• Journal of Powder Materials
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• v.31 no.1
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• pp.37-42
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• 2024

Friction stir spot welding (FSSW) is a solid-state joining process and a rapidly growing dissimilar material welding technology for joining metallic alloys in the automotive industry. Welding tool shape and process conditions must be appropriately controlled to obtain high bonding characteristics. In this study, FSSW is performed on dissimilar materials AA5052-H32 aluminum alloy sheet and SPRC440 steel sheet, and the influence of the shape of joining tool and tool insertion depth during joining is investigated. A new intermetallic compound is produced at the aluminum and steel sheets joint. When the insertion depth of the tool is insufficient, the intermetallic compound between the two sheets did not form uniformly. As the insertion depth increased, the intermetallic compound layer become uniform and continuous. The joint specimen shows higher values of tensile shear load as the diameter and insertion depth of the tool increase. This shows that the uniform formation of the intermetallic compound strengthens the bonding force between the joining specimens and increases the tensile shear load.

• Journal of the Korean Society for Heat Treatment
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• v.37 no.5
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• pp.247-254
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• 2024

Metastable β titanium alloys have been used in implants due to their high specific strength and excellent corrosion resistance. However, the high cost of β-stabilizing elements limits the application of metastable β titanium alloys. Consequently, research has been conducted on low-cost metastable β titanium alloys using relatively inexpenisve β-stabilizing elements such as Mo and Fe. This study analyzes the wear resistance of Ti-5Mo-xFe (x=2,4 wt%) alloys, designed and manufactured as low-cost metastable β titanium alloys. The wear mechanisms of Ti-5Mo-xFe alloys were identified through ball-on disk testing and observation of the worn surfaces. Additionally, the influence of Fe addition on the microstructure and the resulting changes in wear resistance were examined. The wear resistance of the Ti-5Mo-xFe alloys were evaluated in comparison to the Ti-6Al-4V ELI alloy.

• Journal of Powder Materials
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• v.15 no.1
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• pp.31-36
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• 2008

In this study, the bottom-up powder metallurgy and the top-down severe plastic deformation (SPD) techniques for manufacturing bulk nanomaterials were combined in order to achieve both full density and grain refinement without grain growth of rapidly solidified Al-20 wt% Si alloy powders during consolidation processing. Continuous equal channel multi-angular processing (C-ECMAP) was proposed to improve low productivity of conventional ECAP, one of the most promising method in SPD. As a powder consolidation method, C-ECMAP was employed. A wide range of experimental studies were carried out for characterizing mechanical properties and microstructures of the ECMAP processed materials. It was found that effective properties of high strength and full density maintaining nanoscale microstructure are achieved. The proposed SPD processing of powder materials can be a good method to achieve fully density and nanostructured materials.

• Journal of Korea Foundry Society
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• v.28 no.2
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• pp.79-84
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• 2008

Metal foam is one of the most interesting materials with various multi-functional properties such as light weight, energy absorption, high stiffness and damping capability. Among them, energy absorption property has keen interests in the field of automotives for passenger protection. Nowadays, researches about pore size and porosity control of the foam are increased to correspond them. However, though energy absorption properties are improved, these results are not cost-effective process. In present research, however, as a part of improving the energy absorption property of metallic foams, 606X aluminum alloy was used for cell wall material which has higher strength than pure aluminum. And its morphological features are characterized. As a results, porosity and pore size are uniformity distribution with increasing foaming temperature in the case of 6061 alloy foams. 6063 alloy foam specimens have opposite tendency because of the influence of alloying element and viscosity of the molten melt.

• Korean Journal of Materials Research
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• v.21 no.11
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• pp.581-586
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• 2011

This study describes a hydrogen embrittlement evaluation of the subsurface zone in 590DP steel by micro-Vickers hardness measurement. The 590DP steel was designed to use in high-strength thin steel sheets as automotive materials. The test specimens were fabricated to 5 series varying the chemical composition through the process of casting and rolling. Electrochemical hydrogen charging was conducted on each specimen with varying current densities and charging times. The relationship between the embrittlement and hydrogen charging conditions was established by investigating the metallography. The micro-Vickers hardness was measured to evaluate the hydrogen embrittlement of the subsurface zone in addition to the microscopic investigation. The micro-Vickers hardness increased with the charging time at the surface. However, the changing ratio and maximum variation of hardness with depth were nearly the same value for each test specimen under the current density of 150 mA/$cm^2$ and charging time of 50 hours. Consequently, it appears that hydrogen embrittlement in 590DP steel can be evaluated by micro-Vickers hardness measurement.

