This study is aimed at improving the plasma resistance of Al2O3 ceramics on which plasma resistant YAS(Y2O3- Al2O3-SiO2) frit is melt-coated using a simple heat-treatment process. For this purpose, the results of phase analysis and microstructural observations of the prepared YAS frits and the coating layers on the Al2O3 ceramics according to the batch compositions are compared and discussed with regard to the results of plasma resistance test. The prepared YAS frits consist of crystalline or amorphous or co-existing crystalline and amorphous phases according to the batch compositions, depending on the role and content of each raw material. The prepared YAS frit is melt-coated on the densely sintered Al2O3 ceramics, resulting in a dense coating layer with a thickness of at least ~ 80 m. The YAS coating layer consists of crystalline YAG(Y3Al5O12), Y2Si2O7, and Al2O3 phases, and YAS glass phase. Plasma resistance of YAS coated Al2O3 ceramics is strongly dependent on the content of the YAG(Y3Al5O12) and Y2Si2O7 crystalline phases in the coating layer, especially on the content of the YAG phase. Comparing the weight loss of YAS coating ceramics with values obtained for commercial Y2O3, Al2O3, and quartz ceramics, the plasma resistance of the YAS coating ceramics is 6 times higher than that of quartz, 2 times higher than that of Al2O3, and 50 % of the resistance of Y2O3.

A T-800 (Co-Mo-Cr) coating material is fabricated using Co-Mo-Cr powder feedstock and laser cladding. The microstructure and melted Al erosion properties of the laser-cladded T-800 coating material are investigated. The Al erosion properties of the HVOF-sprayed MoB-CoCr and bulk T-800 material are also examined and compared with the laser-cladded T-800 coating material. Co and lave phases (Co2MoCr and Co3Mo2Si) are detected in both the lasercladded T-800 coating and the bulk T-800 materials. However, the sizes of the lave phases are measured as 7.9 μm and 60.6 μm for the laser-cladded and bulk T-800 materials, respectively. After the Al erosion tests, the erosion layer thicknesses of the three materials are measured as 91.50 μm (HVOF MoB-CoCr coating), 204.83 μm (laser cladded T- 800), and 226.33 μm (bulk T-800). In the HVOF MoB-CoCr coating material, coarse cracks and delamination of the coating layer are observed. On the other hand, no cracks or local delamination of the coating layer are detected in the laser T-800 material even after the Al erosion test. Based on the above results, the authors discuss the appropriate material and process that could replace conventional bulk T-800 materials used as molten Al pots.

The annealing characteristics of cold-rolled Al-6.5Mg-1.5Zn-0.5Fe-0.5Mn alloy, newly designed as an automobile material, are investigated in detail, and compared with those of other aluminum alloys. Using multi-pass rolling at room temperature, the ingot aluminum alloy is cut to a thickness of 4 mm, width of 30 mm, and length of 100 mm to reduce the thickness to 1 mm (r = 75 %). Annealing after rolling is performed at various temperatures ranging from 200 to 500 oC for 1 hour. The specimens annealed at temperatures up to 300 oC show a deformation structure; however, from 350 oC they have a recrystallization structure consisting of almost equiaxed grains. The hardness distribution in the thickness direction of the annealed specimens is homogeneous at all annealing temperatures, and their average hardness decreases with increasing annealing temperature. The tensile strength of the as-rolled specimen shows a high value of 496 MPa; however, this value decreases with increasing annealing temperature and becomes 338MPa after annealing at 400 oC. These mechanical properties of the specimens are compared with those of other aluminum alloys, including commercial 5xxx system alloys.

