• 한국주조공학회지
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• 제17권6호
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• pp.569-576
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• 1997

Coating materials for Evaporative Pattern Casting (EPC) process have been developed to investigate the effect of refractories on coating material properties. Three types of developed and one foreign coating materials were used. The former designated as A, B, C and the latter named S.K. The refractory of coating material A is spherical shape of zirconia, and the ones of B, C and S.K. is flake shape of mica. Strength, permeability at room and elevated temperature, anti-sand attachability and carbon residuary were evaluated at each coating materials. Permeability measurement device for elevated temperature was also designed. The zirconia type of coating material had excellent permeability, on the other hand the mica type had good strength and anti-sand attachability. It was found that the refractories were not broken during casting, so permeability indicated same trend at both room and elevated temperature. Based on results, coating material contained small size of mica which is designated as B has the best combination for cast iron.

• KIEAE Journal
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• 제8권5호
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• pp.61-68
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• 2008

For the recycling of the resources and the preservation of the environment, this study's purpose is to measure flexural behavior of the reinforced concrete beams with the major variables like concrete strength, replacement ratio of the recycled aggregate and the waste foundry sand and the tension reinforcement ratio and to present the data of the recycled aggregate used for the structure design. The experiment on the flexural behavior resulted in the followings. The ultimate strength of recycled R/C beam was manipulated proportionate to the tension reinforcement ratio, however the strength instantly decreased after passing the ultimate load due to the destroyed concrete of the compression side. The deflection at the maximum load varied from the tension reinforcement ratio by 5.5 times. The test specimen with the tension reinforcement ratio less than $0.5{\rho}b$ showed constant curve without change in the load from the yield to the ultimate load in contrast to the distinctive plastic region where the displacement was rising. Although the strain of main tension steel with the reinforcement ratio indicate different, the design of recycled concrete member can be applied for current design code for reinforced concrete structure as the ratio of tension reinforcement district the under the reinforcement ration in a balanced strain condition.

• 한국주조공학회지
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• 제42권1호
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• pp.61-66
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• 2022

Hydraulic units are important components of agricultural and construction machinery, and thus require high-quality castings. However, gas defects occurring inside the sand cores of the castings due to the resin used is a problem. This study therefore aimed to develop a casting simulation method that can clarify the gas defect positions. Gas defects are thought to be caused by gas generated after the molten metal fills up the mold cavity. The gas constant is the most effective factor for simulating this gas generated from sand cores. It is calculated by gas generating temperature and analysis of composition in the inert gas atmosphere modified according to the mold filling conditions of molten metal. It is assumed that gases generated from the inside of castings remain if the following formula is established. [Time of occurrence of gas generation] + [Time of occurrence of gas floating] > [Time of occurrence of casting surface solidification] The possibility of gas defects is evaluated by the time of occurrence of gas generation and gas floating calculated using the gas constant. The residual position of generated gases is decided by the closed loops indicating the final solidification location in the casting simulation. The above procedure enables us to suggest suitable casting designs with zero gas defects, without the need to repeat casting tests.

• 한국주조공학회지
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• 제18권5호
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• pp.481-487
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• 1998

Shell sand is widely used to make a complex shape castings due to its good collapsibility. When molten metal is poured into the mold, various gases are generated by the thermal decomposition of binder in the shell core. Casting defects such as blow hole and blister come from these gases. If it is possible to predict the evolution of gas quantitatively, it may provide effective solutions for minimizing the casting defects. To examine the gas evolution by shell core quantitatively, casting experiment and calculation were carried out. Gas pressure and gas volume evolved by shell core were measured in the experiment, and temperature distribution in the shell core was obtained by heat transfer analysis. From the result above, prediction on the gas volume evolved during pouring was tried. As forming pressure of the shell core increased and forming temperature decreased, the gas evolution increased. There was a close relationship between the calculated gas volume evolved and the measured one.

• 한국주조공학회지
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• 제6권1호
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• pp.36-46
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• 1986

The effects of various kind of molds on cast structures were studied in Al-4.5% Cu and Al-8% Cu alloys. Five kinds of sand molds which were mixed with different binders and a metal mold were used. Density, dendrite arm spacing and dendrite arm length of the cast alloys were greatly affected by quantities and materials of mold binders. The macrostructures examined were entirely equiaxed grains with little influences of types of molds. It is possibly due to the separation of growing crystals from the mold wall at the inital stage of solidification.

