• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2007.05a
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• pp.131-134
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• 2007

A semi-solid forming technology has a lot of advantages compared to the die casting, squeeze casting and hot/cold forging, so semi-solid forming has been studied actively. Semi-solid forming has two methods. One is thixoforming with reheating of prepared billet, the other is rheoforming with cooled melt until semi-solid state. Thixoforging technology can produce non-dendritic alloys for semi-solid forming complex shaped parts in metal alloys. In this study, the thixoforging was experimented with made rheology materials by the spiral stirrer equipment. Rheology materials for forging were made by A356 casting aluminum alloy and A6061 wrought aluminum alloy. After experiment, forged samples were measured microstructure and were heat treated for high mechanical properties.

• Transactions of Materials Processing
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• v.11 no.4
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• pp.312-322
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• 2002

In this study, an innovative semi-solid die casting technology to replace heavier cast iron compressor parts with lightweight aluminum castings was proposed, and the application possibility for home-appliance component was investigated. The most important factors regarding the semi-solid die casting process are the reheating process of the raw materials to the semi-solid state, specifications of the forming machine, the optimal injection conditions and die design. Materials used in this study were A3S7 and hSn alloys fabricated by the electromagnetic stirring process. The optimal injection conditions for semi-solid die casting process were Presented with the reheating conditions of the semi-solid materials. To investigate the effect of plunger tip shape on the formability and mechanical properties in semi-solid die casting process for complicated shape part, two kinds of plunger tip shape with long and short plunger tip taper are proposed.

• Journal of Korea Foundry Society
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• v.18 no.3
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• pp.246-253
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• 1998

Precision metal mold casting process is a casting method manufacturing mechanical elements with high precision, having heavy/light alloys as casting materials and using permanent mold. To improve dimensional accuracy and the final mechanical properties of the castings, the solidification speed and the cooling rate of the casting should be controlled with the optimum mold cooling system, and moreover, to obtain more accurate control of the whole process interfacial heat transfer characteristic at the mold/casting interface must be studied in advance. In the present study, aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling system was designed and the temperature histories at points inside the metal mold were measured during the casting process. The heat transfer phenomena at the mold/casting interface was characterized by the heat flux between solidifying casting metal and metal mold, and the heat flux history was obtained using inverse heat conduction method. The effect of mold cooling condition upon the heat flux profile was examined, and the analysis shows that the heat flux value has its maximum at the beginning of the process.

• Journal of Korea Foundry Society
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• v.41 no.1
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• pp.3-10
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• 2021

In the compound casting between the aluminum alloy and the cast iron, the iron component may be dissolved from the cast iron during the process and mixed into the aluminum melt, thereby forming various iron-containing intermetallic compounds and significantly deteriorating the tensile properties of the aluminum alloy. On the other hand, unlike Fe, which is added as an impurity, Cu is added to improve the mechanical properties of the aluminum alloy. In this study, the change in microstructure and tensile properties of aluminum alloys due to the addition of Fe and Cu was investigated. A large amount of iron-containing compounds such as coarse Al₅FeSi phases were formed when the iron content was 1% or more, and the tensile properties were significantly reduced. In the case of the aluminum alloy to which Cu was added, an Al₂Cu phase was additionally formed and the tensile strength was clearly improved.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.11
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• pp.62-67
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• 1999

The RP&M(Rapid Prototyping and Manufacturing) is the most appropriate technology for the small-lot production system, in which the production cycle is getting shorter owing to various needs from consumers. Recently RP products which are made of plastics, wax, and paper are used to verify the design of samples. But these products cannot be applied to the real mold because the strength enough to be a mold cannot be given by soft materials such as plastics. So RP products are copied to AFR(Al powder Filled Resin) molds or metal molds, which is called the RP&M. In this paper, RP&M is applied to a casting process. A porous casting mold, which is made from ceramic powder and binder, is used for rapid tooling of aluminum shoes molds.

