Cross-ministerial Strategic Innovation Promotion Program (SIP)
Research and Development Plan for“Materials Integration” for Revolutionary Design System of Structural
Materials

August 22, 2019

Director-General for Science, Technology, and Innovation
Cabinet Office1Outline of the R&D Plan..................................................................................................... 5
1.

Significance and Objectives ..................................................................................... 52.

Content of the Research ........................................................................................... 53.

Implementation Structure ......................................................................................... 6

4.

Management of Intellectual Properties..................................................................... 6

5.

Evaluation ................................................................................................................. 6

6.

Exit Strategies........................................................................................................... 7(1)

Use of MI systems in corporate R&D (Domain A).................................................. 7(2) Practical application and commercialization of materials developed with MI
systems (Domains B and C)................................................................................................ 7
1.

Significance and Goals ............................................................................................. 7(1)

Background and circumstances at home and abroad................................................ 7(2)

Significance and strategic importance ...................................................................... 8(3)

Objectives/Aims ....................................................................................................... 9(i)

Toward realization of Society 5.0 ............................................................................ 9(ii)

Social objectives ..................................................................................................... 10(iii)

Industrial objectives ............................................................................................... 10(iv)

Technical objectives ............................................................................................... 10(v)

Objectives pertaining to institutional systems ........................................................ 10(vi)

Global benchmarks ................................................................................................. 10(vii) Collaboration with local government bodies.......................................................... 112.

Description of R&D Activities ............................................................................... 11(A)

Fundamental Technological Development for Inverse Design MI ........................ 13(A-1)

Inverse Design Approach .................................................................................... 17(A-2)

Process Design .................................................................................................... 20(A-3)

Structure Design of Atoms and Molecules ......................................................... 23(A-4)

MI Integrated System.......................................................................................... 272

(A-5)

Structural materials database .............................................................................. 30(B)

Carbon Fiber Reinforced Plastic (CFRP) ............................................................... 33(B-1)

Development of Multifunctional CFRP Providing Added Value ....................... 34(B-2) Development of CFRP Design/Manufacturing Automation Technology Using
AI-assisted Stacking Optimization ................................................................................... 37(B-3) Development of 3D High Degree of Freedom Design Technology by Automatic
Lamination of Thin-Layer CFRP ...................................................................................... 40(C)

3D Powder Processing............................................................................................ 43(C-1)

Development of Additive Manufacturing Process for Ni-based Alloys ............ 44(C-2) Development of Ni-based Powder Metallurgy Processing for High Performance
Aircraft Engine Disk ......................................................................................................... 46(C-3)

Development of Powder Additive Manufacturing Process for Titanium Alloys 49(C-4) Development of Powder Manufacturing Process and Basic Technologies forHigh Performance TiAl-based Alloy Turbine Blades ...................................................... 50(C-5) Realistic Simulation of Ceramic Matrix Composites Targeted for High
Temperature Components in Jet Engines ......................................................................... 52
3.

Implementation structure ........................................................................................ 55(1)

Program Director, Deputy Program Director, and management agency ............... 55(2)

Selection of Principal Researchers ......................................................................... 55(3)

Measures to optimize the research system ............................................................. 55(4)

Coordination with government ministries and agencies ........................................ 56(5)Commitment from industry .................................................................................... 56

4.

Matters related to intellectual properties ................................................................ 57(1)Intellectual property committee and subcommittees .............................................. 57(2)

Arrangement concerning IP rights ......................................................................... 57(3)

Licensing of background IP rights ......................................................................... 57(4)

Handling of foreground IP rights ........................................................................... 57(5)

Licensing of foreground IP rights .......................................................................... 58

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(6) Approval for transfer of, and establishment and transfer of an exclusive license for,foreground IP rights .......................................................................................................... 58(7)

Handling of IP rights at the time of termination .................................................... 59(8) Participation by overseas organizations, etc. (such as foreign companies,
universities, and researchers) ............................................................................................ 59
5.

