• Korean Journal of Metals and Materials
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• v.50 no.12
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• pp.897-905
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• 2012

Directional solidification experiments were carried out in a hypoeutectic Al-11.3Si-3.5Cu system to investigate the microstructural evolution with the solidification rate. At a fixed temperature gradient, a dendritic microstructure was observed at a constant speed of more than $25{\mu}ms^{-1}$, a cellular interface developed at $5{\mu}ms^{-1}$ and the growth rate of $0.5{\mu}ms^{-1}$ led to the stability of the planar interface. The results revealed that primary silicon phases formed among cells, even though the studied Al-Si alloy system formed the composition within a hypoeutectic silicon composition. This suggests that the liquid concentration among cells during solidification reached a higher concentration, i.e., the eutectic concentration. It is, however, interesting that primary silicon phases did not form during a dendritic growth of more than $25{\mu}ms^{-1}$. These experimental observations are explained using the theoretical models on the interface temperatures.

• Journal of Korea Foundry Society
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• v.25 no.4
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• pp.156-160
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• 2005

There are many factors that influence solidification behavior during continuous casting, e.g. include superheat, casting speed, cooling rate and holding time. However, when melt is stirred by electromagnetic force, there would be some changes in its solidification behavior compared to that of the ordinary casting process. In this study, the billets of A356 alloy with a diameter of 3 inch were fabricated with electromagnetic stirring under various conditions of superheat, casting speed and input voltage of electro magnetic stirring (EMS) device. The microstructure was also investigated under the various casting conditions and electromagnetic input voltages. When increase in input voltage, the microstructure was changed from dendritic to rosette type and finally to spheroidal. With pouring temperature, casting speed and electromagnetic input voltage were $650^{\circ}C$, 100 mm/min and 140 V, respectively, the billet with a diameter of 3 inch, which has a uniform dispersed spheroidal particles in the whole area of billet except for the surface area, was manufactured.

• Journal of Welding and Joining
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• v.32 no.6
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• pp.41-46
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• 2014

In this study, cracking susceptibility of laser cladding was investigated according to the processing parameters such as laser power, scan speed and feeding rate with blended powders of stellite#6 and technolase40s (WC+NiCr). The solidification microstructure of clad was composed of Co-based dendrite structures with ${\gamma}+Cr7C3$ eutectic phases at the dendritic boundaries. The crack propagation showed transgranular fracture along dendritic boundaries due to brittle chrome carbide at the eutectic phases. From results of fractography experiments, the fracture surface was typical cleavage brittle fracture in the clad and substrate. The number of clad cracks, caused by a tensile stress after the solidification, increased with increase of laser power, scan speed and feeding rate. Increase of the laser power caused large pores by facilitating WC decarburizing reaction. And the pores affected increase of crack susceptibility. High scan speed caused increment of clad cracks due to thermal stress and WC particle fractures. Also, increase of the feeding rate accompanied an amount of WC particles causing crack initiation and decarburizing reaction.

• Journal of Korea Foundry Society
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• v.14 no.5
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• pp.464-470
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• 1994

The horizontal continuous casting method with the heated mold was applied to study the solidification structures of the pure Al and Al-0.5wt%Si and Al-1.0wt%Si alloy rods. The results could be summarized as follows: 1. The S/L interface structures of pure Al represented the hexagonal cells at the casting speed of 590 and 350mm/min, respectively. However, the hexagonal cells became irregular as the casting speed and(or) Si amount increased. 2. The striation increased as the Si amount and casting speed increased and was found to result from the occurrence of growth twin crystals by XRD analysis. 3. The striation did not affect the mechanical and electrical property of the drawn wire from the casted rod. This means the striation is not a serious defect which has to consider in the production of micro-sized fine wire in the drawing process.

• Journal of Korea Foundry Society
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• v.12 no.3
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• pp.220-229
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• 1992

The degree of purification and the macrostructure of high purity aluminium were studied through the alternate stirring method in order to improve the nonuniformity of solute concentration in the unidirectional stirring method. The $2^3$ factorial design was done to examine the effects of experimental factors more qualitatively. In the relatively low stirring speed of 1500 rpm with alternate stirring mode, the uniform solute profile and refined grain structure were obtained due to strong washing effect and turbulent fluid flow. It was induced by the transition of the momentum boundary layer by alternation of the stirrer. It was concluded from this study that the alternate stirring mode was more effective to obtain the uniformity of solute even in the stirring speed of 1500 rpm. But the degree of purification decreased below the critical alternating period. When 2N(99.8wt.%) aluminium was used as the starting material the morphology of solid-liquid showed the cellular shape and the columnar grains were inclined to the direction of rotation. This inclined grain growth resulted from the difference of relative velocities of solid and liquid. The inclined angle was increased as the stirring speed increased and solidification proceeded. In the case of 4N aluminium, there was no inclined grain growth and it was confirmed from the macrostructure and SEM work that the morphology of solid-liquid interface was planar. From the factorial design, it was found that the alternate stirring mode showed poorer purification effect than that of unidirectional stirring mode at low speed(500 rpm). In addition, the factor that had the most significant effect on the degree of purification was the stirring speed.

