A hybrid cladding technology was developed by combining direct energy deposition (DED) and ultrasonic nanocrystal surface modification (UNSM). This is an effective process to control the mechanical properties inside the metal-clad layer, but the scope to improve the internal properties is low. Therefore, in this study, the UNSM process was applied while heating at 300 and 600℃ to increase the effectiveness of this hybrid additive process. To validate the characteristics of this method, a study on the cross-sectional properties upon application of heating was conducted. Hybrid cladding at 300 degrees produced improvements- over a 40% larger area than the results at room temperature. At 600 degrees, the hybrid cladding improved mechanical properties over a larger area by nearly 2 times. In this study, the characteristics of the roomtemperature and the high-temperature hybrid cladding process were analyzed. The proposed method shows a high improvement effect and is a promising method to improve the internal mechanical properties of the cladded layer.

We studied compressive behavior of two types of lattice structures having small-scale struts fabricated by utilizing a metal additive manufacturing process. Generally known, the lattice structure has some advantages such as lightweight and high specific mechanical strength, allowing diverse potential applications in the aerospace and mobility industries. In this work, we proposed two types of lattice such as body-centered truss (BCT) and octahedral truss (OCT) that were designed and fabricated for a compression test. From the experimental results, the OCT has much higher strength than the BCT, and all cases showed several buckling modes during the compressive behavior. Furthermore, ‘restructuring’ occurred with BCT, and the compressive force increased overall but fluctuated due to the restructuring by an increase of compression. Through this work, we found out that the BCT has the interesting compressive behaviors, and a repetitive bucking-restructuring was found. In fact, its strength could be increased continuously by the restructuring during compression. In conclusion, the BCT has key-characteristics of lightweight and re-strengthening, which are applicable to various applications in the industry.

We propose a novel fin-tube expanding process using a spiral-grooved-expanding ball, prepared by the metal additive manufacturing process, to improve heat exchange performance in a fin-tube type heat exchanger. In this study, deformation of inner grooves in a tube, was minimized during the expanding process. For this, we developed lab-scale expanding equipment, and a spiral-grooved-expanding ball, was newly designed and fabricated. Comparing to a conventional tube expanding process, it was deduced that a deformation rate of groove height was reduced to approximately 8.3%, when the proposed process was used. Through this fundamental study, we validate that the developed process can be used to fabricate large-surface grooved tubes, for application to a high efficiency heat exchanger.

In this study, we proposed an effective and simple way to directly generate wrinkle patterns on a curved surface. A curved surface was prepared using a 3D printer and an UV (Ultraviolet)-lighting system was utilized to weakly polymerize the UV-curable thin resin layer coated on the surface, resulting in a gradient of material properties in the layer thickness. Subsequently, a thermal curing process was conducted to generate microscale wrinkles by compressive forces that were generated during complete curing. Wrinkle shapes from 5, 15, 25 sec of UV-light exposure were compared. With increasing UV-exposure, the line-width of wrinkles became thicker due to much higher strength of skin zone. The results indicated that the proposed fabrication process could be utilized for surface modification in diverse research fields.

In this work, casting processes, such as filling and solidification, were simulated in order to accurately predict volume shrinkage defects in large-sized sand gravity casting. Turbulent flow of melted materials and a difference of solidification speed can cause volume shrinkage defects. In order to solve this problem and to understand the phenomenon, a porous filter application was studied. Two different porosities of 10 and 20 p.p.i filters were introduced into the gating system, and in view of the results so far achieved, the defect was dramatically reduced by 22%, compared to that without the use of the filter.

A thin sheet of metal with corrugated structures has been utilized in various devices: heat exchangers, separators in fuel cells, and many others. However, it is not easy to fabricate thin corrugated structures using a single-step stamping process due to their geometrical complexity. To solve this problem, firstly, a plate type heat exchanger was redesigned to attain the optimal value of aspect ratio and the optimal shape of corrugated structures for the actual loading conditions. A forming analysis of the corrugated plate was then carried out to determine the process parameters. From this work, the optimal value of aspect ratio was found to be 4.6. In addition, the process parameters of heat exchanger forming were optimized using the optimal value of aspect ratio, and the analytical results were evaluated through experiments. The results obtained indicated good agreements between them.

A bending process is considered as one of fundamental sheet metal forming processes, and it is widely used for fabrication of simple or complicated sheet metal products in industrial fields. Most of automobiles and electronics have many parts made by the bending process inside or outside of them. However, till now, there is few research reports on the bending process of hemmed plates. A hemmed plate has a locally different bending strength, so a waving shape occurs after bending. A poor outlook due to local uneven shape influences greatly on product competitiveness. To settle this problem, we studied the bending parameters of a hemmed plate and showed the major sensitive design-parameters on the bending quality.

