• Korean Journal of Metals and Materials
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• v.48 no.1
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• pp.28-38
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• 2010

High temperature high cycle and low cycle fatigue deformation behavior of automotive heat resistant aluminum alloys (A356 and A319 based) were investigated in this study. The microstructures of both alloys were composed of primary Al-Si dendrite and eutectic Si phase. However, the size and distribution for eutectic Si phase varied: a coarse and inhomogeneous distributed was observed in alloy B (A319 based). A brittle intermethallic phase of ${\alpha}-Fe\;Al_{12}(Fe,Mn)_3Si_2$ was detected only in B alloy. Alloy B exhibited high fatigue life only under a high stress amplitued condition in the high cycle fatigue results, whereas alloy A showed high fatigue life when stress was lowered. With regard to the low-cycle fatigue result ($250^{\circ}C$) showing higher fatigue life as ductility increased, alloy A demonstrated higher fatigue life under all of the strain amplitude conditions. Fractographic observations showed that large porosities and pores near the outside surface could be the main factor in the formation of fatigue cracks. In alloy B. micro-cracks were formed in both the brittle intermetallic and coarse Si phasese. These micro-cracks then coalesced together and provided a path for fatigue crack propagation. From the observation of the differences in microstructure and fractography of these two automotive alloys, the authors attempt to explain the high-temperature fatigue deformation behavior of heat resistant aluminum alloys.

• Journal of Sensor Science and Technology
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• v.24 no.6
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• pp.379-384
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• 2015

An infrared image sensor is a core device in a thermal imaging system. The fabrication method of a focal plane array (FPA) is a key technology for a high resolution infrared image sensor. Each pixels in the FPA have $Si_3N_4/SiO_2$ membranes including legs to deposit bolometric materials and electrodes on Si readout circuits (ROIC). Instead of polyimide used to form a sacrificial layer, the feasibility of an amorphous silicon (${\alpha}-Si$) was verified experimentally in a $8{\times}8$ micro-bolometer array with a $50{\mu}m$ pitch. The elimination of the polyimide sacrificial layer hardened by a following plasma assisted deposition process is sometimes far from perfect, and thus requires longer plasma ashing times leading to the deformation of the membrane and leg. Since the amorphous Si could be removed in $XeF_2$ gas at room temperature, however, the fabricated micro-bolomertic structure was not damaged seriously. A radio frequency (RF) sputtered nickel oxide film was grown on a $Si_3N_4/SiO_2$ membrane fabricated using a low stress silicon nitride (LSSiN) technology with a LPCVD system. The deformation of the membrane was effectively reduced by a combining the ${\alpha}-Si$ and LSSiN process for a nickel oxide micro-bolometer.

• Design & Manufacturing
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• v.17 no.4
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• pp.42-51
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• 2023

In this study, we investigated the injection molding technology of thick-walled light guides, which are parts that control the light source of automotive lamps. Through injection molding analysis, the gate position that can minimize product shrinkage and deformation was selected, and a mold reflecting the analysis results was manufactured to evaluate the effect of injection speed and holding pressure on transferability during micro-pattern molding through experiments. When designing an injection mold for products with varying thicknesses, it was found that installing the gate on the side of the thicker part was advantageous for reducing volume shrinkage and deformation. It was found that the effect of shrinkage due to thickness may be greater than the position of the gate on pattern transferability. The pattern transfer error decreased as the injection speed and holding pressure increased, and it was found that increasing the injection speed was relatively effective.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.31 no.12
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• pp.1173-1179
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• 2007

In recent years, research to machine large-surface micro-features has become important because of the light guide panel of a large-scale liquid crystal display and the bipolar plate of a high-capacity proton exchange membrane fuel cell. In this study, in order to realize the systematic design technology and performance improvements of an ultra-precision machine for machining the large-surface micro-features, a structural characteristic analysis was performed using its virtual prototype. The prototype consisted of gantry-type frame, hydrostatic feed mechanisms, linear motors, brushless DC servo motor, counterbalance mechanism, and so on. The loop stiffness was estimated from the relative displacement between the tool post and C-axis table, which was caused by a cutting force. Especially, the causes of structural stiffness deterioration were identified through the structural deformation analysis of sub-models.

• Transactions of Materials Processing
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• v.15 no.8 s.89
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• pp.609-614
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• 2006

Micro-alloyed steels(MA steels) for cold forging was developed to replace the usual quenched and tempered steel. MA steels have several advantages over the conventional quenched and tempered carbon steels. First of all, energy consumption could be lowered due to the elimination of spherodizing annealing and quenching/tempering heat treatment. Also, bending during quenching could be avoided when MA steels are applied for manufacturing of long fastener parts. However, larger amount of load is exerted on the dies compared than in the case of conventional mild steels, which might lead to the earlier fracture of dies, when MA forging steels are applied in forging practice. Therefore, die lift could be a critical factor to determine whether HA forging steels could be widely applied in cold forging practice. In the present study, authors have investigated the forging characteristics of non-heat treated micro-alloyed steel by using a series of experimental and numerical analyses. Firstly, microstructural features and its effect on the deformation behavior have been studied. Numerical analysis has been done on the forging of guide rod pin to investigate for the optimization of forging process and die stress prediction.

