were manufactured using conventional machining method. The other porous parts were designed and optimized with molding simulation. As the feature size of porous implant was so small that perfect feature of it using 3D printing technology could not be obtained. So, we proposed another scheme for manufacturing of the porous implant in the replace of the former approach. Polymer mold cores with 3D printing technology were considered. The effects of addictive manufacturing process parameters on the properties of mechanical and dimensional accuracy were investigated. Direct 3D printed polymer mold cores were designed and manufactured under the simulation of thermal and molding analysis. It was shown that 3D printed mold core with polymer could be adapted to the injection molding for porous implant.

• Advances in Computational Design
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• v.4 no.1
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• pp.43-52
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• 2019

Variation Analysis (VA) is used to simulate final product variation, taking into consideration part manufacturing and assembly variations. In VA, all the manufacturing and assembly processes are defined at the product design stage. Process Capability Data Bases (PCDB) provide information about measured variation from previous products and processes and allow the designer to apply this to the new product. A new challenge to this traditional approach is posed by the Industry 4.0 (I4.0) revolution, where Smart Manufacturing (SM) is applied. The manufacturing intelligence and adaptability characteristics of SM make present PCDBs obsolete. Current tolerance analysis methods, which are made for discrete assembly products, are also challenged. This paper discusses the differences expected in future factories relevant to VA, and the approaches required to meet this challenge. Current processes are mapped using I4.0 philosophy and gaps are analysed for potential approaches for tolerance analysis tools. Matching points of simulation capability and I4.0 intents are identified as opportunities. Applying conditional variations, incorporating levels of adjustability, and the un-suitability of present Monte Carlo simulation due to changed mass production characteristics, are considered as major challenges. Opportunities including predicting residual stresses in the final product and linking them to product deterioration, calculating non-dimensional performances and extending simulations for process manufactured products, such as drugs, food products etc. are additional winning aspects for next generation VA tools.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.20 no.9
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• pp.1-10
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• 2021

Recently, the repair and recycling of damaged mechanical parts via metal additive manufacturing processes have been industrial points of interest. This is because the repair and recycling of damaged mechanical parts can reduce energy and resource consumption. The directed energy deposition(DED) process has various advantages such as the possibility of selective deposition, large building space, and a small heat-affected zone. Hence, it is a suitable process for repairing damaged mechanical parts. The shaft is a core component of various mechanical systems. Although there is a high demand for the repair of the shaft, it is difficult to repair with traditional welding processes because of the thermal deformation problem. The objective of this study is to propose a repair procedure for a damaged shaft using the DED process and discuss its applications. Three types of cases, including a small shaft with a damaged surface, a medium-size shaft with a worn bearing joint, and a large shaft with serious damage, were repaired using the proposed procedure. The microstructure and hardness were examined to discuss the characteristics of the repaired component. The efficiency of the repair of the damaged shaft is also discussed.

• Journal of the Korean Vacuum Society
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• v.21 no.1
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• pp.22-28
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• 2012

Transparent dye-sensitized solar cells have been widely investigated for the application to building integrated photovoltaic system. Thin film Si-based solar cells are emerging as a substitute for the dye-sensitized solar cells because their merits of well-established manufacturing processes. Since the selective transmitting layer transmits visible light and reflects infrared light, the solar cell efficiency increases with the introduction of the selective transmitting layer. In this work, AlTiO thin films were grown as the selective transmitting layer by cost-effective sputter deposition and their transmittances were improved by controlling deposition parameters.

• Journal of Korean Society for Quality Management
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• v.43 no.3
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• pp.359-372
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• 2015

Purpose: Through studying the expert's and non-experts panel responses to the questions regarding the attributes of chemical-biological protection cloth quality in terms of the levels of customer demand and technical factors has been studied. We are applied to a QFD matrix with find out the relationship between the selective removal efficiency of chemical-biological cloth and the guidelines of technical approach. Methods: We fabricated several composite of ion-exchange resins with selectively permeable performance designed to facilities water vapor transport and selective adsorption of the harmful gases. With these materials, we characterized on the selectively permeable performance to identify ion-exchange resin with chemical-biological protective cloth. Results: Results showed that ion exchange materials possessed performance with selectively efficiencies as NH3, SOx, NOx and HCl gas. The selective adsorption amount of ammonia and hydrogen gases were $90-80{\mu}g/g$ with TRILITE SCR-BH sulfonated ion exchange resin. The PP non-woven/ion exchange resin adsorbent materials possessed performance with water vapor permeability were 1,100-1,350 g/m2/day, it's was two times high value compare with activated carbon. With these materials, we characterized selectively removal efficiency to identify new ion-exchange material with chemical-biological protective capability. Conclusion: This study shows that a QFD aids in deciding with of the adsorption parameters to optimized with chemical-biological protection cloth manufacturing.

