• Transactions of the Korean Society of Mechanical Engineers B
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• v.33 no.7
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• pp.469-476
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• 2009

Most material of engineering interest undergoes solidification process from liquid state. Identifying the underlying mechanism during solidification process is essential to determine the microstructure of material thus the physical properties of final product. In this paper, effect of fluid convection on the dendrite solidification morphology is studied using Level Contour Reconstruction Method. Sharp interface technique is used to implement correct boundary condition for moving solid interface. The results showed good agreement with exact boundary integral solution and compared well with other numerical techniques. Effects of Peclet number and undercooling on growth of dendrite tip of both single and multiple seeds have been also investigated.

• Proceedings of the KSME Conference
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• 2000.04b
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• pp.37-44
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• 2000

Numerical investigation is made to study the effects of natural convection on the formation of macrosegregation of a Pb-Sn alloy solidification process in a 2-D confined rectangle mold. The governing equations are calculated using previous continuum models with SIMPLE algorithm doring the solidification process. In addition. to track the solid-liquid interface with time variations. the moving boundary condition Is adopted and irregular interface shapes are treated with Boundary-Fitted Coordinate system. As the temperature reduce from the liquidus to the solidus, the liquid concentration of Sn. the lighter constituent, increases. Then the buoyancy-driven flow due to temperature and liquid composition gradients, called thermosolutal convection or double diffusion, occurs in the mushy region and forms the complicated macrosegregation maps. Related to this phnomena, effects on the macrosegregation formation depending on the cooling condition and gravity values are described.

• Journal of Korea Foundry Society
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• v.20 no.2
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• pp.80-88
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• 2000

Continuous casting equipment was designed to cast the metallic uranium rods, and a thermal analysis was carried out to calculate the temperature and solidification profiles. Fluid flow and heat transfer analysis model including the effects of phase change was used to simulate the continuous casting process by finite volume method. In the design of continuous casting equipment, the casting speed, pouring temperature and cooling conditions should be considered as significant factors. In this study, the effects of casting speed, pouring temperature, and air gap between the uranium and mold were investigate. The results represented that the temperature and solidification profiles of continuous casting equipment varied with the casting speed, pouring temperature, and air gap.

• Journal of Powder Materials
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• v.21 no.5
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• pp.366-370
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• 2014

The present study demonstrates the effect of solidification condition on the pore structure in freeze drying process using the slurries of CuO/sublimable vehicles. Camphene and Camphor-45 wt% naphthalene based slurries with 14 vol% CuO powder were frozen into a mold at $-25^{\circ}C$, followed by sublimation at room temperature. The green bodies were hydrogen-reduced and sintered at $500^{\circ}C$ for 1 h. The porous Cu specimen, frozen the CuO/camphene slurry into the heated mold of the upper part, showed large pores with unidirectional pore channels and small pores in their internal wall. Also, it was observed that the size of large pores was decreasing near the bottom part of specimen. The change of pore structure depending on the freezing condition was explained by the nucleation behavior of camphene crystals and rearrangement of solid powders during solidification. In case of porous Cu prepared from CuO/Camphor-naphthalene system, the pore structure exhibited plate shape as a replica of the original structure of crystallized vehicles with hypereutectic composition.

• Journal of Mechanical Science and Technology
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• v.19 no.9
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• pp.1773-1780
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• 2005

The process of mould design in the foundry industry has been based on the intuition and experience of foundry engineers and designers. To bring the industry to a more scientific basis the design process should be integrated with scientific analysis such as heat transfer. The production by foundry techniques is influenced by the geometry configuration, which affects the solidification conditions and subsequent cooling. Numerical simulation and/or experiments make possible the selection of adequate materials, reducing cycle times and minimizing production costs. The main propose of this work is to study the heat transfer phenomena in the mould considering the phase change of the cast-part. Due to complex geometry of the mould, a block unstructured grid and a generalized curvilinear formulation engaged with the finite volume method is described and applied. Two types of boundary conditions, diffusive and Newtonian, are used and compared. The developed numerical code is tested in real case and the main results are compared with experimental data. The results showed that the solidification time is about 6 seconds for diffusive boundary conditions and 14.8 seconds for Newtonian boundary conditions. The use of the block unstructured grid in combination with a generalized curvilinear formulation works well with the finite volume method and allows the development of more efficient algorithms with better capacity to describe the part contours through a lesser number of elements.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.15 no.3
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• pp.1707-1710
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• 2014