• 한국지반공학회논문집
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• 제16권4호
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• pp.17-30
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• 2000

본 연구의 목적은 폐주물사-플라이애쉬 혼합재료의 옹벽 뒷채움재 이용시 옹벽에 작용하는 토압과 안정성에 대한 특성을 평가하는 것이다. 세종류의 폐주물사(생형사, 후란사, 코티드사)와 ASTM 분류 기준 F 등급의 플라이애쉬를 이용한 유동성 뒷채움재의 옹벽 적용성평가를 위해 인위적 변위제어 실험 및 자유변위제어실험을 이용하여 모형옹벽실험을 수행하였다. 인위적 변위제어실험의 경우 유동성 뒤채움의 타설 직후 토압계수의 크기는 0.8~1 사이의 값으로 나타났고, 약 12시간이 경과하면 옹벽에 작용하는 토압이 상당부분 저감되었다. 2단계 타설 방법을 적용한 자유변위실험의 경우, 슬러리 형태의 유동성 뒤채움재의 타설초기에 후란사와 코티드사 혼합재는 빠른 배수효과에 의해 토압 경감 효과가 빨리 나타났지만, 1일 후의 토압은 같은 양생시간의 생형사에 비해 크게 유지되었다. 모형실험의 자유변위제어 실험결과를 이용한 안정성 해석으로부터 6m 옹벽에 타설할 수 있는 뒤채움재의 시공단계별 1차타설 높이 및 2차타설 높이는 생형사의 경우 3.9m 및 3.57m, 후란사의 경우 4.07m 및 3.64m, 코티드사의 경우 3.86m 및 3.54m, 혼합사의 경우 3.9m 및 3.44m로 결정되었고, 실제 옹벽의 뒤채움 높이 5.4m보다 크므로 2단계 시공으로 옹벽의 뒤채움을 완공할 수 있는 것으로 판정되었다. 또한 재료의 양생특성에 따른 옹벽의 안정성은 양생기간이 경과함에 따라 더욱 증가되는 결과를 나타내었다.

• 한국주조공학회지
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• 제7권4호
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• pp.366-379
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• 1987

The influences of some factors on the variation of compression strength of $CO_2$ process were investigated with an attention given to use of high $SiO_2\;/Na_2O$ silicate, addition of organics and gassing operation. 1) Higher ratio binder offers faster rates of hardening with lower $CO_2$ consumption requiring more concentration for a good strength development. A mixture containing 4 percent of 2.7:1 ratio silicate produces the strength above $8kg\;/\;cm^2$ after 80 seconds gassing, but 5% and 6% respectively of 3.0:1 and3.3:1 ratio silicate are necessary to achieve equivalent levels of strength. 2) The correct water content in sand mixtures containing higher ratio silicates is necessary for the better strength properties to be obtained. The addition of 1% water to the sand mixtures bonded with 5%,3:1 ratio and 6%,3.3:1 ratio silicates maintains near-maximum strength on extended gassing. 3) When higher ratio silicates with 3:1 and 3.3:1 ratios are used,the addition of organic additives such as oil, sucrose and polyol results in considerable changes in strength. The presence of 1.0 to 1.5 percent of polyol produces a noticiable improvement 4) Gas diluted with air raises the efficiency of gas utilization. When gas contains 50 percent $CO_2$, the efficience is significantly increased with the best strength in the silicates having high ratios of 3:1 and 3.3:1. 5) The strength of molds is liable to change on storage with the reduction in water content. The magnitude of the strength change is determinded with the mole ratio. The presence of polyol in the mixture with 3.3:1 ratio silicate has a pronounced effect on maintaining the gassed strength.

• 한국주조공학회지
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• 제26권1호
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• pp.17-26
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• 2006

The substitution of cooling method from water quenching to air cooling after solution heat treatment was aimed for the development of a convenient and economical heat treatment process of duplex stainless steels without deterioration of mechanical and corrosion resistant properties for the industry. In order to achieve this goal, the mechanical properties and corrosion properties of a ASTM A890-4A duplex stainless steel were systematically investigated as functions of casting condition and cooling method after solution heat treatment. A 3-stepped sand mold and a permanent Y-block mold were used to check the effects of solidification structure and cooling rate after solution heat treatment. The microstructural characteristics such as the ferrite/austenite phase ratio and the precipitation behavior of ${\sigma}$ phase and carbides were investigated by combined analysis of OM and SEM-EDX with an aid of TTT diagram. Hardness and tension test were performed to evaluate the mechanical properties. Impact property at $-40^{\circ}C$ and corrosion resistance were also examined to check the possibility of the industrial application of this basic study. Throughout this investigation, air-cooling method was proved to effectively substitute for water-quenching process after the solution heat treatment, when the duplex stainless steel was sand mold cast with a thickness below 15 mm or permanent mold cast with a thickness below 20 mm.

• 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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• 제11권1호
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• pp.54-62
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• 1991

A computer program which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of steel castings. The pre-processor is used for mesh generation in a small personal computing system. The modified finite difference method is adopted for the main solidification simulation algorithm. The post -processor graphically presents the simulation results and shows the formation of shrinkage defects. Several experiments on large steel castings in sand mold were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. Several numerical examples for the prediction of shrinkage cavity in large steel casting of SC42 and SCNCrM2 alloys are compared with experimental results. The effect of sleeve and chills on solidification patterns are also studied. Formation of shrinkage defects for the three cases of experimental castings are relatively well predicted by present model.