• Korean Journal of Materials Research
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• v.32 no.9
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• pp.391-395
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• 2022

Research is being actively conducted on the continuous thin plate casting method, which is used to manufacture magnesium alloy plate for plastic processing. This study applied a heat transfer solidification analysis method to the melt drag process. The heat transfer coefficient between the molten magnesium alloy metal and the roll in the thin plate manufacturing process using the melt drag method has not been clearly established until now, and the results were used to determine the temperature change. The estimated heat transfer coefficient for a roll speed of 30 m/min was 1.33 × 10⁵ W/m²·K, which was very large compared to the heat transfer coefficient used in the solidification analysis of general aluminum castings. The heat transfer coefficient between the molten metal and the roll estimated in the range of the roll speed of 5 to 90 m/min was 1.42 × 10⁵ to 8.95 × 10⁴ W/m²·K. The cooling rate was calculated using a method based on the results of deriving the temperature change of the molten metal and the roll, using the estimated heat transfer coefficient. The DAS was estimated from the relationship between the cooling rate and DAS, and compared with the experimental value. When the magnesium alloy is manufactured by the melt drag method, the cooling rate of the thin plate is in the range of about 1.4 × 10³ to 1.0 × 10⁴ K/s.

• International Journal of Precision Engineering and Manufacturing
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• v.7 no.3
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• pp.47-50
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• 2006

High-speed machining is a very useful tool and one of the most effective rapid manufacturing processes. This study sought to produce various high-speed machining materials with excellent quality and dimensional accuracy. However, high-speed machining is not suitable for microscale thin-walled structures because the structure stiffness lacks the ability to resist the cutting force. This paper proposes a new method that is able to rapidly produce very thin-walled structures. This method consists of high-speed machining followed by filling. A strong work-holding force results from the solidification of the filling materials. Low-melting point metal alloys are used to minimize the thermal effects during phase changes and to hold the arbitrarily shaped thin-walled structures quickly during the high-speed machining. We demonstrate some applications, such as thin-walled cylinders and hemispherical shells, to verify the usefulness of this method and compare the analyzed dimensional accuracy of typical parts of the structures.

• Journal of the Korean Society for Precision Engineering
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• v.33 no.6
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• pp.469-475
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• 2016

In this work, casting processes, such as filling and solidification, were simulated in order to accurately predict volume shrinkage defects in large-sized sand gravity casting. Turbulent flow of melted materials and a difference of solidification speed can cause volume shrinkage defects. In order to solve this problem and to understand the phenomenon, a porous filter application was studied. Two different porosities of 10 and 20 p.p.i filters were introduced into the gating system, and in view of the results so far achieved, the defect was dramatically reduced by 22%, compared to that without the use of the filter.

• Korean Journal of Materials Research
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• v.9 no.4
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• pp.386-391
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• 1999

The charge-discharge, the high-rate dischargeability, and the self discharge characteristics of the electrodes composed of rapidly solidified ZrV\ulcornerMn\ulcornerMo\ulcornerNi\ulcorneralloy, which has the form of partial substitution of Mn, Mo, Ni for V in $ZrV_2$ were studied. The alloys were prepared using Arc & RSP(Rapid Solidification Process) at the rotating roller speed of 2000 and 5000 rpm. Some of them were received heat treatment at$ 560 ^{\circ}C$ for 1 hour after the solidification to investigate the effect of the heat treatment. It was fond that cycle life was significantly improved by RSP, whereas discharge capacity, activation rte and high rate dischargeability were decreased compared with the conventional arc melting method. The capacity loss seems to be due to the loss of the crystallinity and the increase of the cycle life ascribed to the presence of the amporphous phase as well as the refined grain size of less than 0.2$\mu\textrm{m}$. Heat treatment of the alloy cooled at 2000 rpm improved the cycle life. In case of the alloys cooled at 5000 rpm, both the discharge capacity and the activation rate were significantly improved by the heat treatment.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.20 no.10
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• pp.3313-3321
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• 1996

A fundamental study in cooling and solidification process focused on ice storage was performed, including the interesting phenomena of density inversion, supercooling and dendritic ice. A numerical study was performed for natural convection and ice formation in the cooling and freezing processes with supercooling in a space between double cylinders. When water was cooled under the freezing point by a cooling wall in a cavity, solidification was not started at once, but a subcooled region was formed near the wall. Especially, when the cooling rate was low, subcooled region extended to a wide area. However, after a few minutes, supercooling is released by some triggers. Dendritic ice is suddenly formed within a subcooled region, and a dense ice layer begins to be developed from the cooling wall. Due to the difficulties, most previous studies on solidification process with numerical methods had not treated the supercooling phenomena, i.e. the case considering only the growth of dense ice. In this study, natural convection and ice formation considering existence of supercooling and dendritic ice were analyzed numerically with using finite difference method and boundary fixing method. The results of numerical analysis were well compared with the experimental results.