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.

The objective of this paper is to optimize the cross-section of aluminum decking units used in the bass boats under operating conditions, and to verify the optimized model from the results via by ANSYS software. Aluminum decking unit is needed to endure specific loading while leisure activity and sailing. For a stiffer and more cost-neutral aluminum decking unit, optimization is often considered in the naval and marine industries. This optimization of the aluminum decking unit is performed using the ANSYS program, which is based on the topology optimization method. The generation of finite element models and stress evaluations are conducted using the ANSYS Multiphysics module, which is based on the Finite Element Method (FEM). Through such a series of studies, it was possible to determine the most suitable case for satisfying the structural strength found among the phase-optimized aluminum deck units in bass boats. From these optimization results, CASE 1 shows the best solution in comparison with the other cases for this optimization. By linking the topology optimization with the structural strength analysis, the optimal solution can be found in a relatively short amount of time, and these procedures are expected to be applicable to many fields of engineering.

Light weighting is one of techniques considered importantly at designing the mechanical structure using the light weight material. This study deals with aluminum-6061 and aluminum foam which stood in the spotlight of light weight material. And the finite element method for safety evaluation has been carried out in order to prevent from the damage and fatigue fracture due to crack appearing at the mechanical structure with this material. The simulation analysis as MT(middle tension) test was carried out by using the core of aluminum foam and the material laminated with sandwich structure of Al-6061. The mechanical structure is linked together with various parts and designed as the material with hole or crack. So, MT test is one of the test methods to evaluate the fatigue fracture characteristic of material and the strength inside material with the center crack by applying the load to the part connected pin. The real material strength is thought to be evaluated through the study result of MT test analysis.

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.

Recently, the use of an aluminum nitride(AlN) buffer layer has been actively studied for fabricating a high quality gallium nitride(GaN) template for high efficiency Light Emitting Diode(LED) production. We confirmed that AlN deposition after N2 plasma treatment of the substrate has a positive influence on GaN epitaxial growth. In this study, N2 plasma treatment was performed on a commercial patterned sapphire substrate by RF magnetron sputtering equipment. GaN was grown by metal organic chemical vapor deposition(MOCVD). The surface treated with N2 plasma was analyzed by x-ray photoelectron spectroscopy(XPS) to determine the binding energy. The XPS results indicated the surface was changed from Al2O3 to AlN and AlON, and we confirmed that the thickness of the pretreated layer was about 1 nm using high resolution transmission electron microscopy(HR-TEM). The AlN buffer layer deposited on the grown pretreated layer had lower crystallinity than the as-treated PSS. Therefore, the surface N2 plasma treatment on PSS resulted in a reduction in the crystallinity of the AlN buffer layer, which can improve the epitaxial growth quality of the GaN template.

Al/expanded graphite was successfully synthesized through a facile method including ultrasonic and heat treatment. In the well-designed three dimensional structure, expanded graphite(EG) works as a conductive matrix to support coated Al particles. The effects of the fabrication parameters on the microstructures and thermal conductivities of these composites were investigated. As a result, it was found that composites with graphite volume fraction of 17.4-69.4% sintered at 600 oC/45 MPa exhibit in-plane thermal conductivities of 380-940 W/mK, over 90 % of the predictions by rule of mixture. According to the non-destructive analysis results, the synergistic enhancement was caused by the formation of efficient thermally conductive pathways due to the hybrid of the differently sized EG. The structure integrates the advantages of expanded graphite as a conductive support, preserving the electrode activity and integrity and improving the electrochemical performance.

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.

This study was carried out to investigate the optimum condition of a friction stir welding process for a joint of AA2219-T87 and AA2195-T8 dissimilar aluminum alloys. These alloys are known to have good cryogenic properties, and as such to be suitable for use in fuel tanks of space vehicles. The welding parameters include the travelling speed, rotation speed and rotation direction of the tool. The experiment was conducted under conditions in which the travelling speed of the tool was 120-300 mm/min and the rotation speed of the tool was 400-800 rpm. To investigate the effect of the rotation direction of the tool, the joining was performed by switching the positions of the two dissimilar alloys. After welding, the microstructure was observed and the micro-hardness were measured; non-destructive evaluation was carried out to perform tensile tests on defect-free specimens. The result was that the microstructure of the weld joint underwent dynamic recrystallization due to sufficient deformation and frictional heat. The travelling speed of the tool had little effect on the properties of the joint, but the properties of the joint varied with the rotation speed of the tool. The conditions for the best joining properties were 600 rpm and 180-240 mm/min when the AA2219-T8 alloy was on the retreating side(RS).

In this study, the laser welding experiments were performed with the 1 mm thickness of Al 6061-T6 using by 5 kW fiber laser welding system. The optimum laser welding condition of the lap joint has been investigated by analyzing the penetration depth and the porosity fraction through observation of the cross-sections. Based on the test results, the sound joint was obtained from the welding condition with the power of 2 kW and the focal position of -0.8 mm at the continuous laser welding speed of 2 mpm. Also, the tensile strength of the sound joint after heat treatment(170℃, 12hr) was increased almost 87% that of the base material. Especially, the fatigue test result of the sound joint showed that the fatigue cycle was 3×10 4 at the highest test load of 100 MPa.