Matters related to assessment ................................................................................. 59(1)

Assessing entities ................................................................................................... 59(2)

Timing of assessments............................................................................................ 59(3)

Assessment items and criteria ................................................................................ 59(4)

Methods of reflecting assessment outcomes .......................................................... 60(5)Disclosure of outcomes .......................................................................................... 60(6)

Self-inspections ...................................................................................................... 60(i)

Self-inspection by Principal Researchers ............................................................... 60(ii)

Self-inspection by the PD ....................................................................................... 60(iii)

Self-inspection by the management agency ........................................................... 61

6.

Exit Strategies......................................................................................................... 61(1)

Use of MI systems in corporate R&D .................................................................... 61(2) Practical application and commercialization of materials developed with MI
systems .............................................................................................................................. 61
7.

Other important matters.......................................................................................... 62(1)

Legal basis .............................................................................................................. 62(2)

Flexible plan modifications .................................................................................... 62(3) Successive Generations of Project Director, Deputy Project Director, and theManager ............................................................................................................................ 63
Attachment ........................................................................................................................ 64
Appendix

Financial planning and estimation ............................................................... 64

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Outline of the R&D Plan
1. Significance and Objectives
While Japan has been highly competitive in the field of materials, manufacturing in thisfield is undergoing dramatic changes as many other countries are investing heavily in theinnovation of AI-driven methods of materials development. If these methods become
established overseas first, Japan may be relegated to a role of materials provision andruns the risk of rapidly losing its presence in the field. In order to remain competitive
with other countries, it is critical that Japan accelerates its R&D efforts through industryacademia-government collaboration.
By leveraging the groundwork of materials integration (MI) established in Japan, we will
work to develop the world’s first next-generation MI system capable of solving inverse
problems for designing materials and processes to achieve a desired performance.
Utilizing MI, we will strive to develop innovative materials that are competitive andhighly reliable and to establish technologies for their design, manufacture, and evaluation
with the aim of commercializing advanced structural materials and processes for
producing materials used in power plants and aircraft. By utilizing a materials databasestoring Japan’s accumulated knowledge on materials and working to augment a databasefor process and evaluation technologies, we will accelerate the “materials revolution”
through new materials development that merges the cyber world with the physical world.
2. Content of the Research
In order to establish basic MI technologies for solving inverse problems and todemonstrate their effectiveness in the development of practical materials, we will apply
MI to the development of cutting-edge structural materials and processes that are inincreasingly higher demand internationally and that are one of Japan’s strengths.
Domain A: Inverse Design MI
To establish a new integrated materials development system that combines materials
science and engineering with data science with the goal of realizing Society 5.0. The
system will be able to propose required structures and properties of materials based on adesired performance and the processes needed to achieve them. The goal is for businesses
in Japan to use this system as a means of social implementation, and particularly thosecompanies that work with advanced structural materials and processes, which will be thesubject of increasingly fierce international competition.
Domain B: CFRP
To utilize an integrated materials development system to develop technologies for
improving the properties and productivity of carbon fiber reinforced plastics (CFRP) thatare becoming increasingly popular for use in lightweight structures. The results of these
efforts will help us lead the world in the development of aircraft and other transportationequipment.
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Domain C: 3D Powder Processing
To utilize an integrated materials development system to realize innovative materials andprocesses for 3D powder processes on heat-resistant alloys, for which competition indevelopment is intense, and ceramic matrix composites (CMCs), which are ultra-hightemperature heat-resistant materials for next-generation transportation and energy
equipment in an effort to bolster Japan’s industrial competitiveness.
3. Implementation Structure
Program Director (hereinafter “PD”) Yoshinao Mishima will be in charge of theestablishment and promotion of the research and development plan, while Deputy
Program Director (hereinafter “Deputy PD”) Tetsuo Mohri will assist the PD. A
Promotion Committee composed of related ministries and agencies and specialists will
perform general coordination, with the PD serving as chair and the Cabinet Office as
secretariat. A call for research proposals will be conducted through funding by the Japan
Science and Technology Agency (JST). A Selection Committee established at the sameagency will, after adequate evaluation, select the best-suited research subjects as requiredin the research and development plan while coordinating with the Promotion Committee,
and will organize research teams comprising universities, national research anddevelopment agencies, and private companies to carry out the research tasks. The
progress of each research topic will be controlled under the management of JST. Overall,
the research subject shall be managed under a coherent structure in which inverse design
MI is developed in Domain A while being applied to advanced structural materials andprocesses in Domains B and C, with the aim of demonstrating the effectiveness of inverse
design MI to the industrial world in the hope that it will lead to social implementation.
4. Management of Intellectual Properties
R&D for each theme will be tackled under an intellectual property strategy emphasizing
commercialization. An Intellectual Property Committee will be established under JST forthe purpose of learning and managing trends in intellectual properties applied for by eachcontract research organization and coordinating with the contract research organizations
to make their intellectual properties more adaptable to industrial use.
5. Evaluation
Prior to the Governing Board conducting each end-of-year evaluation, the PD andresearch bodies will conduct self-inspections. Technology readiness levels (TRLs) will beutilized to thoroughly manage the progress of research, and research tasks will be
evaluated after three years, with research topics being reorganized or adjusted as needed
to maintain research and development at a high level. Additionally, peer reviews are to be
conducted by domestic and foreign experts while taking meticulous care to avoid
information leaks.

