• 한국주조공학회지
• /
• 제28권3호
• /
• pp.136-140
• /
• 2008

A new concept of salt core, a melting temperature of which is lower than the solidus temperature of cast alloy, was introduced to produced an integrated casting part having a complicated inner shape or requiring under-cut in high pressure die casting or squeeze casting process. The main goal of this study is to develop a new integrated net-shape forming technology using fusible core of lower melting temperature than that of a casting alloy. This integrated net-shape forming technology would be very successful and cost-effective for producing the integrated products having a complicated inner shape or requiring under-cut. The technology for measuring and evaluating a various property of fusible core such as a thermal conductivity and thermal expansion coefficient, melting temperature was established. Also, the work space can be cleaned without a pollution inducing products.

• 대한기계학회논문집A
• /
• 제26권10호
• /
• pp.2104-2113
• /
• 2002

A finite element model is developed for the process of squeeze casting of metal matrix composites (MMCs) in cylindrical molds. The fluid flow and the heat transit. are fundamental phenomena in squeeze casting. To describe heat transfer in the solidification of molten aluminum, the energy equation is written in terms of temperature and enthalpy are applied in an axisymmetric model which is similar to the experimental system. A one dimensional flow model simulates the transient metal flow. A direct iteration technique was used to solve the resulting nonlinear algebraic equations, using a computer program to calculate the enthalpy, temperature and fluid velocity. The cooling curves and temperature distribution during infiltration and solidification were calculated fer pure aluminum. Experimentally, the temperature was measured and recorded using thermocouple wire. The measured time-temperature data were compared with the calculated cooling curves. The resulting agreement shows that the finite element model can accurately estimate the solidification time and predict the cooling process.

• 한국정밀공학회:학술대회논문집
• /
• 한국정밀공학회 2005년도 추계학술대회 논문집
• /
• pp.786-789
• /
• 2005

The proper parameters in a twin roll strip casting are important to obtain the stabilization of the Mg sheet. What is examined in this paper is the quantitative relationships of the important control parameters such as the roll speed, height of pool region, outlet size of nozzle, solidification profile and the final point of solidification in a twin roll strip casting Unsteady conservation equations were used for transport phenomena in the pool region of a twin roll strip casting in order to predict a velocity, temperature distributions of fields and a solidification process of molten magnesium. The energy equation of cooling roll Is solved simultaneously with the conservation equations of molten magnesium In order to consider the heat transfer through the cooling roil. The finite difference method (2-D) and the finite element method (2-D) are used in the analysis of pool region and cooling roil to reduce computing time and to improve the accuracy of calculation respectively.

• 자원리싸이클링
• /
• 제4권1호
• /
• pp.25-30
• /
• 1995

본 연구에서는 Al 스크랩으로부터 재생지금 제조시 시료의 예비처리, 용제첨가 및 용해분위기가 Al 회수율에 미치는 영향을 조사하였다. 실험결과에 따르면 Al 드로스는 용탕표면에서의 산화반응에 의해 발생하였다. 예비처리의 영향에 다르면 탈지하지 않고 압착한 칩 bale 시료의 경우에는 압착하지 않은 칩 시료에 비해 약 14%의 회수율이 증가하였으며, Al seed 용해공법을 채택하는 경우에는 탈지하지 않고 단지 세편과 압착만을 행하여도 97%의 높은 회수율을 얻을 수 있었다. Al 스크랩 용해시 7wt%까지 첨가된 염에 의해 회수율은 최대 95%까지 증대되었으며, 탄소 및 질소분위기에서도 역시 회수율은 증가하였으나, 염과 탄소의 혼합분 첨가시 과잉 첨가된 탄소는 오히려 회수율을 감소시켰다.

• 대한금속재료학회지
• /
• 제46권6호
• /
• pp.382-389
• /
• 2008

To manufacture Al MMCs, in-situ melt mixing process is used because it is free from contamination, and it makes reinforcements homogeneously dispersed. Large eddy simulation method is used to find the optimum melt mixing condition. At the Re 3000, the most suitable mixing is occurred between Al-Ti and Al- B melts. The in-situ formed $TiB_2$ particles has the size varying from 40 nm to 130 nm, due to the increase of cooling rate, and exhibits a homogeneous dispersion. And the interface between reinforcement and matrix is clean. Both hardness and Young's modulus of this composite are improved with increasing the cooling rate.

• 대한금속재료학회지
• /
• 제50권1호
• /
• pp.28-33
• /
• 2012

Ball-milled Ni-Al powder compacts have been synthesized by the heat of molten cast iron and have been coated on cast iron. The effects of the ball-milling time on the microstructure of the intermetallic coatings have been investigated. The experimental results showed that the ball-milled Ni-Al powder compacts were completely reacted and were successfully coated on the cast iron without re-melting the substrate. Densification of the coating layers was enhanced by increasing the ball-milling time. This might be attributed to the fact that the heat released during the intermetallic reaction was dispersed over a prolonged reaction time by the ball-milling of the elemental powders.

