• Title, Summary, Keyword: Aluminum Casting

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A study on the Horizontal Continuous Casting by Horizontal Continuous Casting Machine of Al-xSi(x=10-15%) Aluminum Alloy (수평식 연속주조 시스템을 이용한 Al-xSi(x=10-15%)합금 수평연주에 관한 연구)

  • Seo, Heesik;Ha, Sangbaek
    • Journal of the Korean Society of Industry Convergence
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    • v.17 no.3
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    • pp.122-135
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    • 2014
  • This paper was studied on the horizontal continuous casting of Al-xSi(x=10~15%) aluminum alloy. The experiments of the horizontal continuous casting was carried out by the horizontal continuous casting machine for various casting conditions and investigated on fracture types and mechanisms. Surface defect types for the horizontal continuous casting is also investigated. And the study was carried out that the horizontal continuous casting conditions such as casting temperature, cooling rate, and drawing speed affect the hardness and primary silicon size of Al-xSi(x=10~15%) aluminum rod bar. Casting temperature within this experiment conditions don't affect on the hardness of rod bar but the higher casting temperature is the smaller primary silicon size. The higher cooling rate and drawing speed have the higher hardness and the smaller primary silicon size.

Ni-Al Based Intermetallics Coating Through SHS using the Heat of Molten Aluminum (알루미늄 주물 위 용탕열을 이용한 N-Al계 금속간화합물의 연소합성 코팅)

  • Lee, Han-Young;Cho, Yong-Jae
    • Journal of Korea Foundry Society
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    • v.31 no.2
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    • pp.83-86
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    • 2011
  • Ni-Al based intermetallic compounds of self-propagating high-temperature synthesis (SHS) by the heat of molten aluminum and been coated on the aluminum casting alloy. The effects of the pouring temperature in casting and the thickness of casting substrate on SHS of the coating layer have been investigated. The experimental result showed that the reaction of the coating layer was activated with increasing the pouring temperature in casting and the thickness of casting substrate. However, the aluminum substrate was re-melted by the heat of formation for intermetallic compounds. Then, it was considered that some mechanical or thermal treatments for elemental powder mixtures were required to control the heat of formation for intermetallic compounds in advance.

3D scanning based mold correction for planar and cylindrical parts in aluminum die casting

  • Seno, Takashi;Ohtake, Yutaka;Kikuchi, Yuji;Saito, Noriaki;Suzuki, Hiromasa;Nagai, Yukie
    • Journal of Computational Design and Engineering
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    • v.2 no.2
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    • pp.96-104
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    • 2015
  • Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD) data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

Development of Large-Scale Aluminum Castings of Air Bag Support Components for the Korean High Speed Trains (한국형 고속전철 객차 연결부 에어백 지지부 대형 알루미늄 주물의 개발)

  • Yoo, Seung-Mok;Nam, Jeong-Ho;Kim, Jeong-In;Lim, Chae-Ho;Kim, Young-Hyun;Park, Soo-Hyun
    • Proceedings of the KSR Conference
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    • pp.2046-2052
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    • 2008
  • For the lighting of vehicles structural casting components of aluminum casting alloys are substituted for those of steel or iron. For the manufacturing of large-scale premium quality aluminum castings the developments of a new casting process and a heat treatment process are necessary. The optimum casting design and heat treatment condition for large-scale castings are drawn with the help of Z-Cast software for the casting process analysis in this study. Low pressure sand casting method is applied successfully to produce air bag support components of D357 aluminum casting alloy.

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Effect of the Anti-Freeze Coolant on the Corrosion Resistance of Aluminum Cylinder Heads (알루미늄 실린더헤드의 내식성에 미치는 부동액의 영향)

  • 김영찬;배도인
    • Transactions of the Korean Society of Automotive Engineers
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    • v.7 no.5
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    • pp.89-95
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    • 1999
  • In this study, the corrosion resistance of the aluminum casting commercial materials used in the automotive engine parts with respect to the anti-freeze coolant environment has been tested by the potentio dynamic method. especially, the effect of borax additive in engine coolant on the corrosion resistance of the aluminum casting materials has been evaluated. It was found that the borax in commercial engine coolant, used to prevent the corrosion in cast iron engine, causes a pit corrosion of aluminum casting materials at high temperature. During the engine endurance test with the coolant containing borax, the aluminum cylinder head was failed by the pitting corrosion near the exhaust port. Conclusively, it was suggested that the use of borax in the anti-freeze coolant be restricted for the automotive with aluminum cylinder head.