• Journal of the Korean Society of Industry Convergence
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• v.9 no.2
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• pp.141-145
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• 2006

In case of sense case manufactured by method of outage capacity, sensitivity is declined by outside effect and method of the photo electricity has a problem in transmission. therefore, packing case of composite sense should be developed to improve such a problem about influence of outside environment and its property evaluation has been performed. Mechanical property and result of analysis & test evaluation of Mat'l on aluminum die-casting(ADC 12type) Mat'l developed are as following. Tensile test piece, No. 4 of KS B 0801, has been applied to mechanical property test of Mat'l and It has been tested by method of metal mat'l tensile test(KS B 0802 : 2003). It can be found that physical property to KS(Korea Standard) is excellent. and homogeneous mechanical property appears. Test of Mat'l analysis has been performed by using OE Spectrometer, according to ASTM E 1251 : 1994 regulation. Consequently, good and homogeneous component contents classified by element to standard, except for Fe, have been obtained with coordination of Fe content as below 1.3% from composition standard of Aluminum Die-casting.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.06a
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• pp.135-147
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• 1997

The production of light metal parts using aluminum is mainly performed by die casting and squeeze casting, which directly fabricate the required shape from the liquid state. However, die casting is subject to defects such as shrinkage porosity and air trapped when molten metal enters the cavity, whilst squeeze casting also has defects due to turbulent flow in the die cavity. Both diecasting and sqeeze casting have inhomogeneous mechanical property in terms of dendritic structure during solidification. Active research has been carried out on semi-solid processing, rather than on conventional process methods such as die casting, which involve various problems. Therefore in this paper, to introduce the fundamental technology for d e design, in die casting and forging process with semi-solid materials, relationship between stress and strain of semi-solid materials, and for producing parts die design has been proposed as parameters of globulization of the microstructure and gate shape. The prevention of various defects to produce sound parts are also introduced.

• Journal of Korea Foundry Society
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• v.22 no.3
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• pp.137-143
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• 2002

Silica sand, zircon sand, and steel shots were used as mold packing materials in lost foam casting of the aluminum alloy bar. Vibration acceleration in three directions and temperatures in the casting and mold were measured, and packing and cooling characteristics of these materials were investigated. Packing densities increased with increase in vibration magnitude and time, and were $1.41{\sim}1.49g/cm^2$ for silica sand, $2.54{\sim}2.86g/cm^2$ for zircon sand, and $3.92{\sim}4.52g/cm^2$ for steel shots. Sound castings were obtained only without evacuation of the flask during pouring. Solidification time became faster in order of silica sand, zircon sand and steel shot packing because steel shot has the highest cooling capacity of them. Solidification time of steel shot packing was shortened to about 1/2 of silica sand packing. Cooling capacity of sand mold was generally evaluated by heat diffusivity of the mold, however could be simply evaluated with specific heat per unit volume of the packing material in lost foam casting.

• Korean Journal of Materials Research
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• v.22 no.2
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• pp.97-102
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• 2012

The microstructure and tensile properties of Al-Mn/Al-Si hybrid aluminum alloys prepared by electromagnetic duocasting were investigated. Only the Al-Mn alloy showed the typical cast microstructure of columnar and equiaxed crystals. The primary dendrites and eutectic structure were clearly observed in the Al-Si alloy. There existed a macro-interface of Al-Mn/Al-Si alloys in the hybrid aluminum alloys. The macro-interface was well bonded, and the growth of primary dendrites in Al-Si alloy occurred from the macro-interface. The Al-Mn/Al-Si hybrid aluminum alloys with a well-bonded macro-interface showed excellent tensile strength and 0.2% proof stress, both of which are comparable to those values for binary Al-Mn alloy, indicating that the strength is preferentially dominated by the deformation of the Al-Mn alloy side. However, the degree of elongation was between that of binary Al-Mn and Al-Si alloys. The Al-Mn/Al-Si hybrid aluminum alloys were fractured on the Al-Mn alloy side. This was considered to have resulted from the limited deformation in the Al-Mn alloy side, which led to relatively low elongation compared to the binary Al-Mn alloy.

• Transactions of the Korean Society of Automotive Engineers
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• v.20 no.4
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• pp.52-59
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• 2012

The subframe has been generally manufactured by using stamped steel material. Recently, automotive designers are considering aluminum as lightweight material. This paper describes the development process of an aluminum subframe which is made by high level vacuum die casting process, which is beneficial for minimizing gas contents and material properties. The weight of manufactured subframe is reduced by 4kg with the comparison of steel subframe. The aluminum subframe is packaged for the current vehicle layout and the imposed requirement is to attain a better structural performance that is evaluated in terms of mounting stiffness, noise and vibration, and endurance performance. The NVH evaluation results show that sound level is decreased by 8dB with the help of high roll-rod mounting stiffness as well as high structural modes.