• Resources Recycling
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• v.30 no.4
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• pp.20-26
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• 2021

Solar grade silicon (SoG-Si) has been commercially supplied mainly from off-grade high-purity silicon manufactured for electronic-grade Si (EG-Si). Therefore, for wider application of solar cells, the development of a refining process at a considerably lower cost is required. The most cost-effective and direct approach for producing SoG-Si is to purify and upgrade metallurgical-grade Si (MG-Si). In this study, directional solidification of molten MG-Si was conducted in a high-frequency induction furnace to remove iron from molten Si. The experimental conditions and results were also discussed with respect to the effective segregation coefficient, Scheil equation, and Peclet number. The study showed that when the descent velocity of the specimen decreased, the macro segregations of impurities and ingot purities increased. These results were derived from the decrease in the effective segregation coefficient with the decrease in the rate of descent of the specimen.

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

• Korean Journal of Materials Research
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• v.27 no.10
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• pp.563-568
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• 2017

In this study, the coating of an Al-Cr layer on the surface of a Zircaloy-4 alloy was carried out through plasma pretreatment coating and a laser surface melting process. Two different conditions for laser treatment, severe or minimal surface melting of the Zr alloy substrate, were applied to form the final coating. When there was significant surface melting of the Zr alloy, the solidification microstructure of the newly formed coating layer was mainly composed of needle-shaped $Al_3Zr$, Al(Cr) and $Al_7Cr$ phases. On the other hand, the solidification microstructure of the coating layer was mainly composed of Al(Cr) and $Al_7Cr$ phases when there was minimal surface melting of Zr base in the laser process. However, when the coating was maintained at $1100^{\circ}C$ for 2 hours, significant inter-diffusion occurred between the phases in the coating. As a result, the upper part of the coating layer was observed to mainly consist of $Al_3Zr$ and $Al_8Cr_5$ phases, regardless of the laser treatment conditions.

• Journal of Korea Foundry Society
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• v.32 no.6
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• pp.276-283
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• 2012

This study presents the results on the changes of crucible thermal conductivity and inflow of Ar, and constructed the mathematical model about heat transfer into furnace. As process variables, simulation model was designated thermal conductivity of crucible to $0.5W{\cdot}m^{-1}{\cdot}K^{-1}$, $1W{\cdot}m^{-1}{\cdot}K^{-1}$, $2W{\cdot}m^{-1}{\cdot}K^{-1}$, $4W{\cdot}m^{-1}{\cdot}K^{-1}$, and inflow rate of Ar to 15 L/min, 30 L/min, 60 L/min. Initial condition and boundary condition were set respectively in two terms of process. Each initial conditions were set up by the preceding simulation of heat and fluid flow. The primary goal is the application of unidirectional growth of Si ingot using the result. In the result of the change of heat conductivity of crucible, the higher thermal conductivity of crucible shows the shorter solidification time and the bigger temperature difference. And the flow patterns are changed with the inflow rate of Ar. Finally, we found that the lower crucible's thermal conductivity, the better crucible is at polycrystalline Si ingot growth. But in case of Ar inflow, it is hard to say about good condition. This data will be evaluated as useful reference used in allied study or process variable control of production facilities.

• The Transactions of the Korean Institute of Electrical Engineers C
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• v.51 no.6
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• pp.229-235
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• 2002

This paper presents the fabrication of polycrystalline thin film transistor(TFT) using sequential lateral solidification(SLS) of amorphous silicon. The fabricated SLS TFT showed high Performance suitable for active matrix liquid crystal display(AMLCD). The SLS process involves (1) a complete melting of selected area via irradiation through a patterned mask, and (2) a precisely controlled pulse translation of the sample with respect to the mask over a distance shorter than the super lateral growth(SLG) distance so that lateral growth extended over a number of iterative steps. The SLS experiment was performed with 550$\AA$ a-Si using 308nm XeCl laser having $2\mu\textrm{m}$ width. Irradiated laser energy density is 310mJ/$\textrm{cm}^2$ and pulse duration time was 25ns. The translation distance was 0.6$\mu$m/pulse, 0.8$\mu$m/pulse respectively. As a result, a directly solidified grain was obtained. Thin film transistors (TFTs) were fabricated on the poly-Si film made by SLS process. The characteristics of fabricated SLS p -type poly-Si TFT device with 2$\mu\textrm{m}$ channel width and 2$\mu\textrm{m}$ channel length showed the mobility of 115.5$\textrm{cm}^2$/V.s, the threshold voltage of -1.78V, subthreshold slope of 0.29V/dec, $I_{off}$ current of 7$\times$10$^{-l4}$A at $V_{DS}$ =-0.1V and $I_{on}$ / $I_{off}$ ratio of 2.4$\times$10$^{7}$ at $V_{DS}$ =-0.1V. As a result, SLS TFT showed superior characteristics to conventional poly-Si TFTs with identical geometry.y.y.y.