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Optimization of the Thin-walled Aluminum Die Casting Die Design by Solidification Simulation (응고 시뮬레이션에 의한 박육 알루미늄 다이캐스팅 금형 방안의 최적화)

  • Kim, Young-Chan;Cho, Se-Weon;Cho, Jae-Ik;Jeong, Chang-Yeol;Kang, Chang-Seog
    • Journal of Korea Foundry Society
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    • v.28 no.4
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    • pp.190-194
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    • 2008
  • Thin-walled die casting of aluminum notebook computer housing with less than 1mm thickness was investigated by using computational solidification simulation and actual casting experiment. Three different types of gate design, finger, tangential and split type, were used and the results showed that sound thin-walled die casting was possible with tangential and split type gating design because those gates allowed aluminum melt flowed into the thin-wall cavity uniformly and split type gating system was preferable gating design than tangential type at the point of view of soundness of casting and distortion generated after solidification. Also, solidification simulation agreed well with the actual die-casting and the casting showed no casting defect and distortion.

On the Measurment of Residual Stresses in Aluminum Alloy Casting Parts (알루미늄 합금 주조 부품에 발생하는 잔류응력의 측정)

  • 김채환
    • Proceedings of the Korean Society for Technology of Plasticity Conference
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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

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On the Measurement of Residual Stresses in Aluminum Alloy Parts Fabricated by Precision Metal Mold Casting (정밀금형 알루미늄 합금 주물에서의 잔류응력 측정에 관한 연구)

  • Kim, Chae-Hwan;Mun, Su-Dong;Gang, Sin-Il
    • Transactions of the Korean Society of Mechanical Engineers A
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    • v.23 no.11
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    • pp.2087-2095
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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.

A Study on the Development of Large Aluminum Flange using Casting/Forging Process (주조/단조 기술을 이용한 대형 알루미늄 플랜지 개발에 관한 연구)

  • 배원병;왕신일;서명규;조종래
    • Proceedings of the Korean Society of Precision Engineering Conference
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    • pp.905-909
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    • 2001
  • The significance of casting/forging process for reducing the production cost of large components is being noted in these days. This casting/forging process is a method of forging a workpiece preformed by casting into the final shape. In this study, the casting/forging process has been applied in manufacturing a large aluminum flange in order to determine the optimum forging condition of the aluminum flange. The optimum range of forging temperature of Al 5083 was from $420^{\circ}C$ to $450^{\circ}C$. The suitable strain rate was 1.5 $sec^{-1}$. The deformation amount of a preform in a forging process is key role in the mechanical properties of casting/forging products. In order to find the change of mechanical properties according to effective stain of cast aluminum billets, a hot upsetting test were performed with rectangular blocks and then a uniaxial tensile test was performed with specimens cut from the upsetted billets. The tensile strength and the elongation of cast/upsetted aluminum billets were increased largely until the effective strain was 0.7. FE analysis was performed to determine the configurations of cast preform and die for an aluminum flange. In the FE analysis, the forging load-limit was fixed 1500ton for the low equipment cost. The cast preform was designed so that the effective stain around the neck of a flange exceeds 0.7. In the forging experiment for an aluminum flange, it was confirmed that the optimal configuration of the cast preform predicted by FE analysis was very useful. The cast/forged products using designed preform were made perfectly without any defects.

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A Study of Characteristics of the LED Heat Dissipation According to the Changes in Composition of Die-casting Aluminum (다이캐스팅용 알루미늄의 성분 변화에 따른 LED 방열 특성 연구)

  • Yeo, Jung-Kyu;Her, In-Sung;Yu, Young-Moon;Lee, Se-Il;Choi, Hee-Lack
    • Journal of the Korean Institute of Electrical and Electronic Material Engineers
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    • v.27 no.8
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    • pp.535-540
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    • 2014
  • Because of the development of LED technology, products due to high output and compact, the material with high thermal conductivity has been developed. Now that heat radiating part of the LED lamp is currently used for die casting of aluminum. The development of aluminum with excellent thermal conductivity is required. In this study, we measured the thermal properties and compared them while we produced the alloy by changing the component of die casting aluminum. From this study, the thermal conductivity and thermal resistance of the developed alloy were superior to die casting aluminum.