• Korean Journal of Metals and Materials
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• v.49 no.3
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• pp.203-210
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• 2011

Bake hardening steels have to resist strain aging to prevent the yield strength increment and stretcher strain during press process and to enhance the bake hardenability during baking process after painting. The bake hardening steels need to control the solute carbon and the solute nitrogen to improve the bake hardenability. Ti and/or Nb alloying for nitride and carbide precipitation and low carbon content below 0.003% are used to solve strain aging and formability problem for automotive materials. However, in the present study, the effect of micro-precipitation of copper sulfide on the bake hardenability and fatigue properties of extremely low carbon steel has been investigated. The bake hardenability of Cu-alloyed bake hardening (Cu-BH) steel was slightly higher (5 MPa) than that of Nb-alloyed bake hardening (Nb-BH) steel, but the fatigue limit of Cu-BH steel was far higher (45 MPa) than that of Nb-BH steel. All samples showed the ductile fracture behavior and some samples revealed distinct fatigue stages, such as crack initiation, stable crack growth and unstable crack growth.

• Korean Journal of Metals and Materials
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• v.49 no.9
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• pp.720-725
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• 2011

W-Ni-Fe heavy alloys have been used in various fields, such as kinetic energy penetrators and radiation shielding materials, due to their high density and good mechanical properties. In this study, the sintering of W-Ni-Fe alloys with various Ni/Fe ratios was demonstrated to improve the mechanical properties and penetration capabilities of heavy alloys by formation of interfacial phase. The microstructural changes and the mechanical properties of the W-Ni-Fe alloys after liquid-phase sintering were investigated. The Vickers hardness and tensile strength of the 95W1.3Ni3.7Fe sample, which had coated W grains by $Fe_7W_6$ phase (${\mu}$-phase), were 450 Hv and 1560 MPa, respectively. As a result, enhancement of the mechanical properties was considered to have uniformly generated ${\mu}$-phase around W grains.

• Elastomers and Composites
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• v.57 no.3
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• pp.100-106
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• 2022

Waterborne polyurethane-acrylate(WPUA) dispersions were prepared by surfactant-free emulsion polymerization in a two-step process. In the first step, polytetrahydrofuran, isophorone diisocyanate, dimethylol proponic acid, and 2-hydroxyethyl methacrylate were used to synthesize a vinyl-terminated polyurethane prepolymer. In the second step, styrene, methyl methacrylate, butyl acrylate, and different multi-functional crosslinkers were copolymerized. 1,6-hexanediol diacrylate, trimethylolpropane triacrylate, and pentaerythritol tetraacrylate were used as the crosslinkers, and their effect on the mechanical and thermal properties of WPUA was investigated. Overall, as the number of functional groups of the cross-linker increased, the gel fraction improved to 79.26%, the particle size increased from 75.9 nm to 148.7 nm, and the tensile strength was improved from 5.86 MPa to 12.40 MPa. In thermal properties, the glass transition temperature and decomposition temperature increased by 9.9℃ and 18℃, respectively. The chemical structures of the WPUA dispersions were characterized by Fourier-transform infrared spectroscopy. The synthesized WPUA has high potential for applications such as coatings, leather coatings, adhesives, and wood finishing.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.2
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• pp.137-143
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• 2022

Composite materials, being light-weight and of high mechanical strength, are increasingly used in various industries such as the aerospace, automobile, sporting-goods manufacturing, and ship-building industries. Recently, manufacturing of composite materials using 3D printers has increased. 3D-printed composite materials are made in free-form and adapted for end-use by adjusting the fiber content and orientation. However, research on the machining of 3D printed composite materials is limited. The aim of this study is to develop a machine learning method to select machining conditions for machining of 3D-printed composite materials. The composite material was composed of Onyx and carbon fibers and stacked sequentially. The experiments were performed using the following machining conditions: spindle speed, feed rate, depth of cut, and machining direction. Cutting forces of the different machining conditions were measured by milling the composite materials. PCA, a method of machine learning, was developed to select the machining conditions and will be used in subsequent experiments under various machining conditions.

• Journal of Powder Materials
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• v.30 no.3
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• pp.223-232
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• 2023

Metal additive manufacturing (AM) has transformed conventional manufacturing processes by offering unprecedented opportunities for design innovation, reduced lead times, and cost-effective production. Aluminum alloy, a material used in metal 3D printing, is a representative lightweight structural material known for its high specific strength and corrosion resistance. Consequently, there is an increasing demand for 3D printed aluminum alloy components across industries, including aerospace, transportation, and consumer goods. To meet this demand, research on alloys and process conditions that satisfy the specific requirement of each industry is necessary. However, 3D printing processes exhibit different behaviors of alloy elements owing to rapid thermal dynamics, making it challenging to predict the microstructure and properties. In this study, we gathered published data on the relationship between alloy composition, processing conditions, and properties. Furthermore, we conducted a sensitivity analysis on the effects of the process variables on the density and hardness of aluminum alloys used in additive manufacturing.