• 한국정밀공학회지
• /
• 제13권3호
• /
• pp.110-122
• /
• 1996

Finite element analysis tool was developed to analyze the casting process. Generally, casting process consists of mold filling and solidification. Both filling and solidication process were simulated simultaneously to investigate the effects of process variables and to predict the defect. At filling process, thermal coupling was especially considered to investigate thermal history of material during the filling stage. And thermal condition at the final stage of filling is used as the initial conditions in a solidification process for the exact simullation of the actual casting processes. At mold filling process, Lagragian-type finite element method with automatic remeshing scheme was used to find the material flow. A perturbation method with artificial viscosity is adopted to avoid numerical instability in low viscous fluid. At solidification process, enthalpy-based finite element method was used to solove the heat transfer problem with phase change. And elastic stress analysis has been performed to predict the thermal residual stress. Through the FE analysis, solidification time, position of solidus line, liquidus line and thermal residual stress are found. Through the study, the importance of combined analysis has been emphasized. Finite element tools developed in this study will be used process design of casting process and may be basic structure for total CAE system of castings which will be constructed afterward.

• 한국정밀공학회지
• /
• 제14권12호
• /
• pp.73-85
• /
• 1997

The rolling force and roll deformation behavior in the twin roll type strip continuous casting process has been computed to estimate the thermal charcteristics of a caster roll. To calculation of rolling force, the relationship between flow stress and strain for a roll material and casting alloy are assumed as a function of strain-rate and temperature because mechanical properties of a casting materials depends on tempera- ture. The three dimensional thermal dlastic-plastic analysis of a cooling roll has also been carried out to obtain a roll stress and plastic strain distributions with the commercial finite element analysis package of ANSYS. Temperature fields data of caster roll which are provided by authors were used to estimated of roll deformation. Roll life considering thermal cycle is calculated by using thermal elastic-plastic analysis results. Roll life is proposed as a terms of a roll revolution in the caster roll with and without fine failure model on the roll surface. To obtain of plastic strain distributions of caster roll, thermomechan- ical properties of roll sleeve with a copper alloy is obtained by uniaxial tensile test for variation of temperature.

• 한국주조공학회지
• /
• 제17권6호
• /
• pp.560-568
• /
• 1997

The dissolution behavior of secondary solidification phases in squeeze cast Al-3.9wt%Cu-1.5wt%Si-1.0wt%Mg has been studied using a combination of optical microscope, image analyzer, scanning electron microscope(SEM), energy dispersive spectrometer(EDS), X-ray diffractometer(XRD) and differential thermal analyzer (DTA). Special emphasis was placed on the investigation of the effects of the nonequilibrium heat treatment on the dissolution of the second solidification phases. Ascast microstructure consisted of primary solidification product of ${\alpha}-Al$ and secondary solidification products of $Al_2Cu$, $Mg_2Si$ and $Al_2CuMg$. Equilibrium and non-equilibrium solution treatments were carried out at the temperatures of $495^{\circ}C$, $502^{\circ}C$ and $515^{\circ}C$ for 3 to 5 hours. The amount of the dissolved secondary phases increased with increasing solution treatment temperature, for example, area fractions of $Al_2Cu$, $Mg_2Si$ and $Al_2CuMg$ were approximately 0%, 1.6% and 4.2% after solution treatment at $495^{\circ}C$ for 5hours, and were approximately 0%, 0.36% and 2% after solution treatment at $515^{\circ}C$ for 5hours. The best combination of tensile properties was obtained when the as-cast alloy was solution treated at $515^{\circ}C$ for 3hours followed by aging at $180^{\circ}C$ for 10 hours. Detailed DTA and TEM study showed that the strengthening behavior during aging was due to enhanced precipitation of the platelet type fine ${\theta}'$ phase.

• 한국HCI학회:학술대회논문집
• /
• 한국HCI학회 2008년도 학술대회 1부
• /
• pp.813-816
• /
• 2008

본 연구에서는 주물의 유통해석결과를 3차원 모델로 복원하여 가상현실 디스플레이 상에 가시화 하는 방법을 제안한다. 먼저 기존 CAE 해석 소프트웨어를 사용하여 유한차분법 기반 열유동 수치해석을 수행한다. 이 과정에서는 주물의 설계모델은 그 형태가 규칙적인 사각형 격자에 근사되며 용탕을 주형에 주입하는 것을 시작으로 충전이 완료될 때까지 사전에 정의된 단계수만큼 반복적으로 전체 복셀에 대한 충전도와 온도수치가 기록된다. 다음 단계에서는 그 결과별 입력으로 하여 복셀 단위로 주울 형태를 복원한다. 이 때 유통진행에 따른 각 단계에서 각 복셀의 충전여부와 온도수치를 색상에 대응시켜 복셀의 색상을 결정한다. 복원 모델은 수평형 가상현실 디스플레이 장치인 Projection Table 상에서 가시화 하였으며 액티브 스테레오 방식으로 입체화면을 제공한다.