• Proceedings of the Korean Society of Precision Engineering Conference
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• 2001.04a
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• pp.905-909
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• 2001

The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

• Journal of Korea Foundry Society
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• v.31 no.5
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• pp.274-283
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• 2011

The vacuum die casting is a promising candidate of the stamping process for fabrication of fuel cell bipolar plate due to its advantages, such as precision casting, mass production and short production time. This study proposes vacuum die casting process to fabricate bipolar plates in fuel cell. Bipolar plates were fabricated under various injection conditions such as molten metal temperature and injection velocity. Also, according to injection velocity conditions, simulation results of MAGMA soft were compared to the experimental results. In case of melt temperature $650^{\circ}C$, misrun occurred. When the melt temperature was $730^{\circ}C$, mechanical properties were low due to dendrite microstructure. Injection velocity has to set at more than 2.0 m/s to fabricate the sound sample. When melt temperature, injection velocity (Fast shot), and vacuum pressure are $700^{\circ}C$, 2.5 m/s and 30 kPa respectively, sample had good formability and few casting defects. Simulation results are mostly in agreement with experimental results.

• Journal of Korea Foundry Society
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• v.13 no.3
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• pp.268-275
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• 1993

In gravity die casting, die cooling systems are frequently employed with water cooling to remove the heat of the solidifying metal. Thermal modeling is an important technique in mold design for improving the productivity of the process. Computer simulation system which consists of pre-processor, main solidification simulator and post-processor has been developed for three dimensional solidification analysis of cyclic gravity die casting. The pre-processor is used for mesh generation in a PC system. The modified finite difference method is adopted for the main solidification simulation algorithm during all the casting cycles. The post-processor graphically presents the simulation results. Several experiments in automotive cast piston were carried out. The temperature variations in casting and mold with time are measured experimentally, and the results are compared with calculation results. The effects of cycle number on solidification pattern are also studied. Several experimental results for the prediction of shrinkage defects are compared with calculated results.

• Journal of Mechanical Science and Technology
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• v.17 no.12
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• pp.2010-2018
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• 2003

Although continuous casting process has highly developed, there still remain many problems to be considered. Specifically, two vortex flows resulting from impingement against narrow walls make a flow field unstable in a mold, and it is directly related to internal and external defects of steel products. To cope with this instability, EMBR (Electromagnetic Brake Ruler) technique has been lately studied for the stability of molten steel flow, and it is revealed that molten steel flow in a mold can be controlled with applied magnetic field. However, it is still difficult to clarify flow pattern in an EMBR caster due to complex correlations among variables such as geometric factors, casting conditions, and the place and the intensity of charged magnetic field. In the present study, flow field in a mold is focused with different conditions of electromagnetic effect. To accurately analyze the case, three dimensional low Reynolds turbulent model and appropriate boundary conditions are chosen. To evaluate the electromagnetic effect in molten steel flow, dimensionless numbers are employed. The results show that the location and the intensity of the applied magnetic field significantly influence the flow pattern. Both impingement and internal flow pattern are changed remarkably with the change of the location of applied magnetic field. It turns out that an insufficient magnetic force yields adverse effect like channeling, and rather lowers the quality of steel product.

• Journal of Korea Foundry Society
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• v.20 no.6
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• pp.400-406
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• 2000

Computer simulation for the predictions of casting defects is very important to produce high quality castings with less cost. Complicate shaped Al solenoid housing part was selected to be cold chamber die cast and a numerical simulation technique was applied for the optimization of the chill vent position and gating. A first design led to insufficient central flow. This flow left the last filled areas falling into the inner portion of the part. And last filled area did not fit the chill vent position. So these resulted in a high possibility of air entrapment in the casting and the design was not proper for the part. The design was improved by using a proper gating system, a more chill vent and proper overflow positions. New design provided a homogenous mold filling pattern and the last filled areas that being located at the overflow and chill vent. Casting plan which produce good quality solenoid housing part was established by using the computer simulation.

