• Journal of Conservation Science
• /
• v.37 no.4
• /
• pp.340-356
• /
• 2021

We have tried the experimental research of lost-wax casting to reconstruct Gilt-Bronze Pensive Bodhisattva; preliminary and reconstruction experiment based on ancient texts. Main object to reconstruct is Korean National Treasure No.83, Gilt-Bronze Pensive Bodhisattva (Maitreya), then we measure alloy ratio and casting method based on the scientific analysis. Other impurities were removed from the base metal components(copper : tin : lead) and their ratio was set to 95.5 : 6.5 : 3 where the ratios for tin and lead were increased by 2.5% each. The piece-mold casting method was used, and piece-mold casting experiments were carried out twice in this study but supplementary research on piece-mold casting was necessary. The microstructure was confirmed to be typical cast microstructure and the component analysis result was similar to that of the prior study. Analysis of the chemical composition is confirmed to copper, tin, lead, and zinc, and the chemical composition of the matrix was 87.8%Cu-7.5%Sn-2.7%Pb-2.1%Zn, and similar to previous experimental research. Also resulted in the detection of small impurity in Zn. Analysis of the mould revealed that the mould was fabricated by adding quartz and organic matter for structural stability, fire resistance, and air permeability. We expect that our research will contribute to provide base data for advanced researches in future.

• Journal of Korea Foundry Society
• /
• v.8 no.3
• /
• pp.271-281
• /
• 1988

Al-bronze has a good mechanical property, corrosion resistance and castability, so being highlighted for the new copper alloy. So, effects of alloy composition and cooling rate in the mechaincal properties and solidification behavior have been investigated. The results obtained are as follows; 1) Change in volume on solidification is larger in metal mold casting than in sand mold casting. And it decreases by the addition of Al. 2) The mechanical property in metal mold casting is superior to the one in sand mold casting, and the inclination is obvious up to 9% Al, after heat-treatment ($885^{\circ}C$, $1.5hrs\;{\rightarrow}\;W\;{\cdot}\;Q\;{\rightarrow}\;540^{\circ}C$, 3hrs) 3) By adding Al, the mechanical property is slightly increased up to 9% Al, Above 9% Al, it is increased rapidly, and is accelerated by adding Fe. 4) Cooling rate and hardness, and grain size and cooling rate are related as follows in the range of $1100^{\circ}C$ to $1200^{\circ}C$ pouring temperature. Grain size(${\mu}m$)=$929.6422{\times}cooling\;rate(^{\circ}C\;/\;sec)^{-0.51537}$ Hardness(BHN)=$765.45713{\times}grain\;size({\mu}m)^{-0.31058}$.

• Journal of Korea Foundry Society
• /
• v.18 no.3
• /
• pp.262-270
• /
• 1998

Gravity tilt pour casting can effectively guarantee the reduction of various casting defects by controlling the rotation speed and the tilting angle of the mold during tilt pouring. The relationship between casting process parameters and the soundness of castings has been investigated in order to determine the optimum process variables in the gravity tilt pour casting process. In order to evaluate the effect of rotation speed on mold filling patterns, a video camera was employed to visualize the in-situ fluid flow behavior of the molten metal, and the relevant fluid velocity was also estimated. X-ray and mechanical tests were also performed to evaluate the effect of fluid velocity on casting quality. With the rotation speed lower than 0.5 r.p.m., which is nearly corresponding to the critical velocity of stability in the fluid flow, sound castings were obtained without having any casting defects. It can be concluded that the gravity tilt pour casting process is an effective process for manufacturing sound casting products with enhanced physical and mechanical properties.

• Transactions of Materials Processing
• /
• v.14 no.2 s.74
• /
• pp.112-120
• /
• 2005

In the die casting process, the flow of liquid metal has significant influence on the quality of casting products and die life. For the optimal process design of gear housing of automobile transmission, various analyses were performed in this study by using computer simulation code, MAGMAsoft. The simulation has been focused on the molten metal behaviors during the mold filling and solidification stages for the sound casting products. Also internal defects were predicted by application of air pressure and feeding criteria.

• International Journal of Naval Architecture and Ocean Engineering
• /
• v.6 no.4
• /
• pp.922-934
• /
• 2014

In casting steels for offshore construction, manufacturing integral casted structures to prevent fatigue cracks in the stress raisers is superior to using welded structures. Here, mold design and casting analysis were conducted for integral casting steel. The laminar flow of molten metal was analyzed and distributions of hot spots and porosities were studied. A prototype was subsequently produced, and air vents were designed to improve the surface defects caused by the release of gas. A radiographic test revealed no internal defects inside the casted steel. Evaluating the chemical and mechanical properties of specimens sampled from the product revealed that target values were quantitatively satisfied. To assess weldability in consideration of repair welding, the product was machined with grooves and welded, after which the mechanical properties of hardness as well as tensile, impact, and bending strengths were evaluated. No substantive differences were found in the mechanical properties before and after welding.

