Powder injection molding is an important manufacturing technology to mass produce superalloy components with complex shape. Injection molding step is particularly important for realizing a desired shape, which requires much time and efforts finding the optimum process condition. Therefore computer aided engineering can be very useful to find proper injection molding conditions. In this study, we have conducted a finite element method based simulation for the spiral mold test of superalloy feedstock and compared the results with experimental ones. Sensitivity analysis with both of simulation and experiment reveals that the melt temperature of superalloy feedstock is the most important factor for the full filling of mold cavity. The FEM based simulation matches well the experimental results. This study contributes to the optimization of superalloy powder injection molding process.

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• Powder Injection Molding Process in Industrial Fields
  Joo Won OH, Chang Woo GAL, Daseul SHIN, Jae Man PARK, Woo Seok YANG, Seong Jin PARK
  Journal of the Japan Society of Powder and Powder Metallurgy.2018; 65(9): 539.     CrossRef
• Effect of Diamond Particle Size on the Thermal Shock Property of High Pressure High Temperature Sintered Polycrystalline Diamond Compact
  Ji-Won Kim, Min-Seok Baek, Hee-Sub Park, Jin-Hyeon Cho, Kee-Ahn Lee
  Journal of Korean Powder Metallurgy Institute.2016; 23(5): 364.     CrossRef

In this study, the behavior of densification of copper powders during high-pressure torsion (HPT) at room temperature is investigated using the finite element method. The simulation results show that the center of the workpiece is the first to reach the true density of copper during the compressive stage because the pressure is higher at the center than the periphery. Subsequently, whole workpiece reaches true density after compression due to the high pressure. In addition, the effective strain is increased along the radius during torsional stage. After one rotation, the periphery shows that the effective strain is increased up to 25, which is extensive deformation. These high pressure and severe strain do not only play a key role in consolidation of copper powders but also make the matrix harder by grain refinement.

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• Enhanced wear resistivity of a Zr-based bulk metallic glass processed by high-pressure torsion under reciprocating dry conditions
  Soo-Hyun Joo, Dong-Hai Pi, Jing Guo, Hidemi Kato, Sunghak Lee, Hyoung Seop Kim
  Metals and Materials International.2016; 22(3): 383.     CrossRef

In recent years, industrial demands for superior mechanical properties of powder metallurgy steel components with low cost are rapidly growing. Sinter hardening that combines sintering and heat treatment in continuous one step is cost-effective. The cooling rate during the sinter hardening process dominates material microstructures, which finally determine the mechanical properties of the parts. This research establishes a numerical model of the relation between various cooling rates and microstructures in a sinter hardenable material. The evolution of a martensitic phase in the treated microstructure during end quench tests using various cooling media of water, oil, and air is predicted from the cooling rate, which is influenced by cooling conditions, using the finite element method simulations. The effects of the cooling condition on the microstructure of the sinter hardening material are found. The obtained limiting size of the sinter hardening part is helpful to design complicate shaped components.

The composite of porous silicon (Si) and amorphous carbon (C) is prepared by pyrolysis of a nano-porous Si + pitch mixture. The nano-porous Si is prepared by mechanical milling of magnesium powder with silicon monoxide (SiO) followed by removal of MgO with hydrochloric acid (etching process). The Brunauer-Emmett-Teller (BET) surface area of porous Si (64.52 m²g⁻¹) is much higher than that before etching Si/MgO (4.28 m²g⁻¹) which indicates pores are formed in Si after the etching process. Cycling stability is examined for the nano-porous Si + C composite and the result is compared with the composite of nonporous Si + C. The capacity retention of the former composite is 59.6% after 50 charge/discharge cycles while the latter shows only 28.0%. The pores of Si formed after the etching process is believed to accommodate large volumetric change of Si during charging and discharging process.

In this study, the control of microstructure for increasing surface roughness of Al with an electro-chemical reaction and a post treatment is systematically investigated. The Al specimen is electro-chemically treated in an electrolyte. In condition of the post treatment at 100°C for 10 min, a change of the surface microstructure occur at 50V (5 min), and a oxidized layer is at 400V, to which lead a decreasing surface roughness. The minimum temperature of the post treatment for a change of microstructure is 80°C. Moreover, in the condition of 300V (5 min), the electro-chemical reaction is followed by the post treatment at 100°C, the critical enduring time for the change of microstructure is 3 min. The longer post treatment time leads to the rougher surface. The treated Al specimen demonstrate better heat release ability owing to the higher surface roughness than the non-treated Al.

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• Measurement of the Thermal Conductivity of a Polycrystalline Diamond Thin Film via Light Source Thermal Analysis
  Hojun Kim, Daeyoon Kim, Nagyeong Lee, Yurim Lee, Kwangbae Kim, Ohsung Song
  Korean Journal of Materials Research.2021; 31(12): 665.     CrossRef
• Effect of Tin Addition on the Melting Temperatures and Mechanical Properties of Al-Si-Cu Brazing Filler Metals
  Min Sang Kim, Chun Woong Park, Jong Min Byun, Young Do Kim
  Korean Journal of Materials Research.2016; 26(7): 376.     CrossRef

Flat panel display devices are mainly used as information display devices in the 21st century. The worldwide waste flat panel displays are expected at 2-3 million units but most of them are land-filled for want of a proper recycling technology More specifically, rare earth metals of La and Eu are used as fluorescent materials of Cold Cathode Flourscent Lamp(CCFL)s in the waste flat panel displays and they are critically vulnerable and irreplaceable strategic mineral resources. At present, most of the waste CCFLs are disposed of by land-filling and incineration and proper recovery of 80-plus tons per annum of the rare earth fluorescent materials will significantly contribute to steady supply of them. A dearth of Korean domestic research results on recovery and recycling of rare earth elements in the CCFLs prompts to initiate this status report on overseas research trends and noteworthy research results in related fields.