• Journal of the Korean Society of Industry Convergence
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• v.23 no.4_1
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• pp.541-547
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• 2020

This paper relates a rheo die casting using electromagnetic force, which is one of the representative semi-solid methods for aluminum. The most important factors in electromagnetic stirring would be the melt temperature, sleeve temperature, electromagnetic force, and input time. The effect of the temperature of molten alloy on the direct rheo-casting is assessed in this study. The temperature of the molten alloy is set to 590 ℃ with a solidification of 40%, 600 ℃ with 30%, and 610℃ with less than 20%. Under the condition of 590 ℃ with a solidification of 40%, the whole molten alloy is solidified, causing non-forming during forming process. Meanwhile, under the condition of 600 ℃, where the solidification was 30%, appropriate amount of molten alloy is solidified, filled well into the mold, resulting in good forming, while at 610 ℃ with the solidification of 20%, the molten alloy is not sufficiently solidified and scattered away. The investigation of the defects inside the product with the help of the X-ray equipment shows that the electromagnetic stirring at 590 ℃ with a solidification of 30% produces many air-pores inside the product.

• Journal of Welding and Joining
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• v.31 no.2
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• pp.57-62
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• 2013

Magnesium has good castability and limited workability, so its products have been manufactured by almost casting processes. In this study, a pulsed Nd:YAG laser was used to butt-weld the sand casting magnesium alloys. And the effect of welding conditions such as peak power, pulse width, welding speed was evaluated in detail. As a result of this study, large underfill and plenty of spatter taken place under the conditions with high peak power. Thus, it is recommended to use low peak power and long pulse width to obtain good welds with deep penetration. It is also confirmed that the welding speed and pps(pulse per second) are directly connected at weld defects such as underfill, porosity.

• International Journal of Naval Architecture and Ocean Engineering
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• v.11 no.1
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• pp.462-473
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• 2019

The effects of the location and dimension of the gate, location, and volume of the feeder, application of a chill, chill volume, and heating method of the feeder with respect to the effect of the mold-designing technologies on the defect status of the products are described. It is possible to increase the solidification time of the feeder by heating feeder. Furthermore, the pressure generated from the feeder is imposed on a product, and this decreases the generation of shrinkage porosities. In this study, two types of gating and feeding systems had been proposed: the bottom L-type junctions and the top L-type junctions. Additionally, solidification behaviors, such as solidification time, shrinkage porosities, weight percentage of chill system to product, hot spot, and solidification time ratio (=Solidification time of feeder/solidification time of product), are extensively analyzed by using commercial casting simulation software. Based on the solidification behaviors, reasonable mold design, feeding system, critical feeder heating temperature, and solidification time ratios are proposed in the sand casting process for the fabrication of carrier housing in order to reduce the casting defects and to increase the recovery rate.

• Journal of Korea Foundry Society
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• v.11 no.1
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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.

• Journal of the Korean Ceramic Society
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• v.48 no.1
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• pp.74-79
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• 2011

The pore generation technology using GHM (Glass Hollow Microsphere) was studied in order to reduce the weights of porcelain. In this study, we verify the property of modified slurry by adding GHM. The modified slurry was prepared by adding 1.0~2.5 wt%(K1), 1.0~6.0 wt%(K37) of GHM to the slurry for porcelain. The slurry viscosity were stable inside a content range of 1.0~2.5 wt%(K1), 1.0~6.0 wt%(K37). However, the viscosity of modified slurry increased more than 3.0 wt%(K1) and 6.5 wt%(K37). The formed specimen by slip casting was fired at $1229^{\circ}C$, $1254^{\circ}C$. As the amount of GHM content increased, the weight decreased and the addition of 1.0~2.5 wt%(K1), 1.0~6.0 wt%(K37) of GHM resulted in a weight drop of 30%(K1) and 25(K37). However, when the GHM content increased, the strength decreases over 70%. This is caused by the presence of a large volume of surface defects (pores) and defects from the agglomeration of GHM.