A research institute specializing in Materials Science

Materials Digital Platform Division

Department of Materials Processing

Head of Division 'Kim, Sang-u'
Head of Division
Kim, Sang-u

Department Introduction

Department of Materials Processing is focusing our efforts to create innovative materials processing technologies for enhancing the added value of materials and to develop smart manufacturing process for the 4th industrial revolution. In addition, it is contributing to strengthening the competitiveness of the metallic materials and parts industry by introducing and integrating state-of-the-art pilot-scale manufacturing and evaluating equipment, and subsequently by leading the construction of infrastructure hardware platform.

+82-55-280-3528

Major Activities

  • Multi-functional lattice structure materials: technology transfer (royalty income 55 million KRW)
  • Forming technology to control the yield ratio of high strength materials: technology transfer(70 million KRW)
  • Deformation behavior prediction, formability analysis, and evaluation for various metallic materials: 12 SCI(E) papers published.
  • Battery case and battery cooling system and so on: 3 domestic patents registered, 1 domestic patent applied.

Major Research Area

  • Development of smart forming process and special forming technology based on multi-physics for metallic materials
  • Development of 3D printing and flexible forming processes
  • Development of manufacturing and componentization for dissimilar metallic and lattice structure materials
  • Development of bulk-forming and componentization technologies for corrosion- and heat-resistant alloys
  • Establishment of equipment/infrastructure-based technologies for manufacturing demonstration of metallic materials

Future Research Plan

  • Development of multi-scale flexible and special forming process technologies based on multi-physics: flexible forming of sheet metals, precise micro-shape forming, topology optimization-based 3DP process, etc.
  • Development of exclusive, multi-functional hybrid materials including dissimilar metallic and lattice structure materials
  • Development of parts processing technology for various metallic materials utilized in strategic industries such as power generation, aerospace and defense industries
  • Development of high value-added micro/nanostructure design and manufacturing technologies
  • Development of digital twin-correlated plastic deformation equipment and processing technologies

Major R&D Activities

Development of optimal design and process technology for additive manufactured aircraft parts

  • Establishment of ‘optimal design-simulation-process optimization-prototyping-evaluation’ process for development of additive manufactured aircraft parts.
  • 33% lightweight design of an aircraft part by part integration and topology optimization.
  • Simulation-based additive manufacturing process design: melt pool characteristic and porosity prediction of single bead, deformation and stress prediction of additive manufactured part.
  • Fabrication of additive manufacturing prototype of aircraft parts and evaluation of structural safety.
Development of optimal design and process technology for additive manufactured aircraft parts

Derivation of process optimization technology for roll cladding of corrosion-resistant Ni-based alloys

  • Evaluation of high-temperature deformation behavior and construction of process map for corrosion-resistant Ni-based alloys: Derivation of optimal hot forming conditions
  • Demonstration of sub-size hot rolling for corrosion-resistant Ni-based alloys using a 600-ton hot rolling simulator: Reproduction of the reduction rate above 80% without reheating
  • Comparative verification of hot rolling process variables through finite element analysis
1. Microstructural analysis for base corrosion-resistant alloys / 2. High temperature deformation : construction fo processing map / 3. Sub-sized hot rolling without reheating above 80% reduction ratio / 4. Comparison of major hot rolling variables by finite element analysis

Development of AI-based forming process optimization for the Light-weight metals

  • Evaluation of high-temperature Nakajima tests analysis of lightweight metals using high-temperature Erichsen machine installed for the first time in Korea.
  • Construction of a DB of mechanical properties and formability of light-weight metals from experimental and multi-scale based simulated data.
  • Manufacturing process innovation through the development of optimal forming process design technology that combines analysis results and artificial intelligence models.