This paper is the study for the directional solidification of the ingot through the thermal analysis simulation and structural change of casting furnace. The activation analysis of metal impurities were also detected the total number of 10 different metals, but the concentration distribution showed no significant positional deviations in the same position from the top to the bottom. With the results of thermal analysis simulation, the silicon as a whole has reached the melting temperature as the retention time 80 min. The best cooling conditions showed at the upper cooling temperature $1,400^{\circ}C$ and cooling time 60min. The fabricated wafers showed the superior etching result at the grain boundary than that of existing commercial wafers.

• Journal of Korea Foundry Society
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• v.17 no.3
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• pp.302-308
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• 1997

In spite of the fact that magnesium has low density and good machinability, its applications are restricted as a structural engineering material because of the poor strength, ductility, and corrosion resistance of the conventional ingot metallurgy alloys. Such properties can be improved by microstructural refinement via rapid solidification processing. In this study, Mg-5wt%Zn alloys have been produced as continuous strips by the melt overflow technique. In order to evaluate the influence of the cooling rate on the grain refinement and mechanical properties, seven different thickness strips were produced by means of controlling the speed of the cooling wheel. Then the microstructual observations were undertaken with the objective of evaluating the grain refinement as function of the cooling rate. The tremendous increase in hardness of Mg-Zn alloy was mainly due to the refinement of the grain structure by the effect of rapid solidification. The formation of intermetallic phases on the grain boundaries may have a positive effect on the corroion resistance. Therefore, despite competition from many other developments, the rapid solidification process emerges as a valuable method to develop superior and commercially acceptable magnesium alloys.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.25 no.3
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• pp.285-295
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• 2001

The transport phenomena in a wedge-shaped pool of twin-roll continuous caster are affected by the various operating parameters such as the melt-feed pattern, roll-gap thickness, melt-superheat, and casting speed. A computer program has been developed for analyzing the two-dimensional, steady conservation equations for transport phenomena during twin-roll continuous casting process in order to estimate the turbulent melt-flow, temperature fields, and solidification in the wedge-shaped pool. The turbulent characteristics of the melt-flow were considered using a low-Reynolds-number K-$\xi$ turbulence model. Based on the computer program, the effects of the different melt-feed patterns, roll-gap thicknesses, and superheats of melt on the variations of the velocity and temperature distributions, and the mushy solidification were examined. The results show that the liquidus line is located considerably at the upstream region, and in the lower region appear the well-mixed melt-flow and most widely developed mushy zone. Besides, the variation of melt-flow due to varying melt-feed patterns, affects mainly the liquidus line, and scarcely has effects on the solidus line in the outlet region.

• Korean Journal of Materials Research
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• v.16 no.11
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• pp.668-675
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• 2006

In the partial squeeze casting process, the filling behavior of liquid metal and solidification pattern in thick area have significant influence on the quality of casting products and die life. For the optimal casting design of automobile transmission gear housing, various analyses were performed in this study by using computer simulation code, MAGMAsoft and the simulation results were compared and analyzed with experimental results. By air pressure criteria, internal porosities caused by air entrap during the mold filling were predicted and reduced remarkably by modification of gating system. Also, optimal squeeze-time lag to apply partial squeeze pin in thick area was calculated and the castings was free from shrinkage defects with the result of solidification analysis. Consequently, casting design for automobile transmission gear housing was optimized and approved by Computer Tomography.

• 제어로봇시스템학회:학술대회논문집
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• 2000.10a
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• pp.352-352
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• 2000

ESR(ElectroSlag Remelting) Process is secondary fine process and melts steels by electric resistance heat and fines the melting steels by an appropriate solidification process parameters which affects the melting and solidification processes to get the high quality products. This paper describes a method to derive the mathematical model and analysis the dynamic characteristics for designing a controller of the ESR processes. The ESR process consists of a melting and solidificating processes and electrical system include the contact resistance mechanism. In this paper, we consider only the static relationship between inputs and outputs of the electric system because the dynamics of the electric system is so fast compared with the melting and solidificating processes which are analysed by using finite difference method. As the results, the fine processing in ESR is analysed and the process controller could be designed based on the process dynamic analysis.