66. Exit Strategies(1) Use of MI systems in corporate R&D (Domain A)
The starting point of the inverse problem is set to numerical values of a target
performance required by participating companies, i.e., potential users, and theeffectiveness of the MI system is confirmed through solutions in cyberspace anddemonstrations in physical space. We will develop a distributed computation and control
technology for seamlessly linking a system operated by a centrally located MI center withcalculations in a local corporate environment over the Internet. In order to use and apply
company-held data, a standard data description format will be designed and widely
shared (even if the actual data cannot be). These efforts are hoped to encourage the use
and application of data that lies dormant in companies.
(2) Practical application and commercialization of materials developed with MI systems(Domains B and C)
Cutting-edge materials and processes for aircraft fuselages and engines and industrial
power plants are envisioned as applications for MI, and practical applications andcommercial products for research achievements will be found through collaboration withmaterial and heavy industry manufacturers. While our long-term goal is to commercialize
private aircraft on the global market, we will work to promote applications for our own
products at an earlier stage as a form of social implementation.

1. Significance and Goals(1) Background and circumstances at home and abroad
While Japan has been highly competitive in the field of materials, manufacturing in thisfield is undergoing dramatic changes as many other countries are investing heavily in theinnovation of artificial intelligence (AI)-driven methods of materials development. If
these methods are established overseas first, Japan may be relegated to a role of materials
provision and runs the risk of rapidly losing its presence in the field. In order to remaincompetitive with other countries, it is critical that Japan accelerates R&D throughindustry-academia-government collaboration.
Europe and America are also working on methods of materials development thatincorporate AI. For example, Northwestern University in the U.S. (QuesTek) and VTT
Technical Research Centre of Finland Ltd are in the forefront of developing multiscale
multiphysics computational techniques for designing actual materials as a consulting toolfor companies in the West. However, these techniques are not sufficiently versatile forgeneral businesses in the private sector to use and, hence, the businesses themselves
cannot employ them in materials development.
Japan has worked with domestic manufacturing companies on materials integration(hereinafter “MI”) in order to develop a support tool for general-purpose development
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that manufacturers having strength and expertise in the field of materials can use
themselves according to need, and has established the world’s first system forconsistently predicting performance from processes. Based on this groundwork, we willdevelop the first MI system that supports inverse problems for designing actual materials
and processes to meet a desired performance and will apply this system to actual
advanced materials and processes to realize more efficient development.
Specifically, we will develop and implement an inverse design MI system to be used inindustry and will utilize the system for developing advanced structural materials andprocesses that play to Japan’s strengths. In addition to such metal-based materials as
steels, aluminum alloys, and heat-resistant alloys and intermetallic compounds, examplesof advanced structural materials may include ceramics, polymers, and particularly theircomposites, which are increasing in use as structural materials. Advanced processes may
be process technologies that are currently undergoing reform in target fields, such as
powder metallurgy (PM) processes focusing on additive manufacturing (AM), andinjection molding of composites.
(2) Significance and strategic importanceMI must be utilized to develop advanced materials and processes capable of maximizing
Japan’s potential in materials science and technology and the raw materials industry,
which is at a higher level internationally than in the past. Figure 1 shows the overall
concept of this research subject. The aircraft industry is one example of a field that
requires the highest level of qualities possessed by structural materials, including specificstrength, heat-resistance, and reliability, and may have a large ripple effect on otherindustries in the fields of environment and energy, such as gas turbines for power
generators. These days in particular, there is demand internationally to provide new
added value in carbon fiber reinforced plastics (hereinafter CFRP) used to achieve lighter
fuselages, such as flame-retardancy and other new features or greater freedom of design,with a focus on expanding future demand for small and medium aircraft and developing
next-generation aircraft. Additionally, AM and other new powder processing
technologies are expected to spread to the manufacture of intricately shaped components
used in industrial power plants, for example, further expanding applications for thesetechnologies.
Introducing MI into the development of such diverse advanced structural materials andprocesses will contribute further to Japan’s international competitiveness in the raw
materials industry by greatly reducing the time required for development andmanufacturing and dramatically reducing manufacturing costs.

