• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1999.03b
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• pp.102-106
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• 1999

One of the main causes of unwanted dimensional changes in precision metal mold casting parts is excessive and irregular residual stresses induced by temperature gradients and plastic deformation in the solidifying shell. Residual stresses can also cause stress cracking and lower the fatigue life and fracture strength of the casting parts,. In the present study aluminum alloy casting system with metal mold equipped with electrical heating elements and water cooling units was designed and the casting specimens were produced to quantify the effects of different cooling conditions on the development of residual stresses. the layer removal method was used to measure the biaxial residual stresses in casting specimens produced from the experiments. The experimental results agreed with Tien-Richmond's theoretical model for thermal stress development for the solidifying metal plate

• Transactions of the Korean Society of Mechanical Engineers
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• v.10 no.1
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• pp.62-69
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• 1986

Fatigue surface crack growth was studied in 7075-T651 aluminum alloy plates subjected largely to bending loads. The surface crack length and its depth were measurement by the unloading elastic compliance method. The surface crack growth rate dc/dN, on the surface and da/dN, in the depth direction were obtained by the secant method. The stress intensity factor range .DELTA.K was computed by means of Newman and Raju equation. The aspect ratio a/c was presented in form of a/c=0.815-0.853(a/T). The effect of the stress ratio on the stable surface crack growth rates under increasing .DELTA.T is larger in lower .DELTA.K, while the relation between dc/dN, da/dN and the effective stress intensity factor range .DELTA.K$_{eff}$ is weakly dependent on the stress ratio.o.

• Steel and Composite Structures
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• v.17 no.2
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• pp.145-157
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• 2014

This study aimed to investigate the fatigue crack growth behavior of a kind of fiber metal laminates (FML) under four different stress levels. The FML specimen consists of three 2024-T3 aluminum alloy sheets and two layers of glass/epoxy composite lamina. Tensile-tensile cyclic fatigue tests were conducted on centrally notched specimen at four stress levels with various maximum values. A digital camera system was used to take photos of the propagating cracks on both sides of the specimens. Image processing software was adopted to accurately measure the length of the cracks on each photo. The test results show that: (1) a-N and da/dN-a curves of FML specimens can be divided into transient crack growth segment, steady state crack growth segment and accelerated crack growth segment; (2) compared to 2024-T3 aluminum alloy, the fatigue properties of FML are much better; (3) da/dN-${\Delta}K$ curves of FML specimens can be divided into fatigue crack growth rate decrease segment and fatigue crack growth rate increase segment; (3) the maximum stress level has a large influence on a-N, da/dN-a and da/dN-${\Delta}K$ curves of FML specimens; (4) the fatigue crack growth rate da/dN presents a nonlinear accelerated increasing trend to the maximum stress level; (5) the maximum stress level has an almost linear relationship with the stress intensity factor ${\Delta}K$.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.136-138
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• 2005

The responses of nanocrystalline aluminum powder of different grain sizes, was modeled Using, Khan, Huang, and Liang (KHL) viscoplastic model including hi-linear Hall-Petch type, based on experimental measurements. Correlation of strain-rate-dependent stress responses for different grain sizes were in good agreement with the experimental results.

• Journal of the Korean Society for Heat Treatment
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• v.31 no.6
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• pp.307-314
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• 2018

Simple tensile tests and microstructural investigations have been performed on extrudates of high strength aluminum alloys such as 7075, 7021 and 7xxx(Sc) to understand correlation between extruding conditions and extruded properties. Tensile specimens which were taken from different locations at the same cross section of an extrudate were tested at room temperature and with a strain rate of $8.9{\times}10^{-5}/s$. The microstructures according to the locations at the cross section have been observed using optical microscopy and electron back-scattered diffraction (EBSD) mapping to characterize the effect on stress-strain curve. The results could be classified in three types independent of alloying contents and extusion methods. The fine differences in the stress-strain curves were resulted from inhomogenity in the microstructures according to locations of an extrudate which were performed through instantaneous extruding conditions such as temperature, strain rate and strain.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.24 no.6 s.177
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• pp.1584-1592
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• 2000

Reversed plane bending fatigue tests were conducted on SiC whisker reinforced aluminum composite which were consolidated by squeeze casting process. Initiation and growth of small surface fatigue c racks were investigated by means of a plastic replica technique. The fatigue crack initiated in the vicinity of SiC whisker/matrix interface. It was found that a fatigue crack deflected along SiC whisker and grew in a zig-zag manner microscopically, although the crack propagated along the direction normal to the loading axis macroscopically. The coalescence of micro-cracks was observed in the tests conducted at high stress levels, but were not evident in tests in which lower levels of stress were applied. Due to the coalescence, a higher crack growth rate of small cracks rather than those of long cracks was recognized in da/dn -ΔK realtionship.