The effect of heat treatment environment on the microstructure and properties of tantalum coating layer manufactured by kinetic spraying was examined. Heat treatments are conducted for one hour at 800°C, 900°C, and 1000°C in two different environments of vacuum and Ar gas. Evaluation of microstructure and physical properties are conducted. High density α- tantalum single phase coating layer with a porosity of 0.04% and hardness of 550 Hv can be obtained. As heat treatment temperature increases, porosity identically decreases regardless of heat treatment environment (vacuum and Ar gas). Hardness of heat treated coating layer especially in Ar gas environment deceases from 550 Hv to 490 Hv with increasing heat treatment temperature. That in vacuum environment deceases from 550 Hv to 530 Hv. The boundary between particles became vague as heat treatment temperature increases. Oxygen distribution of tantalum coating layer is minute after heat treatment in vacuum environment than Ar gas environment.

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• Sintering Behavior and Microstructures of Tantalum and Tantalum-Tungsten Alloys Powders
  Youngmoo Kim, Sung Ho Yang, Seong Lee, Sung Ho Lee, Joon-Woong Noh
  Journal of Korean Powder Metallurgy Institute.2020; 27(5): 373.     CrossRef

In this study, cobalt nanopowder is fabricated by sonochemical polyol synthesis and magnetic separation method. First, sonochemical polyol synthesis is carried out at 220°C for up to 120 minutes in diethylene glycol (C₄H₁₀O₃). As a result, when sonochemical polyol synthesis is performed for 50 minutes, most of the cobalt precursor (Co(OH)₂) is reduced to spherical cobalt nanopowder of approximately 100 nm. In particular, aggregation and growth of cobalt particles are effectively suppressed as compared to common polyol synthesis. Furthermore, in order to obtain finer cobalt nanopowder, magnetic separation method using magnetic property of cobalt is introduced at an early reduction stage of sonochemical polyol synthesis when cobalt and cobalt precursor coexist. Finally, spherical cobalt nanopowder having an average particle size of 22 nm is successfully separated.

A precipitation behavior of nano-oxide particle in Fe-5Y₂O₃ alloy powders is studied. The mechanically alloyed Fe-5Y₂O₃ powders are pressed at 750°C for 1h, 850°C for 1h and 1150°C for 1h, respectively. The results of Xray diffraction pattern analysis indicate that the Y₂O₃ diffraction peak disappear after mechanically alloying process, but Y₂O₃ and YFe₂O₄ complex oxide precipitates peak are observed in the powders pressed at 1150°C. The differential scanning calorimetry study results reveal that the formation of precipitates occur at around 1054°C. Based on the transmission electron microscopy analysis result, the oxide particles with a composition of Y-Fe-O are found in the Fe-5Y₂O₃ alloy powders pressed at 1150°C. It is thus conclude that the mechanically alloyed Fe-5Y₂O₃ powders have no precipitates and the oxide particles in the powders are formed by a high temperature heat-treatment.

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• Mechanical properties of Mo-Si-B alloys fabricated by using core-shell powder with dispersion of yttria nanoparticles
  Jong Min Byun, Su-Ryong Bang, Won June Choi, Min Sang Kim, Goo Won Noh, Young Do Kim
  Metals and Materials International.2017; 23(1): 170.     CrossRef

As well-known wrought stainless steel, sintered stainless steel (STS) has excellent high-temperature anticorrosion even at high temperature of 800°C, and exhibits good corrosion resistance in air. However, when temperature increases above 900°C, the corrosion resistance of STS begins to deteriorate and dramatically decreases. In this study, the effects of phase and composition of STS on high-temperature corrosion resistances are investigated for STS 316L, STS 304 and STS 434L above 800°C. The morphology of the oxide layers are observed. The oxides phase and composition are identified using X-ray diffractometer and energy dispersive spectroscopy. The results demonstrate that the best corrosion resistance of STS could be improved to that of 434L. The poor corrosion resistance of the austenitic stainless steels is due to the fact that NiFe₂O₄ oxides forming poor adhesion between the matrix and oxide film increase the oxidation susceptibility of the material at high temperature.

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• The effect of different turbulent flow on failure behavior in secondary loop of the pressurized water reactor
  Y. Hu, L. Zhao, Y.H. Lu, T. Shoji
  Nuclear Engineering and Design.2020; 368: 110812.     CrossRef

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• Study on the Demagnetization and Classification of NdFeB Magnets According to Different Heat Treatment Temperatures
  Byeong Jun Kim, Ik Keun Park, Young Sung Kim
  Journal of the Korean Society of Manufacturing Technology Engineers.2021; 30(2): 119.     CrossRef
• Study on Demagnetization and Magnetization to Reuse NdFeB-based Magnets
  Byeong Jun Kim, Young Sung Kim, Gi Tae Joo, Joon Hyun Kim, Ik Geun Park, Jae Yong Lee, Su Won Yang
  Journal of the Korean Society of Manufacturing Technology Engineers.2021; 30(4): 269.     CrossRef
• Study on the Optimization of Reduction Conditions for Samarium-Cobalt Nanofiber Preparation
  Jimin Lee, Jongryoul Kim, Yong-Ho Choa
  Journal of Korean Powder Metallurgy Institute.2019; 26(4): 334.     CrossRef