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Figure 1 Overall concept of our research subject(3) Objectives/Aims(i)Toward realization of Society 5.0
The “integrated materials development system” established as one of eleven systems
for realizing Society 5.0 in the 5th Science and Technology Basic Plan is in fact theMI system. The achievements in MI established to date will be used to integratematerials science (physical space) with information science (cyberspace) to a highdegree.
Our aim is to develop an inverse design MI that lowers material development costs by
at least 50% and the development period by at least 50% and that elicits new functionsof materials. The effectiveness of the MI will be demonstrated by solving inverse
problems to attain desired performance in the eleven subjects, and we will create aplatform through which the MI system can be utilized broadly by private companies
and research institutes.
Inverse design MI will be utilized to develop cutting-edge processes for manufacturingcomposites and heat-resistant alloys with a high degree of freedom. These materials
will be used in actual parts for power plants and other applications in the environment
and energy industries, as well as the aircraft industry.

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(ii)

Social objectives

Research centers and networks will be constructed for the development of advanced
materials and molding processes utilizing MI and efforts will be made to promoteinternational collaboration and human resources development for innovation.
The use of high specific strength and heat-resistant materials developed through MI
systems promoted to improve fuel efficiency in energy and transportation equipment
and to reduce greenhouse gas emissions.
(iii) Industrial objectives
Our aim is to establish centers available to industries for utilizing inverse design MI
and to optimize materials development by dramatically reducing the development
period and costs.
We hope to expand Japan’s order share and industrial scale of aircraft parts andindustrial power plants by supplying parts produced domestically using new materials
and processes developed with MI.
(iv) Technical objectives
An objective of this plan is to establish an integrated materials development system forrealizing Society 5.0, which will be able to propose required structures and propertiesof materials based on a desired performance and present feasible processes fordeveloping those materials.
Technologies for improving the properties and productivity of CFRPs, which arebecoming widely used as materials for lightweight structures, will be developed
utilizing an integrated materials development system.
Innovative materials and processes utilizing an integrated materials development
system will be realized for powder processing of heat-resistant alloys, for which
competition in development is intense, and ceramic matrix composites, which areultra-high-temperature heat-resistant materials for next-generation transportation andenergy equipment.
(v)

Objectives pertaining to institutional systems

Our aim is to establish and standardize new testing and evaluation methods using MI
for materials and process development.
We will promote an institutional system for utilization and security of a shared
database platform.
Recommendations on MI-related intellectual properties will be offered.
(vi) Global benchmarks
It is remarkable how major countries overseas, and particularly Asian nations, havedramatically closed the gap in materials technology, which has been one of Japan’s
strengths. America, Europe, and other regions have been investing heavily in AIdriven methods of materials development.
Utilizing its massive accumulation of high-quality materials data, Japan has worked
with domestic manufacturing companies to develop a support tool incorporating MI

