• Journal of the Semiconductor & Display Technology
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• v.11 no.2
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• pp.39-43
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• 2012

This paper presents a study on the design of a pulling module for silicon ingot and an apparatus of manufacturing silicon single crystal ingot using the same method. The pulling module is conceptually designed by using TRIZ. Czochralski method(CZ) is representative way to manufacture single crystal ingot for wafers. The seed can be broken by high tension which is caused by large weight of a silicon ingot. The solution of this problem has been derived using 6SC(6 steps creativity)TRIZ. The pulling module is actuated by DC motor and rollers. High tension in the seed is removed by the rotate-elevate motion of rollers in the pulling module. A rubber belt is included in the rotate-elevate mechanism for increasing friction between rollers and silicon ingot.

• Transactions of Materials Processing
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• v.8 no.1
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• pp.101-107
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• 1999

The upset forging stage is the initial work in the forging process. It is used to remove the segregation and cavities of the ingot. Specially in handling large sized ingot, an improper upset forging can cause serious surface tearing. However, there is no detail reference for stable upset forging work. To resolve this difficulty, we studied several factors such as upset forging time, temperature varation of ingot, damage, load and stain rate etc., by using the rigid-plastic finite element approach available in the DEFORM code. Numerical simulation results indicated that: the load value of upset forging works shows severe decreasing trend at a certain point, same as strain rate. Also defects were found to be concentrated around the upper and lower portions of the ingot. With these results, we can estimate a guideline for stable upset forging work.

• Journal of Korea Foundry Society
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• v.22 no.4
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• pp.160-166
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• 2002

The structure and properties of Fe-29Ni-17Co alloy which had been melted using induction furnace in air atmosphere and than electroslag-remelted were investigated. The oxygen content was reduced to 0.03% when the ingot was refined from $0.09{\sim}0.12%$ of that air melted. The amounts of spheroidal oxides inclusions and gas porosities of ingot were markedly reduced by the ESR process. CTE of ESR ingot contained small amount of oxides and porosities was found to be lower than that of AIM ingot, and tensile properties of ESR ingot and plate were found to be superior than that of AIM ingot and plate.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.31 no.3
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• pp.17-23
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• 2008

In this research article, scheduling a casting sequence in a job-shop type foundry involving a variety of casts made of an identical alloy but with different shapes and II weights, has been investigated. The objective is to produce the assigned mixed orders satisfying due dates and obtaining the highest ingot efficiency simultaneously. Implementing simple integer programming instead of complicated genetic algorithms accompanying rigorous calculations proves that it can provide a feasible solution with a high accuracy for a complex, multi-variable and multi-constraint optimization problem. Enhancing the ingot efficiency under the constraint of discrete ingot sizes is accomplished by using a simple and intelligible algorithm in a standard integer programming. Employing this simple methodology, a job-shop type foundry is able to maximize the furnace utilization and minimize ingot waste.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2009.05a
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• pp.91-93
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• 2009

A large steel ingot needs to be larger and larger in size and an ultra high clean, no defect in quality with a low hot top ratio for the resent heavy industry. The demands are very difficult to achieve simultaneously because of their contradictive effect to each other in results. In this study, 30ton steel ingot was cast in a foundry with an optimized design parameter of cast mold and cast process conditions for the low hot top ratio, 12%. The cast ingot was analyzed in macro defect, segregations, and cleanness. No macro defect was founded in central surface of the ingot. The degree of segregation and cleanness are in the controlled range with a sound quality.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.24 no.5
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• pp.190-195
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• 2014

Because of the temperature gradient occurring during the growth of the ingot with directional solidification method, defects are generated and the residual stress is produced in the ingot. Changing the growth and cooling rate during the crystal growth process will be helpful for us to understand the defects and residual stress generation. The defects and residual stress can affect the properties of wafer. Generally, it was found that the size of grains and twin boundaries are smaller at the top area than at the bottom of the ingot regardless of growth and cooling condition. In addition to that, in the top area of silicon ingot, higher density of dislocation is observed to be present than in the bottom area of the silicon ingot. This observation implies that higher stress is imposed to the top area due to the faster cooling of silicon ingot after solidification process. In the ingot with slower growth rate, dislocation density was reduced and the TTV (Total Thickness Variation), saw mark, warp, and bow of wafer became lower. Therefore, optimum growth condition will help us to obtain high quality silicon ingot with low defect density and low residual stress.