The powder manufacturing process using the gas atomizer process is easy for mass production, has a fine powder particle size, and has excellent mechanical properties compared to the existing casting process, so it can be applied to various industries such as automobiles, electronic devices, aviation, and 3D printers. In this study, a modified A4032-xSn (x = 0, 1, 3, 5, and 10 wt.%) alloy with low melting point properties is investigated. After maintaining an argon (Ar) gas atmosphere, the main crucible is tilted; containing molten metal at 1,000℃ by melting the master alloy at a high frequency, and Ar gas is sprayed at 10 bar gas pressure after the molten metal inflow to the tundish crucible, which is maintained at 800℃. The manufactured powder is measured using a particle size analyzer, and FESEM is used to observe the shape and surface of the alloy powder. DSC is performed to investigate the change in shape, according to the melting point and temperature change. The microstructure of added tin (Sn) was observed by heat treatment at 575℃ for 10 min. As the content of Sn increased, the volume fraction increased to 1.1, 3.1, 6.4, and 10.9%.

Two different casting speeds of 60 and 80mm/min are adopted to determine the effect of casting speed on the microstructure and mechanical properties of Al-Mg-Si/Al hybrid material prepared by duo-casting. The obtained hybrid material has a uniform and straight macro-interface between the pure Al side and the Al-Mg-Si alloy side at both casting speeds. When the casting speed is increased to 80mm/min, the size of primary α phases in Al-Mg-Si alloy decreases, without change of shape. Although the Al-Mg-Si alloy produced at higher casting speed of 80mm/min shows much higher ultimate tensile strength (UTS) and 0.2 % proof stress and lower elongation, along with higher bending strength compared to the case of the 60mm/min in casting speed, the tensile properties and bending strength of the hybrid material, which are similar to those of pure Al, are the same regardless of the increase of casting speed. Despite the different casting speeds, deformation and fracturing in hybrid materials are observed only on the pure Al side. This indicates that the macro-interface is well-bonded, allowing it to endure tensile and bending deformation in all hybrid materials.

sesses the finishing capabilities for application to high-precision machining. Because Ti-6AL-4V (Eli) is widely used in applications where it is exposed to the human body, the industrial grinding oil that is commonly used in the magnetic abrasive finishing process was replaced by vegetable oils; the processing performances of these different grinding oils were compared and verified. The characteristics of magnetic abrasive finishing were also investigated according to the temperature of the material. The experimental results show that olive oil yields a surface roughness improvement of 87%. Also, in terms of the roundness and the amount of material removal, the performance was excellent. This demonstrates the possibility of replacing the conventional industrial oil for grinding. Furthermore, when olive oil was used at different temperatures, the finishing characteristics at room temperature were the most excellent. SEM and EDX analyses of the machined components (before and after processing) showed that the material composition was not changed. Additionally, the magnetic abrasive tool composition was not found on the surface of the finished samples. In conclusion, the possibility of using vegetable oil as the grinding oil for high-precision machining of Ti-6Al-4V (Eli) bars via a magnetic abrasive finishing process at room temperature conditions was verified.

Titanium aluminides have attracted special interest as light-weight/high-temperature materials for structural applications. The major problem limiting practical use of these compounds is their poor ductility and formability. The powder metallurgy processing route has been an attractive alternative for such materials. A mixture of Ti and Al elemental powders was fabricated to a mechanical alloying process. The processed powder was hot pressed in a vacuum, and a fully densified compact with ultra-fine grain structure consisting of Ti3Al intermetallic compound was obtained. During the compressive deformation of the compact at 1173 K, typical dynamic recrystallization (DR), which introduces a certain extent of grain refinement, was observed. The compact had high density and consisted of an ultra-fine equiaxial grain structure. Average grain diameter was 1.5 μm. Typical TEM micrographs depicting the internal structure of the specimen deformed to 0.09 true strain are provided, in which it can be seen that many small recrystallized grains having no apparent dislocation structure are generated at grain boundaries where well-developed dislocations with high density are observed in the neighboring grains. The compact showed a large m-value such as 0.44 at 1173 K. Moreover, the grain structure remained equiaxed during deformation at this temperature. Therefore, the compressive deformation of the compact was presumed to progress by superplastic flow, primarily controlled by DR.

