In this analysis, the analytical model was verified through the normal mode analysis of the piston for the 2.9 liter IDI (indirect injection) engine. Heat transfer analysis was carried out by selecting two cases of applied temperature using the validated model. The first case was a condition of 350℃ on the piston upper surface and 100℃ on the piston body and inner wall. In the second case, the conditions were set to give a temperature of 400℃ on the upper surface of the piston and 100℃ on the piston body and the inner wall. In addition, the temperature distribution due to heat transfer was obtained for the pistons with boundary conditions of two cases, and then the thermal stress distribution due to thermal expansion was obtained using the input. Using this analysis result, the thermal stress caused by thermal expansion due to the thermal conduction of the piston is examined and used as the basic data for design.

Damping and sound absorption not only reduce environmental pollution caused by vibration and noise, but also improves processing accuracy, resolution of precision measuring instruments and fatigue life of machine parts in various precision machines. The vibration-damping plate is largely divided into a constrained type in which the resin is confined by a plate and a non-constrained type in which a plate is made of a polymer material mainly composed of polymer. The external vibration energy is absorbed by the thermal energy required for friction, stretching and compression of resin, so that the noise and vibration generated by resonance are reduced. The vibration damping ability of the sandwich plate produced in this study was found to be somewhat superior, which may be due to the difference in adhesive force during the manufacture of the sandwich plate. In the experimental results, it was confirmed that the sandwich plate material is superior to the vibration damping ability than the 5182 aluminum single plate material, it can be seen that the sandwich plate is effective for vibration damping of the aluminum alloy plate material.

In this study, the whole process of 6xxx series aluminum extruded alloy for high speed train interior and exterior parts are characterized. The mechanical properties, and chemical composition of the case materials were evaluated for the 6063, 6061 and 6N01 alloy profiles and compared to the commercial materials and the evaluation results satisfied the standard. The cast product was extruded using the air slip(AS) casting method and the direct casting(DC) method and these were again heat-treated conditions with T5 or T6. The remarkable point is that the extrusion temperature and pressure of 6061 alloy were somewhat higher than those of other alloys. The reason is that 6061 alloy exhibited brittle fracture due to grain boundary segregation even at the tensile fracture surface and the fact that the product used a billet by the direct casting method instead of air slip one. The mechanical properties were evaluated for the 6063, 6061, 6N01 extruded alloys and the evaluation results were analyzed and satisfied the standard properties.

In this study, the whole process of 6xxx series aluminum cast alloy for high speed train interior or exterior parts are characterized. For casting, selection of optimum alloying elements, dissolution technology, de-gassing process, production of molds conforming to the conditions of use, development of casting process control technology for various shapes and materials are performed for the development of high-quality, high strength aluminum alloys. The development of more reliable lightweight aluminum and aluminum alloy for interior or exterior materials has been the scope of this study. The mechanical properties, and chemical composition of the case materials were evaluated for the 6063, 6061 and 6N01 alloy profiles and compared to the commercial materials and the evaluation results satisfied the standard.