• Journal of the Korean Ceramic Society
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• v.47 no.4
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• pp.283-289
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• 2010

Physical properties of Plasma electrolytic oxidized 8 different kinds of Al alloys, A-1100, A-2024, A-5052, A-6061, A-6063, A-7075, ACD-7B and ACD-12 were investigated. The electrolyte for PEO was $Na_2SiO_3$ and NaOH and some alkali earthen metal salts system solution. $\eta$-alumina, as well as $\gamma$-alumina, was main crystal phase, which were ever reported. Also, $Al_{4.95}Si_{1.05}O_{9.52}$ was found only in this research. So we can conclude that the process conditions of PEO apparatus and composition and concentration of its electrolyte affects crystal structure and physical properties of PEO layers much more than the compositions of Al alloy.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.1240-1243
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• 2005

The wrinkling in the flange and wall of a part is a predominant failure mode in stamping of sheet metal parts. In many cases this wrinkling may be eliminated by appropriate control of the blank holding force(BHF), but BHF affects the draw depth. Gotoh had studied the wrinkles under $20{\mu}$ in height. In general, the height of wrinkles could be limited under $200{\mu}$ practically. Therefore small BHF can be allowed so that the depth of drawing could be increased. This paper represents the variation of the wrinkles of flange in the part of cup drawing by using aluminium alloy A1050 and A5052. This simulation is used by the explicit finite elements code $PAM-STAMP^{TM}$. The computed results are compared with the experimental results to show the validity of the analysis.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.33 no.3
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• pp.276-282
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• 2009

Wrinkling in the flange and wall of a deep-drawn part is one of the major defects in sheet metal processes. Wrinkling is influenced by many factors, such as material properties, shape of the body, forming conditions, stress state and thickness, etc. It is difficult to analyze the wrinkling initiation and growth according to the factors because the effects of the factors are very complex and the wrinkling behavior may show wide variation even though small deviation of factors. In this study, the influence of wrinkling parameters, such as material properties (Al1050, Al5052), the blank holding force and the drawing depth on the wrinkling initiation and growth is investigated by using the experimental method and the dynamic explicit finite element analysis. From the results, it is shown that the dynamic explicit finite element method can be used effectively to prevent the wrinkling problems advancely in the deep drawing process. Also, there is a good agreement between the experimental result and the dynamic explicit finite element analysis.

• Transactions of Materials Processing
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• v.22 no.4
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• pp.189-195
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• 2013

In this study, the weld strength of extru-rivet spot welding was investigated by simulation and experiment. In order to obtain hot plasticity flow bonding of the two plates by a single rivet, electrodes are used for heating of the two plates and the rivet by electric resistance. Because weld strength is influenced by the temperature in the weld zone, the diameter of the electrodes and the amount of current supplied to the electrodes are important variables. For the simulation, heat distribution and weld strength were calculated using DEFORM-3D. The weld strength in the weld zone was calculated for various values of the experimental parameters. The simulation results showed that the weld strength was the highest when the weld current was 37kA, the electrode diameter was 12mm, and the welding frequency was 90cycle. Aluminum 5052 was used for the experimental study. A total of three aluminum plates, two welding plates with 1mm thickness and one plate with 2mm thickness for the inserting rivet, were used for the experimental extru-rivet spot welding.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
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• 1996.03a
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• pp.188-193
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• 1996

This study was performed the blankholding force and vee-ring effects on Blanking characteristics, such as maximum blanking force, burnish, dish-shape, hardness. etc, in fine-blanking die by the experimental method. Two types of aluminum (Al. 1050-0, Al 5052-H) Such as annealed and unannealed materials were used for the experiment. In order to get a hydrostatic pressure effect, the clearance was set to 0.5% of the thickness of strip, and the counter punch and stripper plate with Vee-ring was set-up. While this experiment was carrying out, the average blanking Velocity was constant (37.5mm/sec) As a result of this study, we got a good surface roughness and a glassy shear plane(burnish) of the sheet over 90% thickness, and such as the excellent accuracy of dimensions, the good squareness and the reduction of dish-shape could be obtained, and also the additional results obtained were such that the hardness of shear plane was increased and the maximum blanking force was reduced in the condition of Vee-ring height of 1.0~1.5mm, and blankholding force of 1200kg.