In a refrigerator, many food boxes are stored, so the flow of chilly air has very complicate stream paths inside the room of a refrigerator. Moreover, on some occasions, there is no flow of chilly air in a space due to blocking flow paths by food boxes, which is an important issue to be settled for improving the ability of food storage with fresh states. One of methods to solve this problem is to redesign the flow-pattern of chilly air to be uniform flow inside room, if possible. In this work, we have tried to design the duct-structure for the uniform flow of a chilly air using a FE-analysis method. And we conducted real commercial tests using a refrigerator having the redesigned duct. The results showed that good agreements with general requirements.

Recently porous polymer has widely been applied to packaging, heat isolation, and sound absorption in various fields from the electrics to the automobiles industry. A lot of micro porosities inside foamed polymer provide lower heat conduction and lighter weight than non-porous polymer, because they involve gas or air during foaming process. In this paper experimental approaches of the UV laser micro machining behavior for Expanded Polypropylene (EPP) foamed polymer materials, which have different expansion rates, were investigated. From these results, the ablation phenomena were finally observed that the ablation is depended upon stronger photochemical than photo-thermal effect. This study will also help us to understand interaction between UV laser beam and porous polymer.

Recently, the biochip which is a prime representation of NT, IT, BT, as an example of convergence technology, has been frequently mentioned. With the recent rapid advance in biotechnology, these compact devices, such as lab-on-a-chip or u-TAS, have been developed, and more research is needed. These compact devices typically use the micro-channel in order to shed or detach and mix a variety of materials. Specially, in micro-fluidic systems, a mixer is necessary to produce a mixture because only laminar flow occurs at a low-Reynolds number. To solve this problem, HVM a micromixer that induces a horizontal and vertical multi-mixing flow motion, is proposed. The mixing performance was analyzed and verified by optimizing the shape through the CFD analysis and evaluating the structural analysis and the soundness with material properties that are obtained through the basic experiment.

Dew generation on an outer surface is considered as an important issue to be settled in the field of home appliances. In the case of a refrigerator that is subject to the dew generation problem on the surface of an outer-door of refrigeration thread, and so as to solve this problem, the electric heater is generally used for drying the dew. However, the heater inevitably requires electrical power consumption that is one of critical issues on the refrigerator. In this study, to prevent dew generation without the heater, a method of using induced heat from room temperature was proposed. In edge sides of a door, high conductive plates are installed and received the heat from outside that is relatively high temperature, and the heat is transferred onto dew generation region. Using prototypes, performance test was conducted under a certain temperature and humidity condition. The experimental results show that the surface temperature on the dew generation region was increased about 0.3~ 2.5℃ without use of any heater.

Subminiature devices such as Lab-on-a-chip and μ-TAS(Micro Total Analysis System) have been intensively studied in biotechnology and chemistry. In many cases, a micromixer was widely used to mix different solutions for synthesizing novel materials. However, in microfluidic system, there is generally a laminar flow under very small Reynolds number so it is difficult to mix each solution perfectly. To settle this problem, we propose a new mixing mechanism which generates a horizontal and vertical multi-mixing (HVM) flow for effective mixing within a short mixing section. We evaluated the proposed mechanism using CFD analysis, and the results showed that the HVM mechanism had a relative high-effectiveness comparing to the existing methods.

A slide-rail system is widely used in home appliances, furniture, mechanical rigs, and so many other applications; due to its high strength and performance for easy moving heavy objectives. In general, a pair of side slide-rails is set on both sides of a drawer to support and move it. So an unbalanced sliding motion can occur during opening and closing a drawer with pull and push force. To settle this problem, single central slide-rail having three collapsible rail-bodies was firstly proposed in this work. ‘H’-beam shaped rail-body was newly designed to have enough bending and twisting strength. The experimental test showed that the proposed rail could be applied to large-size home appliances for easy moving drawer with heavy weight.

UV laser micromachining of metallic materials has been used in microelectronic and other industries. This paper shows on experimental investigation of micromachining of copper using a 355㎚ UV laser with 50㎱ pulse duration. A finite element model with high strain rate effect is especially suggested to investigate the phenomena which are only dominated by mechanically pressure impact in disregard of thermally heat transfer. In order to consider the strain rate effect, Cowper-Symonds model was used. To analyze the dynamic deformation during a very short processing time, which is nearly about several tens nanoseconds, a commercial Finite Element Analysis (FEA) code, LS-DYNA 3D, was employed for the computational simulation of the UV laser micro machining behavior for thin copper material. From these computational results, depth of the dent (from one to six pulsed) were observed and compared with previous experimental results. This will help us to understand interaction between UV laser beam and material.