• Transactions of Materials Processing
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• v.16 no.5 s.95
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• pp.354-359
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• 2007

Effects of forging and mechanical properties of 6061 aluminum alloy wheel for automobiles were investigated in the present study. Microstructural and tensile characteristics of automobile wheel after hot forging process using dynamic screw press were analyzed to evaluate effect of metal flow on mechanical properties. The results showed advanced mechanical properties of 6061 alloy wheel because of $Mg_2Si$ precipitation by T6, elongated grain by forging, and work hardening by dense metal flow, etc. Hot compression tests were conducted in order to characterize high temperature compression deformation behaviors and microstructural variation in the range of $300{\sim}450^{\circ}C$, in the strain rate range of $10^{-3}{\sim}10^1\;sec^{-1}$. As strain rate increased, maximum compression stress increased but it was shown the reverse linear relation between temperature and maximum stress irrelevant to strain rate variation. On the other hand, temperature and yield stress didn't have any linear relation and its relation showed big deviation by a function of strain rate and test temperature.

• Transactions of Materials Processing
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• v.26 no.3
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• pp.156-161
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• 2017

In this study, the reason of die fracture occurring in hot forging of an aluminum fixed scroll was studied, based on experiments and finite element predictions. The material is assumed to be rigid-viscoplastic, and the die is rigid for the finite element predictions. The stress in the tension at the wrap root is known to cause brittle fracture, and the increase in the tensile stress is owing to the unbalanced filling of material into the die cavities between both sides of the warp. Based on the empirical and numerical achievements, the effects of geometrical parameters of the material on the die fracture were examined to find practical measures for elongated die life. It has been shown from the parametric study that the material with the optimized trapezoidal cross-section, which can be easily made during cutting or the optimized cylindrical billet with its eccentric placement in the die cavity, can considerably reduce the magnitude of the tensile stress around the die corner fractured, indicating that economical manufacturing with reduced number of stages and elongated die life can be realized at once using the optimized practical initial material.

• Journal of Adhesion and Interface
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• v.21 no.1
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• pp.20-26
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• 2020

Single lap-shear joints (SLJ) specimens with and without partial round fillets were fabricated to measure the average shear strength of adhesives. The effects of the length of the adherend on the SLJ specimens were also investigated. An epoxy adhesive was used to bond aluminum alloy. Tensile tests were performed on the adhesive bulk specimens to measure the mechanical properties. The finite element analysis (FEA) method was used to measure the adhesive stress distributions, i.e., the peel and shear stresses, on the bonded part. The experimental results revealed that the specimen consisting short length of adherend and without the partial round fillets exhibited the smallest average shear strength of adhesive among the investigated specimens. FEA revealed that the low average shear strength for the specimen with a short adherend length was caused by high stress concentrations on the adhesive at the edge of the bonded part.

• Transactions of Materials Processing
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• v.27 no.2
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• pp.87-92
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• 2018

Auto industries have tried to employ lightweight alloys to improve the fuel efficiency of manufactured vehicles, as the environmental concern becomes an important issue. Even though the aluminum alloy is one of the most appropriate lightweight alloys for auto parts, the low formability of an aluminum alloy has been an obstacle to its application. In order to resolve the low formability problem, a recent study (Lee et al., 2017 [1]) showed that the infrared (IR) local heat treatment can improve the formability with a reduction of heating energy. However, the aforementioned study was limited to only a linear line heating. Since many of the available auto parts as applicable to vehicle manufacturing have a curved line shape, the heating experiments for a curved line should be studied. The possibility of building IR lamps having complex shapes is an advantage of the IR lamp, since it can control the heating shape. This work conducted the IR local heat treatment for the curved line. The experimental results show that the IR local heat treatment can improve the formability of the aluminum alloy for curved line. Additionally, it is shown that the IR local heat treatment also reduces the heating energy when it is compared with the furnace heating which heats a blank as a whole. A numerical simulation with a stress-based forming limit diagram also supports the experimental results.