10for general-purpose development. Manufacturers with strength and expertise inmaterials development can use the tool as needed. With this tool, Japan has establishedthe world’s first system for consistently predicting performance from processes. Basedon this groundwork, we will develop the first MI system that supports inverse
problems for designing actual materials and processes to meet a desired performanceand will apply this system to actual advanced materials and processes to realize more
efficient development.
We will integrate MI with Japan’s strength in materials technology to develop
advanced materials and processes for which Japan is known. However, to continue
carrying out strategic R&D we must conduct a more detailed survey of global
benchmarks in the future.
(vii) Collaboration with local government bodies
Advanced materials development utilizing MI will be promoted in a unified national
effort by assembling cutting-edge technologies from regional universities, whosestrengths lie in specific technologies, and public research institutes that have amassed
sophisticated technologies.
We will publish research results in coordination with local and regional governing
bodies and assist in promoting industry and developing human resources.

2. Description of R&D Activities
In order to establish basic MI technologies for solving inverse problems and todemonstrate their effectiveness in the development of practical materials, we will apply
MI to the development of cutting-edge structural materials and processes that are inincreasingly higher demand internationally and that are one of Japan’s strengths. Program
Director (hereinafter “PD”) Yoshinao Mishima and Deputy Program Director (hereinafter“Deputy PD”) Tetsuo Mohri will establish three domains under the direction of the PD,
and specifically Domain A (Inverse Design MI), Domain B (CFRP), and Domain C (3D
Powder Processing). The objectives of these domains are as follows.
Domain A: Inverse Design MI
To establish a new integrated materials development system that combines materials
science and engineering with data science with the goal of realizing Society 5.0. The
system will be able to propose required structures and properties of materials based on adesired performance and the processes needed to achieve them. The goal is for businesses
in Japan to use this system as a means of social implementation, and particularly thosecompanies that work with advanced structural materials and processes, which will be thesubject of increasingly fierce international competition.
Domain B: CFRP
To utilize an integrated materials development system to develop technologies for
improving the properties and productivity of carbon fiber reinforced plastics (CFRP) thatare becoming increasingly popular for use in lightweight structures. The results of these11efforts will help us lead the world in the development of aircraft and other transportationequipment.
Domain C: 3D Powder Processing
To utilize an integrated materials development system to realize innovative materials andprocesses for powder processes of heat-resistant alloys, for which competition indevelopment is intense, and ceramic matrix composites (CMCs), which are ultra-hightemperature heat-resistant materials for next-generation transportation and energy
equipment in an effort to bolster Japan’s industrial competitiveness.
The domains are configured of five teams in Domain A, three teams in Domain B, andfive teams in Domain C (see Fig. 2). Collaboration between Domains A and B is
promoted through Team A3 (Atomic (Molecular) Structure Design), and collaboration
between Domains A and C is promoted through Team A2 (Process Design) (see Fig. 3).
Researchers that belong to Domains B and C are also placed in these two collaboration
teams to facilitate the utilization in Domains B and C of technologies developed in
Domain A.

Figure 2 Organization of R&D

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Figure 3 Overview of the R&D domains(A) Fundamental Technological Development for Inverse Design MI
Co-directors
Masahiko Demura (National Institute for Materials Science (NIMS))
Manabu Enoki (the University of Tokyo)
OutlineMaterials Integration (MI) is defined as integrated materials engineering that can lead toinnovation in efficient materials development and processing. In MI, theory andempirical law of materials science are combined with experimental data and various
databases by integrating computational science with data science. This enables us to
implement a system for predicting in silico correlations among the structures, properties,
and performances of materials. In the first phase of SIP, Structural Materials forInnovation, Japan succeeded in developing MI System ver. 1.0 using weld joints of steel
materials as an exercise. This effort to realize the world’s first MI system involved
developing 162 modules and 101 workflows linking those modules. Thus, we areachieving success in developing calculation modules of various types and workflows thatlink these modules through materials engineering, as well as an integrated system to
execute computational sequences according to the workflows. This system will enable us
to predict performance aspects essential to structural materials, such as fatigue, creep,hydrogen embrittlement, and brittle fracture, from welding processes.