In this study, three kinds of metal chills such as SS400, AC4CH and brass, with different thicknesses of 40 ~ 80 mm, were applied for low pressure casting of Al-Si alloy to control cooling rate. The microstructural characteristics with increasing cooling rate were represented using factors including D1, D2, size of primary α phases and shape factor and size of eutectic Si. The tensile properties were investigated and additionally analyzed based on the microstructural characteristics. As the cooling rate increased, D1, D2, and sizes of primary α phases and eutectic Si apparently decreased and the shape factor of eutectic Si increased to over 0.8. The ultimate tensile strength (UTS) and yield strength (YS) increased with decreasing D1, D2, and size of primary α phases, while elongation increased with decreasing size of eutectic Si and concurrently increasing shape factor of eutectic Si. This indicated that the primary α phases and eutectic Si in Al-Si alloy were refined with increasing cooling rate, resulting in improvement of UTS and YS without sacrificing elongation. After the tensile test, preferential deformation of primary α phases was observed in the Al-Si alloy produced at higher cooling rates of more than 0.1 K/s.

The Fe-22wt.%Cr-6wt.%Al foams were fabricated via the powder alloying process in this study. The structural characteristics, microstructure, and mechanical properties of Fe-Cr-Al foams with different average pore sizes were investigated. Result of the structural analysis shows that the average pore sizes were measured as 474 μm (450 foam) and 1220 μm (1200 foam). Regardless of the pore size, Fe-Cr-Al foams had a Weaire-Phelan bubble structure, and α-ferrite was the major constituent phase. Tensile and compressive tests were conducted with an initial strain rate of 10−3 /s. Tensile yield strengths were 3.4 MPa (450 foam) and 1.4 MPa (1200 foam). Note that the total elongation of 1200 foam was higher than that of 450 foam. Furthermore, their compressive yield strengths were 2.5 MPa (450 foam) and 1.1 MPa (1200 foam), respectively. Different compressive deformation behaviors according to the pore sizes of the Fe-Cr-Al foams were characterized: strain hardening for the 450 foam and constant flow stress after a slight stress drop for the 1200 foam. The effect of structural characteristics on the mechanical properties was also discussed.

The effect of intercritical annealing temperature on the microstructure and mechanical properties of Fe-9Mn-0.2C- 3Al-0.5Si medium manganese steels containing Cu and Ni is investigated in this study. Six kinds of medium manganese steels are fabricated by varying the chemical composition and intercritical annealing temperature. Hardness and tensile tests are performed to examine the correlation of microstructure and mechanical properties for the intercritical annealed medium manganese steels containing Cu and Ni. The microstructures of all the steels are composed mostly of lath ferrite, reverted austenite and cementite, regardless of annealing temperature. The room-temperature tensile test results show that the yield and tensile strengths decrease with increasing intercritical annealing temperature due to higher volume fraction and larger thickness of reverted austenite. On the other hand, total and uniform elongations, and strain hardening exponent increase due to higher dislocation density because transformation-induced plasticity is promoted with increasing annealing temperature by reduction in reverted austenite stability.

In this study, the effects of Sm addition (0, 0.05, 0.2, 0.5 wt%) on the microstructure, hardness, and electrical and thermal conductivity of Al-11Si-1.5Cu aluminum alloy were investigated. As a result of Sm addition, increment in the amount of α-Al and refinement of primary Si from 70 to 10 μm were observed due to eutectic temperature depression. On the other hand, Sm was less effective at refining eutectic Si because of insufficient addition. The phase analysis results indicated that Sm-rich intermetallic phases such as Al-Fe-Mg-Si and Al-Si-Cu formed and led to decrements in the amount of primary Si and eutectic Si. These microstructure changes affected not only the hardness but also the electrical and thermal conductivity. When 0.5 wt% Sm was added to the alloy, hardness increased from 84.4 to 91.3 Hv, and electric conductivity increased from 15.14 to 16.97 MS/m. Thermal conductivity greatly increased from 133 to 157 W/m·K.