• Journal of Welding and Joining
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• v.26 no.5
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• pp.49-59
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• 2008

Hastelloy C-276, corrosion resistant alloy at high temperature, is used in chemical plant and power generation industry. In this study, process parameter of laser welding for welding property in Hastelloy C-276 using a continuous wave Nd:YAG laser was studied. As the result of experiment, laser welding did not show segregation or crack at heat affected zone compared to conventional GTWA welding. The melting zone showed cell dendritic structure along with welding line. In addition, planer front solidification is occurred from welding structure, and it was progressed to cellular solidification. Optimal process parameter for butt welding was 1.2kW and 2.0 m/min for laser power and welding speed, respectively. While heat input, output density, tensile stress, and longitudinal strain was $441.98{\times}103$ J/cm2, $29.553{\times}103$ W/cm2, 768 MPa, and 0.689, respectively. Lap welding of the same material showed greater discrepancy in tensile property during 1 line and 2 line welding. For 1 line welding, tensile stress was about 320 MPa, and 2 line showed slightly larger tensile stress. However, strain was decreased by 20%. From this result, lap welding of the same material, Hastelloy C-276, with 2 line welding is considered to be more effective process than 1 line welding with consideration of mechanical property.

• Economic and Environmental Geology
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• v.39 no.6 s.181
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• pp.699-710
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• 2006

Batch scale experiments to investigate the efficiency of the solidification process for metal mine tailing treatment were performed. Portland and MSG (micro silica pouting) cements were used as solidifier and three kinds of mine tailings (located at Gishi, Daeryang, and Aujeon mine) were mixed with cements to paste solidified matrices. Single axis com-pressible strengths of solidified matrices were measured and their heavy metal extraction ratios were calculated to investigate the solidification efficiency of solidified matrices created in experiments. Solidified matrices ($5cm{\times}5cm{\times}5cm$) were molded from the paste of tailing and cements at various conditions such as different tailing/cement ratio, cement/water ratio, and different cement or tailing types. Compressible strengths of solidified matrices after 7, 14, and 28 day cementation were measured and their strengths ranged from 1 to $2kgf/mm^2$, which were higher than Korean limit of compressible strength for the inside wall of the isolated landfill facility ($0.21kgf/mm^2$). Heavy metal extractions from intact tailings and powdered matrices by using the weak acidic solution were performed. As concentration of extraction solution for the powdered solidified matrix (Portland cement + Gishi tailing at 1:1 w.t. ratio) decreased down to 9.7 mg/L, which was one fifth of As extraction concentration for intact Gishi tailings. Pb extraction concentration of the solidified matrix also decreased to lower than one fourth of intact tailing extraction concentration. Heavy metal extraction batch experiments by using various pH conditions of solution were also performed to investigate the solidification efficiency reducing heavy metal extraction rate from the solidified matrix. With pH 1 and 13 of solution, Zn and Pb concentration of solution were over the groundwater tolerance limit, but at pH $1{\sim}13$ of solution, heavy metal concentrations dramatically decreased and were lower than the groundwater tolerance limit. While the solidified matrix was immerged Into very acidic or basic solution (pH 1 and 13), pH of solution changed to $9{\sim}10$ because of the buffering effect of the matrix. It was suggested that the continuous extraction of heavy metals from the solidified matrix is limited even in the extremely high or low pH of contact water. Results of experiments suggested that the solidification process by using Portland and MSG cements has a great possibility to treat heavy metal contaminated mine tailing.

• Journal of the Korean Society for Precision Engineering
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• v.17 no.2
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• pp.130-136
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• 2000

Generally, the build-up printed circuit board manufactured by the sequential process with etching, plating, drilling etc. requires many types of equipments and lead time. Etching process is suitable for mass production, however, it is not adequate for manufacturing prototype in the developing stage. In this study, we introduce a screen printing technology to prototyping a build-up printed circuit board. As for the material, photo/thermal curable resin and conductive paste are used for the formation of dielectric and conductor. The build-up structure is made by subsequent processes such as the formation of liquid resin thin layer, the solidification by UV/IR light, and via filling with conductive paste. By use of photo curable resin, productivity is greatly enhanced compared with thermal curable resin. Finally, the basic concept and the possibility of build-up printed circuit board prototyping are proposed in comparison with to the conventional process.

• Journal of the Korean Society of Manufacturing Technology Engineers
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• v.26 no.4
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• pp.357-364
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• 2017

Metal casting is a process in which molten metal or liquid metal is poured into a mold made of sand, metal, or ceramic. The mold contains a cavity of the desired shape to form geometrically complex parts. The casting process is used to create complex shapes that are difficult to make using conventional manufacturing practices. For the optimal casting process design of sleeve parts, various analyses were performed in this study using commercial finite element analysis software. The simulation was focused on the behaviors of molten metal during the mold filling and solidification stages for the precision and sand casting products. This study developed high-life sleeve parts for the sink roll of continuous hot-dip galvanizing equipment by applying a wear-resistant alloy casting process.

• Journal of Korea Foundry Society
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• v.9 no.5
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• pp.396-402
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• 1989

Metal fibers of Al and stainless steel were fabricated by the PDME method and the Taylor process. Tensile strength of metal fiber produced by both the PDME method and the Taylor process was much higher than that of conventionally solidified materials. Utilizing the PDME method, Al fiber with $100\;{\mu}m$ was fabricated under Ar gas atmosphere, and stainless steel fiber with $50\;{\mu}m$ was fabricated under 0.06 Torr vacuum. Continuous fiber of stainless steel was made by the Taylor process and the surface of this fiber was smother than that fabricated by the PDME method.