• Composites Research
• /
• v.15 no.1
• /
• pp.32-40
• /
• 2002

This study developed fabrication process of $SiC_p/Al$ metal matrix composites as electronic packaging materials by squeeze casting method. The $SiC_p$ preform were fabricated in newly designed preform mold using about 0.8 % of inorganic binder(SiO$_2$) and 5 vol.% of $Al_2O_3$fiber. To infiltrate the molten metal into the preform, fabrication condition such as the temperature and the pressure were selected. Applying the fabrication conditions, heat transfer analysis were preformed using finite element method and thus analyzed the temperature distribution and cooling characteristic during the squeeze casting. For the fabricated composites, impact toughness and thermal expansion coefficient were measured. The metal matrix composites developed in this study have 0.2~0.3 J impact toughness, $8~10 ppm/^{\circ}C$ thermal expansion coefficient and $2.9~3.0g/cm^3$density which is appropriate properties for electronic packaging application.

• Journal of the Korean Society for Precision Engineering
• /
• v.18 no.7
• /
• pp.167-173
• /
• 2001

The simulated die-casting process in which the traditional plaster casting process is combined with Rapid Prototyping technology is being used to produce AI, Mg, and Zn die-casting prototypes. Unlike in the die-casting process, molten metal in the conventional plaster casting process is fed via a gravity pour into a mold and the mold does not cool as quickly as a die-casting mold. The plaster castings have much larger and grosser grain structure as compared with the normal die-castings and the thin walls of the plaster mold cavity may not be completely filled. Because of lower mechanical properties induced by the large grain structure and incomplete filling, the conventional plaster casting process is not suitable for the trial die-casting process to obtain quality prototypes. In this work, an enhanced trial die-casting process has been developed in which molten metal in the plaster mold cavity is vibrated and pressurized simultaneously. Patterns for the casting are made by Rapid Prototyping technologies and then plaster molds, which have a runner system, are made using these patterns. Pressurized vibration to imparted molten metal has made grain structure of castings much finer and improved fluidity of the molten enough to obtain complete filling at thin walls which may not be filled in the conventional plaster casting process..

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.19 no.6
• /
• pp.1422-1430
• /
• 1995

Al6061 alloy reinforced with 15 volume% of Saffil fibers was fabricated by squeeze infiltration method. Uniform distribution of reinforcements and good bondings between reinforcements and matrix alloy were found in the microstructure of composites. Comparing with A16061 matrix alloy, tensile strength and elastic modulus of $Al_{2}$O$_{3}$/Al composites were increased up to 26% and 31%, respectively. Cyclic deformation and fatigue behavior of $Al_{2}$O$_{3}$/Al metal matrix composites were studied. The specimens were cycled using tension-tension(R=0.1) loading and under load controlled fatigue test. Cyclic stress-displacement curve through fatigue test was obtained. Fatigue strength of $Al_{2}$O$_{3}$/Al composites was about 200 MPa, i.e.0.55 of applied stress level(q). During fatigue test, $Al_{2}$O$_{3}$/Al composites displayed cyclic hardening at all applied stress levels. The most of resultant displacement due to permanent plastic deformation occurred in less than the first 5% of fatigue life. Displacement-to-failure of the fatigue test was smaller than that of the tensile test because of accumulative damage by cumulative plastic deformation.

• Korean Journal of Materials Research
• /
• v.16 no.11
• /
• pp.668-675
• /
• 2006

In the partial squeeze casting process, the filling behavior of liquid metal and solidification pattern in thick area have significant influence on the quality of casting products and die life. For the optimal casting design of automobile transmission gear housing, various analyses were performed in this study by using computer simulation code, MAGMAsoft and the simulation results were compared and analyzed with experimental results. By air pressure criteria, internal porosities caused by air entrap during the mold filling were predicted and reduced remarkably by modification of gating system. Also, optimal squeeze-time lag to apply partial squeeze pin in thick area was calculated and the castings was free from shrinkage defects with the result of solidification analysis. Consequently, casting design for automobile transmission gear housing was optimized and approved by Computer Tomography.