유니버설 조인트는 두 회전 축 사이에서 힘을 전달하는 구성 요소이며, 구동축과 피동축이 나란히 정렬되지 않아도 나란히 정 렬되지 않아도 동력전달이 가능하게 하며 각도 변화가 있는 전동축에서도 효율적으로 동력을 전달시키는 부품으로서 자동차의 동력전달 장치에서 많이 적용되고 있다. 차량의 경량화를 위해 고강도 알루미늄의 사용이 증가하고 있다. 본 연구에서는 알루미늄 6061 재질을 사용하여 유니버셜 조인트 샤프트를 성형하기 위해 환봉 압출, U-Shape 성형, Spline 성형 등에 대한 단조 해석 연구하였다. Bar Extrusion 성형 시 23.3Ton, U-shape 성형 시 62.2Ton, Spline 성형 시 3.2Ton, 총 Cycle Time 226sec의 성형 조건을 산출하였으며, 이를 적용하여 알루미늄 유니버셜 조인트를 제작하였다. 비틀림 시험을 통해 토크값은 평균 425.8(N・m), 비틀림 각은 평균 171.6° 의 실험값을 통해 기존 제품에 비해 단조 제품이 12.0∼14.4%의 비틀림 성능의 향상을 보였다.

A stacked high-voltage (900 V) Al electrolytic capacitor made with ZrO2 coated anode foils, which has not been studied so far, is realized and the effects of Zr-Al-O composite layer on the electric properties are discussed. Etched Al foils coated with ZrO2 sol are anodized in 2-methyl-1,3-propanediol (MPD)-boric acid electrolyte. The anodized Al foils are assembled with stacked structure to prepare the capacitor. The capacitance and dissipation factor of the capacitor with ZrO2 coated anode foils increase by 41 % and decrease by 50 %, respectively, in comparison with those of Al anode foils. Zr-Al- O composite dielectric layer is formed between separate crystalline ZrO2 with high dielectric constant and amorphous Al2O3 with high ionic resistivity. This work suggests that the formation of a composite layer by coating valve metal oxide on etched Al foil surface

In the development of advanced ceramic tools, material improvements and design freedom are critical in improving tool performance. However, in the die press molding method, many factors limit tool design and make it difficult to develop innovative advanced tools. Ceramic 3D printing facilitates the production of prototype samples for advanced tool development and the creation of complex tooling products. Furthermore, it is possible to respond to mass production requirements by reflecting the needs of the tool industry, which can be characterized by small quantities of various products. However, many problems remain in ensuring the reliability of ceramic tools for industrial use. In this study, alumina inserts, a representative ceramic tool, was manufactured using the digital light process (DLP), a 3D printing method. Alumina inserts prepared by 3D printing are pressurelessly sintered under the same conditions as coupon-type specimens prepared by press molding. After sintering, a hot isostatic pressing (HIP) treatment is performed to investigate the effects of relative density and microstructure changes on hardness and fracture toughness. Alumina inserts prepared by 3D printing show lower relative densities than coupon specimens prepared by powder molding but indicate similar hardness and higher fracture toughness values.

Additively manufactured metallic components contain high surface roughness values, which lead to unsatisfactory high cycle fatigue resistance. In this study, high cycle fatigue properties of selective laser melted Ti-6Al- 4V alloy are investigated and the effect of dry-electropolishing, which does not cause weight loss, on the fatigue resistance is also examined. To reduce the internal defect in the as-built Ti-6Al-4V, first, hot isostatic pressing (HIP) is conducted. Then, to improve the mechanical properties, solution treatment and aging are also implemented. Selective laser melting (SLM)-built Ti64 shows a primary α and secondary α+β lamellar structure. The sizes of secondary α and β are approximately 2 μm and 100 nm, respectively. On the other hand, surface roughness Ra values of before and after dry-electropolishing are 6.21 μm and 3.15 μm, respectively. This means that dry-electropolishing is effective in decreasing the surface roughness of selective laser melted Ti-6Al-4V alloy. The comparison of high cycle fatigue properties between before and after dry-electropolished samples shows that reduced surface roughness improves the fatigue limit from 150 MPa to 170 MPa. Correlations between surface roughness and high cycle fatigue properties are also discussed based on these findings.