• Journal of the Korean institute of surface engineering
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• v.48 no.2
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• pp.68-72
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• 2015

The corrosion behavior of metals and alloys for the safety of offshore structures in seawater was investigated for the application of sacrificial anodes. The experiments were focused on the polarization behaviors and the surface morphology of each metal after experiments. Pure Zn, pure Al (Al1050), Al alloys (Al5052, Al6061), Mg alloys (AZ31, AZ91D) and steel (SCM440) were assessed in 3.5% sodium chloride solution by means of potentiodynamic polarization to verify the galvanic corrosion potential ($E_{couple}$). Potentiostat plots were plotted to compare the surface and corrosion current density ($i_{couple}$) of metals as sacrificial anodes in seawater to protect steel alloy as a cathode. Al alloys showed the best performance as a sacrificial anode, on the other hand, Mg alloys showed overprotection behavior. The surface morphologies of sacrificial anodes were observed by FESEM and compared.

• Transactions of Materials Processing
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• v.26 no.3
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• pp.174-180
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• 2017

In this study, a new spot welding with electric resistance heated dies is suggested for the spot welding of non-ferrous metal plates for drawing and concurrent spot welding. This welding method involves two heating processes such as heating by conduction of electric resistance heated dies and heating by resistance between contacted surfaces of two plates by welding current induced to copper dies for the fusion of contacted metal. This welding process has welding variables such as current induced in heated and copper dies, the inner diameters of heated dies, and edge shape of the copper dies. Experimental conditions for each current should be established to get successful welding strength. The welding strength could reach to the desired value in industrial fields under the following conditions of contact diameters of heated dies in this case of overlapped aluminum5052 plates with 0.3-mm thickness: inner and outer diameters of 5.0 and 16mm, respectively; diameter of copper dies, 5.0mm; heating current, 6.8kA in heated steel dies; welding current, 8.6 kA in copper dies.

• Korean Journal of Metals and Materials
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• v.49 no.11
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• pp.893-899
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• 2011

Fabrication of a complex aluminum alloy by the ARB process using dissimilar aluminum alloys has been carried out. Two-layer stack ARB was performed for up to six cycles at ambient temperature without a lubricant according to the conventional procedure. Dissimilar aluminum sheets of AA1050 and AA5052 with thickness of 1 mm were degreased and wire-brushed for the ARB process. The sheets were then stacked together and rolled to 50% reduction such that the thickness became 1 mm again. The sheet was then cut into two pieces of identical length and the same procedure was repeated for up to six cycles. A sound complex aluminum alloy sheet was successfully fabricated by the ARB process. The tensile strength increased as the number of ARB cycles was increased, reaching 298 MPa after 5 cycles, which is about 2.2 times that of the initial material. The average grain size was $24{\mu}m$ after 1 cycle, and became $1.8{\mu}m$ after 6 cycles.

• Journal of Powder Materials
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• v.31 no.1
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• pp.37-42
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• 2024

Friction stir spot welding (FSSW) is a solid-state joining process and a rapidly growing dissimilar material welding technology for joining metallic alloys in the automotive industry. Welding tool shape and process conditions must be appropriately controlled to obtain high bonding characteristics. In this study, FSSW is performed on dissimilar materials AA5052-H32 aluminum alloy sheet and SPRC440 steel sheet, and the influence of the shape of joining tool and tool insertion depth during joining is investigated. A new intermetallic compound is produced at the aluminum and steel sheets joint. When the insertion depth of the tool is insufficient, the intermetallic compound between the two sheets did not form uniformly. As the insertion depth increased, the intermetallic compound layer become uniform and continuous. The joint specimen shows higher values of tensile shear load as the diameter and insertion depth of the tool increase. This shows that the uniform formation of the intermetallic compound strengthens the bonding force between the joining specimens and increases the tensile shear load.

• Transactions of Materials Processing
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• v.19 no.8
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• pp.460-467
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• 2010

It was studied that two plates of aluminum can be welded by extru-riveting experiments with extru-rivet welding dies, and that the welding strength and metal flow on the welding section were analyzed by computer simulation according to the welding variable such as the diameter of extrusion insert dies. It was known by computer simulation that welding strength on the welding section of plates could be influenced by the diameter of extrusion insert dies. And it was known by experiments that two plates of aluminum can be welded on a spot point on aluminum plate by extru-rivet welding process, and that welding strength is higher and higher if the diameter of extrusion insert die is smaller and smaller, and that welding strength is the highest when diameter of extrusion insert dies is ${\emptyset}4.2$mm in the case that the diameter of rivet is 5 mm, when aluminum 5052 two plates with 1.5 mm thickness and one plate with 3mm thickness for rivet plate are used as welding material.