• Journal of the Korean Institute of Gas
• /
• v.26 no.6
• /
• pp.16-23
• /
• 2022

In this study, characteristics of effect on hydrogen gas was investigated to hydrogen embrittlement by disk and tensile tests. The developed and commercial alloy was fabricated to a plate material made from an alloy ingot. The prepared materials were processed in the form of a disk to measure rupture pressure by hydrogen and helium gas at a rate of 0.1 to 1,000 bar/min. In the hydrogen pre-charged tensile test, a specimen was hydrogenated using an anode charging method, and the yield strength, ultimate tensile strength, elongation, and reduction in area rate were carried by a strain rate test. Also, the microstructure was observed to the fracture surface of the tensile test specimen. As a result, the developed materials satisfied endurable hydrogen embrittlement, and the fractured surface showed a brittleness fracture surface with a depth of several ㎛, but dimple due to ductile fracture could be observed.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.20 no.3
• /
• pp.753-764
• /
• 1996

The metal matrix composites(MMC) are currently receiving a great deal of attention. These composites possess exellent mechanical and physical properties such as modulus, strength, wear resistance and thermal stability, which make them very attractive for use in automotive piston. In this study, $Al/{Al_2}{O_3}$(15%) composites are fabricated by the squeeze casting method. Mechanical properties such as tensile strength and ductility are performed at room and elevated temperature($250^{\circ}C$ and $350^{\circ}C$), respectively. Through thermomechanical analyser, thermal expansion coefficient of $Al/{Al_2}{O_3}$ composites are conducted for ranging from room temperature to ($400^{\circ}C$.And bending fatigue tests are also performed by the rotary bending machine at room temperature.The tensile strength and elastic modulus have been improved up to 38% and 35% by the addition of the reinforcements, respectively. Thermal expansion coefficients of MMCs which is located normal and parralel to the applied pressure are showed slightly different less than 10%. Fatigue strengh of the composite was improved by about 20% compared with that of unreinforced Al alloy. The results of this study will be used to understand the basic fracture behavior of MMCs and eventually to expand the applocation of MMCs as a machine parts undertaken various loadings.

• Composites Research
• /
• v.23 no.2
• /
• pp.10-16
• /
• 2010

$Al_2O_3$ fiber and SiC particle hybrid metal matrix composites (MMCs) were manufactured by squeeze casting method investigated for their tribological properties. The pin specimens had different ratios of fiber to particle content but their total weight fraction was constant at 20 wt. %. Tribological tests were performed with a pin-on-disk friction and wear tester. The investigation of the dry tribological characteristics of hybrid MMCs were carried out at room temperature and elevated temperature of$100^{\circ}C$ and$150^{\circ}C$. The morphologies of worn surfaces were examined by scanning electron microscope (SEM) to observe tribological characteristics and investigate wear behavior. The results revealed that the wear resistance improved with the content of SiCp increased of the planar random (PR) MMCs at room temperature. At the elevated temperature, it revealed that the wear resistance of normal (N) MMCs was superior to that of the PR-MMCs due to PR-fibers were easily pulled out holistically from the worn surface. Meanwhile, the coefficient of friction decreased with the temperature increasing.

• Composites Research
• /
• v.16 no.1
• /
• pp.1-12
• /
• 2003

This study developed SiC$_{p}$/A1$_2$O$_3$$_{f}$/Al composites for electronic packaging to which reinforcements were added with the volume fractions of 49%, 56% and 63% by the squeeze casting method. 0.8 wt. % of the inorganic binder as well as the A1$_2$O$_3$ fiber and SiC Particles with the volume fraction of 1:10 were added to the composites, which were produced in the newly designed mold. For the produced SiC/Al composites, the CTEs (coefficients of thermal expansion) were measured from 30 to 300 and compared with the FEM numerical simulation to analyze the temperature dependent properties. The experiment showed the CTEs of SiC$_{p}$/A1$_2$O$_3$$_{f}$/Al composites that were intermediate values of those of Rule of Mixture and Turner's Model. The CTEs were close to Turner's Model in the room temperature and approached the Rule of Mixture as the temperature increases. These properties analyzed from the difference of the average stress acting between the matrix and the reinforcements proposed in this study.