• Korean Journal of Materials Research
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• v.29 no.7
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• pp.412-424
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• 2019

Global fitting functions for Fe-selective chlorination in ilmenite($FeTiO_2$) and successive chlorination of beneficiated $TiO_2$ are proposed and validated based on a comparison with experimental data collected from the literature. The Fe-selective chlorination reaction is expressed by the unreacted shrinking core model, which covers the diffusion-controlling step of chlorinated Fe gas that escapes through porous materials of beneficiated $TiO_2$ formed by Fe-selective chlorination, and the chemical reaction-controlling step of the surface reaction of unreacted solid ilmenite. The fitting function is applied for both chemical controlling steps of the unreacted shrinking core model. The validation shows that our fitting function is quite effective to fit with experimental data by minimum and maximum values of determination coefficients of $R^2$ as low as 0.9698 and 0.9988, respectively, for operating parameters such as temperature, $Cl_2$ pressure, carbon ratio and particle size that change comprehensively. The global fitting functions proposed in this study are expressed simply as exponential functions of chlorination rate(X) vs. time(t), and each of them are validated by a single equation for various reaction conditions. There is therefore a certain practical merit for the optimal process design and performance analysis for field engineers of chlorination reactions of ilmenite and $TiO_2$.

• Laser Solutions
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• v.14 no.3
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• pp.1-6
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• 2011

Globally, the interest of renewable energy has become an upsurge. Especially, the solar industry is the one which is getting rapid growth rate. Many of researchers have been undertaking to improve the efficiency of solar cell to accomplish grid parity. The most of research has been concentrated on two methods, one on the selective emitter and the other is on LBSF (Local Back Surface Field) formation. Laser patterning will be needed to eliminate the thin film to form selective emitter and LBSF of solar cell. This paper reports some experimental results in laser patterning process for high-efficiency crystalline solar cell manufacturing. The experimental results indicate that the patterning quality depends on the average power and repetition rate of laser. The experimental results prove that the laser patterning process is an advantageous method to improve the efficiency of solar cell.

• International Journal of Precision Engineering and Manufacturing-Green Technology
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• v.5 no.5
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• pp.605-612
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• 2018

This work investigates the relationships between the static mechanical properties of Ti-6Al-4V manufactured through selective laser melting (SLM) and post-process heat treatments, namely stress relieve, annealing and hot isostatic pressing (HIP). In particular, Ti-6Al-4V parts were fabricated in three different build orientations of X, Z, and $45^{\circ}$ to investigate the multi-directional mechanical properties. The results showed that fully densified Ti-6Al-4V parts with densities of up to 99.5% were obtained with optimized SLM parameters. The microstructure of stress relieved and mill annealed samples was dominated by fine ${\alpha}^{\prime}$ martensitic needles. After HIP treatment, the martensite structure was fully transformed into ${\alpha}$ and ${\beta}$ phases (${\alpha}+{\beta}$ lamellar). Within the realm of tensile properties, the yield and ultimate strength values were found statistically similar with respect to the built orientation for a given heat treatment. However, the ductility was found orientation dependent for the HIP samples, where a lower value was observed for samples built in the X direction.

• Journal of Powder Materials
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• v.29 no.2
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• pp.132-151
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• 2022

The CoCrFeMnNi high-entropy alloy (HEA), which is the most widely known HEA with a single face-centered cubic structure, has attracted significant academic attention over the past decade owing to its outstanding multifunctional performance. Recent studies have suggested that CoCrFeMnNi-type HEAs exhibit excellent printability for selective laser melting (SLM) under a wide range of process conditions. Moreover, it has been suggested that SLM can not only provide great topological freedom of design but also exhibit excellent mechanical properties by overcoming the strength-ductility trade-off via producing a hierarchical heterogeneous microstructure. In this regard, the SLM-processed CoCrFeMnNi HEA has been extensively studied to comprehensively understand the mechanisms of microstructural evolution and resulting changes in mechanical properties. In this review, recent studies on CoCrFeMnNi-type HEAs produced using SLM are discussed with respect to process-induced microstructural evolution and the relationship between hierarchical heterogeneous microstructure and mechanical properties.

• Journal of Powder Materials
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• v.30 no.1
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• pp.7-12
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• 2023

Metal-additive manufacturing techniques, such as selective laser sintering (SLS), are increasingly utilized for new biomaterials, such as cobalt-chrome (Co-Cr). In this study, Co-Cr gas-atomized powders are used as charge materials for the SLS process. The aim is to understand the consolidation of Co-Cr alloy powder and characterization of samples sintered using SLS under various conditions. The results clearly suggest that besides the matrix phase, the second phase, which is attributed to pores and oxidation particles, is observed in the sintered specimens. The as-built samples exhibit completely different microstructural features compared with the casting or wrought products reported in the literature. The microstructure reveals melt pools, which represent the characteristics of the scanning direction, in particular, or of the SLS conditions, in general. It also exposes extremely fine grain sizes inside the melt pools, resulting in an enhancement in the hardness of the as-built products. Thus, the hardness values of the samples prepared by SLS under all parameter conditions used in this study are evidently higher than those of the casting products.