• Journal of the Semiconductor & Display Technology
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• v.16 no.1
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• pp.34-39
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• 2017

Semiconductor is one of the most internationally competitive areas among domestic industries, the major concern of which is the stability of the wafer manufacturing processes. The first process for the manufacturing of the semiconductor wafers is the ingot growing. The vibrations are supposed to be the most important factors for the ingot quality. In order to maintain the ingot quality, the growers have the automatic shut-down equipments which are activated by vibrations, and are sensitive enough to react to the earthquakes generated in Japan. In this study, the structure of an ingot grower was analyzed through experiments and computer simulations, and further the effects of design alterations to suppress the vibrations have been investigated. The final result shows that the vibrations can be reduced substantially to improve the stability of the structure.

• Transactions of Materials Processing
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• v.19 no.6
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• pp.329-336
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• 2010

Ring forging process is more appropriate for high-length and thin walled ring, because it utilizes the forging press and hence does not require heavy-duty ring rolling mill. Although ring forging process is very simple and economic for facilities, the process is not efficient because of multi-forging-step and low material utilization. An effective ring forging process is developed using a hollow ingot. When a hollow ingot is used with a workpiece, the ingot can be forged into a final ring without multi-stage pre-forging process, such as, cogging, upsetting, and piercing, etc.. Finally it has advantages of the material utilization and process improvement because a few reheating and forging process are not necessary to make workpiece for ring forging. The important design variables are the applied plastic deformation energy to eliminate cast structure and make uniform properties. In this study, the mechanical properties after forging of hollow cast ingot were investigated from the experiment using circumferential sectional model. Also, the effects of process variables were studied by FEM simulation on the basis of thermo-visco-plastic constitutive equation. Applied strain is different at each position in length direction because diameter of hollow ingot is different in length direction. The different strain distribution become into a narrow gap by additional plastic deformation during diameter extension process.

• Journal of the Korean institute of surface engineering
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• v.50 no.6
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• pp.465-472
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• 2017

The ingot fabrication conditions related with the thermal shock bearing phase and microstructure have investigated for the rare earth zirconate ceramic material, lanthanum gadolinium zirconate, as a thermal barrier coating using electron beam evaporation method. The thermal shock resistance of the prepared ingot was evaluated by high energy electron beam irradiation. The rare earth zirconate ceramic powder was prepared by controlling the raw material powder composition of $La_2O_3$, $Gd_2O_3$ and $ZrO_2$ so as to have a composition of $(La_{0.3}Gd_{0.7})_2Zr_2O_7$ which was selected from the former study. Ingot samples were prepared under two conditions. The first condition is prepared by sintering the prepared powder mixture to form an ingot. The second condition is prepared by calcining the prepared powder mixture to form a composite phase and then sintering to form an ingot. X-ray diffraction(XRD) and Scanning Electron Microscope(SEM) were used to analyze phase forming behavior and microstructure of ingot samples. Nanoindentation method used to obtain elastic modulus and hardness of each ingot specimen. Also the stress distribution of ingot was simulated by using FEM method assuming the ingot surface was exposed to electron beam. As a results, in the case of an ingot having a network-shaped microstructure in which relatively coarse pores are included, it seems that the thermal shock resistance was higher than in the case of an ingot having a microstructure composed of relatively fine grains only or particles with the similar level size when the high energy electron beam irradiation.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2013.05a
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• pp.29-30
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• 2013