• Transactions of the Korean Society of Mechanical Engineers B
• /
• v.24 no.1
• /
• pp.102-113
• /
• 2000

In this study, a three-dimensional gravity casting problem has been examined to investigate a coupled phenomenon of the filling and solidification process. This work simultaneously considers the two key phenomena of metal casting : the fluid flow during mold filling, and solidification process. The VOF method is used to analyze the free surface flow during filling and the equivalent specific heat method is employed to model the latent heat release during solidification. The time-implicit filling algorithm is applied to save the computational time for analyzing the mold filling process. The three-dimensional benchmark problem used in the MCWASP VII has been solved using both the implicit and explicit algorithm, and the present results are compared with the benchmark experimental results and the other numerical results.

• Journal of Korean Society of Industrial and Systems Engineering
• /
• v.40 no.1
• /
• pp.35-40
• /
• 2017

A most important progress in civilization was the introduction of mass production. One of main methods for mass production is die-casting molds. Due to the high velocity of the liquid metal, aluminum die-casting is so complex where flow momentum is critical matter in the mold filling process. Actually in complex parts, it is almost impossible to calculate the exact mold filling performance with using experimental knowledge. To manufacture the lightweight automobile bodies, aluminum die-castings play a definitive role in the automotive part industry. Due to this condition in the design procedure, the simulation is becoming more important. Simulation can make a casting system optimal and also elevate the casting quality with less experiment. The most advantage of using simulation programs is the time and cost saving of the casting layout design. For a die casting mold, generally, the casting layout design should be considered based on the relation among injection system, casting condition, gate system, and cooling system. Also, the extent or the location of product defects was differentiated according to the various relations of the above conditions. In this research, in order to optimize the casting layout design of an automotive Oil Pan_BR2E, Computer Aided Engineering (CAE) simulation was performed with three layout designs by using the simulation software (AnyCasting). The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process with three models, internal porosities caused by air entrapments were predicted and also compared with the modification of the gate system and overflows. With the solidification analysis, internal porosities occurring during the solidification process were predicted and also compared with the modified gate system.

• Journal of Korea Foundry Society
• /
• v.24 no.3
• /
• pp.159-164
• /
• 2004

The aim of the present work is to investigate the possibility of in-situ synthesis and net-shape forming of the titanium matrix (TiC+TiB) hybrid composites using a casting route. From the scanning electron microscopy, electron probe micro-analyzer, X-ray diffraction and thermodynamic calculations, the spherical TiC and needle like TiB reinforced hybrid titanium matrix composites could be obtained in-situ by the conventional melting and casting route between titanium and $B_4C$. No melt-mold reaction occurred between the titanium matrix (TiC+TiB) hybrid composites and the SKK mold, since the mold is consisted with interstitial and substitutional metal-mold reaction products. Not only the sound in-situ synthesis but also the economic net-shape forming of the titanium matrix (TiC+TiB) hybrid composites could be possible by the conventional casting route.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.18 no.7
• /
• pp.83-89
• /
• 2019

In the conventional casting and forging method, there is a disadvantage that a mold is an essential addition, and a production cost is increased when a small quantity is produced. In order to overcome this disadvantage, a metal 3D printing production method capable of directly forming a shape without a mold frame is mainly used. In particular, overseas research has been conducted on various materials, one of which is a metal printer. Similarly, domestic companies are also concentrating on the metal printer market. However, In this case of the conventional metal 3D printing method, it is difficult to meet the needs of the industry because of the high cost of materials, equipment and maintenance for product strength and production. To compensate for these weaknesses, printers have been developed that can be manufactured using sand mold, but they are not accessible to the printer company and are expensive to machine. Therefore, it is necessary to supply three-dimensional casting printers capable of metal molding by producing molds instead of conventional metal 3D printing methods. In this study, we intend to reduce the unit price by replacing the printing method used in the sand casting printer with the FDM method. In addition, Ag paste is used to design the output conditions and enable ceramic printing.

• Korean Journal of Materials Research
• /
• v.32 no.12
• /
• pp.538-544
• /
• 2022

In existing ceramic mold manufacturing processes, inorganic binder systems (Si-Na, two-component system) are applied to ensure the effective firing strength of the ceramic mold and core. These inorganic binder systems makes it possible to manufacture a ceramic mold and core with high dimensional stability and effective strength. However, as in general sand casting processes, when molten metal is injected at room temperature, there is a limit to the production of thin or complex castings due to reduced fluidity caused by the rapid cooling of the molten metal. In addition, because sodium silicate generated through the vitrification reaction of the inorganic binder is converted into a liquid phase at a temperature of 1,000 ℃. or higher, it is somewhat difficult to manufacture parts through high-temperature casting. Therefore, in this study, a high-strength ceramic mold and core test piece with effective strength at high temperature was produced by applying a Si-Na-Ti three-component inorganic binder. The starting particles were coated with binary and ternary inorganic binders and mixed with an organic binder to prepare a molded body, and then heat-treated at 1,000/1,350/1,500 ℃ to prepare a fired body. In the sample where the two-component inorganic binder was applied, the glass was liquefied at a temperature of 1,000 ℃ or higher, and the strength decreased. However, the firing strength of the ceramic mold sample containing the three-component inorganic binder was improved, and it was confirmed that it was possible to manufacture a ceramic mold and core via high temperature casting.