In this study, clinching characteristics of aluminum and galvanized steels were investigated for the application of clinching as a joining technique to aluminum wheelhouse assembly. A6451 aluminium alloy and galvanized steel sheets were joined by hybrid joining(clinching + adhesive bonding). Tensile-shear load and fracture mode of hybrid joints were investigated. Maximum tensile-shear load of hybrid joints was about six times higher than that of clinched joints without adhesive. Energy absorption values of hybrid joints were higher than those of clinched joints without adhesive as well as resistance spot welded steel joints. Developed aluminum wheelhouse assembly showed higher static stiffness than the existing steel parts. Aluminum wheelhouse inner panel unit was 44% lighter than the steel unit, and the final assembled aluminum wheelhouse was 14.6% lighter than the existing steel parts.

For the aerospace structural application of high-strength 2xxx series aluminum alloys, stress corrosion cracking(SCC) behavior in aggressive environments needs to be well understood. In this study, the SCC sensitivities of 2024- T62, 2124-T851 and 2050-T84 alloys in a 3.5% NaCl solution are measured using a constant load testing method without polarization and a slow strain rate test(SSRT) method at a strain rate of 10-6 /sec under a cathodic applied potential. When the specimens are exposed to a 3.5% NaCl solution under a constant load for 10 days, the decrease in tensile ductility is negligible for 2124-T851 and 2050-T84 specimens, proving that T8 heat treatment is beneficial in improving the SCC resistance of 2xxx series aluminum alloys. The specimens are also susceptible to SCC in a hydrogen-generating environment at a slow strain rate of 10−6/sec in a 3.5% NaCl solution under a cathodic applied potential. Regardless of the test method, low impurity 2124-T851 and high Cu/Mg ratio 2050-T84 alloys are found to have relatively lower SCC sensitivity than 2024-T62. The SCC behavior of 2xxx series aluminum alloys in the 3.5% NaCl solution is discussed based on fractographic and micrographic observations.

The purpose of this study is to enhance heat insulation effect and to decrease fire hazard by attaching aluminum foil to expanded polystyrene, which is mainly used for insulating materials, to have fire retardant. The result of the test confirmed that the insulating materials, expanded polystyrene of 10 kg/m3 and 14 kg/m3 of density attached aluminum foil on both sides, showed 12%, 14% of improved heat transfer coefficient respectively compared to existing expanded polystyrene of the same density. Besides, they met all the standards for the testing of heat release and gas hazard. On the other hand, the one made of general expanded polystyrene could not meet the standards of the heat release test and the gas hazard test.

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.

The objective of this study was to develop formability evaluation techniques in order to apply aluminum sandwich panel for automotive body parts. For this purpose, formability evaluation by using FLD (forming limit diagram) was carried out in order to secure the fundamental data for the measurement of sheet metal forming and the establishment of optimum forming conditions of the aluminum sandwich panel. From the results of these formability evaluation, the formability of aluminum alloy sheet which was the skin component for the sandwich panel was higher than that of sandwich panel. In addition, the formability of sandwich sheet which was made by present study was same as that of sandwich panel made by foreign country. Also, it was found that sandwich panel made in present study could have the excellent deep draw-ability when it was compared to the foreign made sandwich panel.

The investigation on the lightweight of automobiles has been underway in commercial vehicles as well as passenger cars due to global warming and strengthening of European emission standards. In this study, the V-arm were developed for lightweight parts using aluminum alloy instead of steel with high pressure die casting processing. This study has focused on lightweight adaptive concept design. Several models of V-arm were designed and analyzed for the fluidity and solidification. V-arm was produced with ADC12 by high pressure die-casting process. The mechanical properties of developed V-arm were measured; such as tensile strength, elongation, shear strength, and durability. The possibility of mass production with the light weight aluminum V-arm substitute from the steel. The weight was reduced about 38% from 16kg to 9.98kg. The productivity was improved with decreasing the process from 8 to 5 by All-in-0ne process using high pressure die-casting.