• Transactions of Materials Processing
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• v.21 no.6
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• pp.348-353
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• 2012

Micro-drawn parts have received wider acceptance as products become smaller and more precise. The subject of this study was the deformation characteristics of ultra thin sheet metal in micro drawing of a rectangular shaped part. The influence of drawing speed and blank holding force on the product quality was investigated in micro-drawing of ultra thin sheet of beryllium copper (C1720) alloy. The specimen had a diameter of 4.8 mm and a thickness of $50{\mu}m$. Experiments were carried out in which, different blank holding force and drawing speed were considered. The product quality was evaluated by measuring the thickness and hardness along two specified directions, namely, the side and diagonal directions. The distribution of the thickness strain showed severe thinning especially around the punch radius in both directions. In the diagonal direction, thickening occurred in the flange area due to the axi-symmetric drawing mode. The increase of blank holding force and/or drawing speed was found to cause severe thinning around the punch radius. The blank holding force had a greater effect on thinning of the product than the drawing speed.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.25 no.6
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• pp.410-420
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• 2016

The geometric dimension and shape of microchannels that are formed during surface texturing are widely studied for applications in flow control, and drag and friction reduction. In this research, a new method for controlling the deformation of U channels during micro-rolling-based surface texturing was developed. Since the width of the U channels is almost constant, controlling the depth is essential. A calibration procedure of initial rolling gap, and proportional-integral PI controllers and a linear interpolation have been applied simultaneously to control the depth. The PI controllers drive the position of the pre-U grooved roll as well as the rolling gap. The relationship between the channel depth and rolling gap is linearized to create a feedback signal in the depth control system. The depth of micro channels is studied on A2021 aluminum lamina surfaces. Overall, the experimental results demonstrated the feasibility of the method for controlling the depth of microchannels.

• Corrosion Science and Technology
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• v.22 no.4
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• pp.265-272
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• 2023

The aim of this study was to develop a new in-situ observation method and instrument in micro-scale to investigate the mechanism of stress corrosion cracking (SCC) initiation of Ni-base alloys in a high temperature water environment of pressurized water reactors (PWRs). A laser confocal microscope (LCM), an autoclave with diamond window view port, and a slow strain-rate tester with primary water circulation loop system were components of the instrument. Diamond window, one of the core components of the instrument, was selected based on its optical, chemical, and mechanical properties. LCM was used to observe the specimen in micro-scale, considering the experimental condition of a high-temperature primary water environment. Using in-situ method and instrument, it is possible to observe oxidation and deformation of specimen surface in micro-scale through the diamond window in a high-temperature primary water in real-time. The in-situ method and instrument developed in this work can be utilized to investigate effects of various factors on SCC initiation in a high-temperature water environment.

• Journal of the Korean Society for Precision Engineering
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• v.29 no.12
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• pp.1272-1278
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• 2012

The micro barrier rip array structures have been applied in a variety of areas including as privacy films, micro heat sinks, touch panel and optical waveguide. The increased aspect ratio (AR) of barrier rip array structures is required in order to increase the efficiency and performance of these products. There are several problems such as burr, defect of surface roughness and deformation and breakage of barrier rip structure with machining high-aspect ratio micro barrier rip array structure using orthogonal cutting method. It is essential to develop technological methods to solve these problems. The optimum machining conditions for machining micro barrier rip array structures having high-aspect ratio were determined according to lengths ($200{\mu}m$ and $600{\mu}m$) and shape angles ($2.89^{\circ}$ and $0^{\circ}$) of diamond tool, overlapped cutting depths ($5{\mu}m$ and $10{\mu}m$), feed rates (100 mm/s) and three machining processes. Based on the optimum machining conditions, micro barrier rib array structures having aspect ratio 30 was machined in this study.

• Computers and Concrete
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• v.19 no.5
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• pp.443-449
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• 2017

Taking high geothermal tunnels as background, the deformation of concrete for shotcrete use was studied by simulating hot-humid and hot-dry environments in a laboratory. The research is made up by two parts, one is the influence of two kinds of high geothermal environments on the deformation of shotcrete, and the other is the shrinkage inhibited effect of fiber materials (steel fibers, polypropylene fibers, and the mixture of both) on the concrete in hot-dry environments. The research results show that: (1) in hot and humid environments, wet expansion and thermal expansion happened on concrete, but the deformation is smooth throughout the whole curing age. (2) In hot and dry environments, the concrete suffers from shrinkage. The deformation obeys linear relationship with the natural logarithm of curing age in the first 28 days, and it becomes stable after the $28^{th}$ day. (3) The shrinkage of concrete in a hot and dry environment can be inhibited by adding fiber materials especially steel fibers, and it also obeys linear relationship with the natural logarithm of curing age before it becomes stable. However, compared with no-fiber condition, it takes 14 days, half of 28 days, to make the shrinkage become stable, and the shrinkage ratio of concrete at 180-day age decreases by 63.2% as well. (4) According to submicroscopic and microscopic analysis, there is great bond strength at the interface between steel fiber and concrete. The fiber meshes are formed in concrete by disorderly distributed fibers, which not only can effectively restrain the shrinkage, but also prevent the micro and macro cracks from extending.