Publications

Showing 9 results for Author: Sunyong Kwon

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  • Aug, 2026

    Conference Paper

    RidgeAlloy: A high pressure die casting alloy that captures the approaching wave of automotive body sheet scrap

    Oak Ridge National Laboratory (ORNL) has recently launched an effort to economically expand the North American aluminum supply chain by designing and developing a new family of Al-Mg-Si-Fe-Mn structural die cast aluminum alloys that can be made from up to 100% mixed 5xxx and 6xxx series automotive post-consumer sheet scrap and do not require heat treatment. The goal is to…

  • Aug, 2026

    Journal

    Solidification phase and morphology prediction for Al–Fe castings using a cellular automata nucleation and growth model

    Non-equilibrium phase formation and the interaction between the nucleation and solidification of competing phases are significant challenges in aluminum alloy design, as key properties such as ductility heavily depend on the grain morphologies and phases present in solidified castings. This manuscript expands upon existing multiphase cellular automata (CA) modeling work to…

  • May, 2026

    Journal

    A modified scheil approach for nucleation-dependent solidification pathways

    As-solidified microstructures of near-eutectic alloys often contain multiple primary phases that are not expected from equilibrium phase diagrams. Such microstructures are caused by cooling-rate-dependent solidification pathways, a factor not captured by the Scheil–Gulliver model or variations thereof. Here, we present a model and algorithm that incorporate the critical nu…

  • Mar, 2026

    Conference Paper

    Microstructural Heterogeneity in a High Pressure Die Cast Al-7Si-0.5Mn-0.2Mg Alloy Containing Elevated Fe Impurities

    There is a growing trend to die cast structural automotive components from scrap aluminum sources to reduce embodied energy and cost. However, the ability to include most post-consumer scrap is severely limited due to the sensitivities of current industrial high pressure die cast (HPDC) Al alloys to Fe impurities introduced during the recycling process. This study characte…

  • Aug, 2025

    Journal

    Physics-coupled Data-driven Design of High-Temperature Alloys

    We present a materials design loop, which streamlines physics-coupled machine learning (ML) surrogate models to discover new alloy chemistries with improved properties. The efficacy is demonstrated by discovering a high-temperature alumina-forming austenitic (AFA) stainless steel with enhanced creep, followed by experimental validation. The ML models have been trained usin…

  • Dec, 2024

    Journal

    Effect of Si impurities on microstructure and tensile properties of a cast Al-Mg-Fe alloy

    Al-Mg alloys are attractive for structural castings owing to their superior strength and ductility in the as-cast state. However, given the tight tolerance for impurities, Al-Mg alloys produced from secondary sources still face multiple challenges. Here, we report the effect of increased Si impurity (0.05–1.6 wt%), which is commonly found in secondary Al sources, on micros…

  • Aug, 2024

    Journal

    Equilipy: a python package for calculating phase equilibria

    The CALPHAD (CALculation of PHAse Diagram) approach provides predictions for thermodynamically stable phases in multicomponent-multiphase materials across a wide range of temperatures. Consequently, the CALPHAD calculations became an essential tool in materials and process design. Such design tasks frequently require navigating a high-dimensional space due to multiple comp…

  • Jun, 2024

    Journal

    Effect of microalloying additions on microstructural evolution and thermal stability in cast Al-Ni alloys

    Enhancement of thermal stability in Al-Ni alloys through microalloying with slow-diffusing elements, specifically Zr, has been previously reported which is attributed to Zr segregation at the Al/Al3Ni interface. In this study, we explore the influence of microalloying Al-Ni alloys with Zr, Ti, V, and Fe on microstructural evolution, hardness, and electrical and thermal con…

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