Multiple galvanized steel and aluminium alloy sheets were joined by self-piercing rivet(SPR) and hybrid joining(SPR + adhesive bonding). In this study, tensile-shear load and fatigue properties of multi-layer SPR and hybrid joints were investigated. Moreover, tensile-shear deformation behavior of the joints under different specimen configurations was investigated. Depending on the specimen configurations either top sheet tearing failure mode or rivet tail pull-out failure mode was observed during the tensile-shear tests. The top sheet tearing failure mode resulted in low maximum tensile-shear load, but it led to larger displacement value as compared to that in the tail pull-out failure mode. Maximum tensile-shear load of hybrid joints was about four times higher than that of SPR joints. Also, fatigue limit of hybrid joints was about two times higher than that of SPR joints.

In this study, the extrusion process of 6xxx series aluminum cast alloy for high speed train interior or exterior parts are developed. 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 high farmable extruded aluminum casting alloys for interior or exterior materials has been the scope of this study. The extruded die design was performed for the 6063, 6061 and 6N01 alloy profiles and extrusion test was executed. From these results, the extrusion conditions such as extrusion pressure following as billet temperature and materials were carefully examined.

Synthetic wood has been widely used in place of wood such as the building exterior materials and/or the floor plate of moving path. However, it has many disadvantages such as relatively low strength, low durability, and heavy weight, etc. In this study, the synthetic wood deck combined with an aluminum profile was suggested to overcome these disadvantages. The flexural strength of the aluminum-synthetic wood deck was obtained through the theoretical equations under three-point bending conditions. In addition, the finite element analyses were also conducted to evaluate the flexural strength of the aluminum-synthetic wood deck.

Hot-press forming(HPF) steel can be applied successfully to auto parts because of its superior mechanical properties. However, its resistances to aqueous corrosion and the subsequent hydrogen embrittlement(HE) decrease significantly when the steel is exposed to corrosive environments. Considering that the resistances are greatly dependent on the properties of coating materials formed on the steel surface, the characteristics of the corrosion and hydrogen diffusion behaviors regarding the types of coating material should be clearly understood. Electrochemical polarization and impedance measurements reveal a higher corrosion potential and polarization resistance and a lower corrosion current of the Al-coating compared with Zn-coating. Furthermore, it was expected that the diffusion kinetics of the hydrogen atoms would be much slower in the Al-coating, and this would be due mainly to the much lower diffusion coefficient of hydrogen in the Al-coating with a face-centered cubic structure. The superior surface inhibiting effect of the Al-coating, however, is degraded by the formation of local cracks in the coated layer under severe stress conditions, and therefore further study will be necessary to gain a clearer understanding of the effect of cracks formed on the coated layer on the subsequent corrosion and hydrogen diffusion behaviors.

Alane(aluminum trihydride, AlH3)으로 명명되는 고에너지 물질인 삼수소알루미늄은 수소저장 물질로서 뿐만 아니라 우주항공분야의 고체 추진제나 방위산업의 화약제조용으로도 사용될 수 있다. 본 연구는 습식공정을 통하여 합성하고, 에테르를 세밀하게 분리하는 결정화 공정을 통하여 최종 수소화물을 추출하였다. 결정화 공정에서 삼수소알루미늄-에테레이트(AlH3·(C2H5)2O)가 alane으로 상변이하면서 입자가 성장하고, 85℃에서 2 시간의 결정화 시간이 이루어졌을 때 가장 안정된 결정상이 나타나는 모습을 확인하였다. 최종적으로 추출된 고체상 삼수소알루미늄은 막대모양의 γ-형태가 가장 많은 양을 차지하는 것으로 나타났으며, 크기는 50-100 μm 수준이었다

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.

In this study, the electroless nickel plating method has been investigated for the coating of Ni nanoparticles onto fine Al powder as promising energetic materials. The adsorption of nickel nanoparticles onto the surface of Al powders has been studied by varying various process parameters, namely, the amounts of reducing agent, complexing agent, and pH-controller. The size of nickel nanoparticles synthesized in the process has been optimized to approximately 200 nm and they have been adsorbed on the Al powder. TGA results clearly show that the temperature at which oxidation of Al mainly occurs is lowered as the amount of Ni nanoparticles on the Al surface increases. Furthermore, the Ni-plated Al powders prepared for all conditions show improved exothermic reaction due to the selfpropagating high-temperature synthesis (SHS) between Ni and Al. Therefore, Al powders fully coated by Ni nanoparticles show the highest exothermic reactivity: this demonstrates the efficiency of Ni coating in improving the energetic properties of Al powders.