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Making advances in MI and developing applications for important areas of materials arevital to the materials revolution in which new materials will lead to innovation in society.
Innovative materials for supporting Society 5.0 must be developed and implemented assoon as possible, and the framework of materials development itself must be madedramatically more efficient through our approach to Society 5.0, and specifically themerging of cyberspace (MI) and physical space (manufacturing).
Globally, we are seeing accelerated investment in AI-driven materials development.
There is some debate over whether AI can be used to develop materials with complex
structures, and particularly whether materials developed with AI will find acceptance foruse as structural materials that require long-term reliability. However, if realized, thisachievement is expected to give rise to disruptive technological innovation in areas ofmaterials wherein Japan’s strength lies.
With the considerable advances being made in computer and information science, it has
recently become important to incorporate computer and information science inconventional materials engineering. Japan holds a prominent place internationally inareas of materials owing to its accumulation of materials engineering knowledge,
manufacturing technologies, and high-quality data. We must work to maximize theseaccumulations and to further expand these accumulations efficiently using computer andinformation science.
Taking this into account, we intend to revamp our methods of materials development byintegrating materials engineering with computer and information science using the
groundwork of MI developed thus far in basic MI areas. Japan will lead the world in
disruptive innovation by making use of its strengths in areas of materials. Specifically,
we must make advances in MI, and particularly must establish a new MI foundation
addressing inverse problems for optimizing materials and processes to achieve desired
performance, while bearing in mind its application in important materials areas.
This foundation for inverse design MI signifies computer programs such as MI systems
and tools for solving inverse problems, hardware for executing the programs (hereinafter
called an “inverse design MI system”), and a framework/structure for the use andcontinuous maintenance and development of these elements by companies. Thesesystems will enable the design of optimal materials and processes in much vaster space
while requiring fewer expensive experiments and trial manufacturing than conventional
methods of R&D. That is, trial-and-error, conventionally performed through experiments
and trial manufacturing, can be conducted efficiently and comprehensively in the inverse
design MI system. As a specific method of use, the user connects to the inverse design
MI system over the Internet and performs analyses for solving issues in materials
development. A framework will be constructed to seamlessly connect to and utilize
calculations in the user’s local environment to allow for analyses that include in-house
data.

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Specific Approaches to Inverse Design MI
Approaches to inverse design MI differ according to the issue, but typically involve
developing forward calculation techniques (modules and workflows) for predicting
performance from materials and processes and attempting to optimize materials andprocesses efficiently in silico using these techniques. Utilizing the results of the firstphase of SIP and special technologies and materials possessed by participatingorganizations, we will develop inverse design MI by applying design and analysis
techniques for required forward problems, incorporating AI technology, and soliciting theparticipation of specialists in computer and information science needed to solve inverse
problems efficiently. Products of this development will include modules and workflows
developed and accumulated while solving various inverse problems, data science
methods for analyzing inverse problems, and MI systems that integrally incorporate theseproducts. For development to proceed efficiently, we must make advances in forward
calculation techniques while simultaneously analyzing inverse problems from any point
possible.
Collecting data is important for computing valid solutions with the use of AI and othertechnologies. Companies that establish inverse design issues possess a considerable
amount of base data that can be utilized to tackle these issues. We will also conduct
development based on data and expertise accumulated through many years of research atuniversities and national research institutes where modules are created. Experimental dataneeded for complementing this knowledge will be efficiently collected using suchtechnologies as process monitoring and 3D structure analysis. This will allow us to secure
enough necessary data (and expertise) to solve the established inverse problems.
The aim of Domain A is to establish an inverse design MI foundation through the
combined efforts of (A-1) pioneering development in analytical techniques for inverse
design, (A-2) developing new calculation modules for applying inverse problems tovarious advanced processes, (A-3) developing techniques for designing structures fromatoms, (A-4) developing a system that integrates the aforementioned technologies totackle inverse design, and (A-5) developing a database as a basic tool for developing
structural materials.
First, for (A-1) pioneering development in analytical techniques for inverse design, R&D
will be conducted on methods of analyzing inverse problems in conjunction with AI
technology that target materials and processes directly utilizing calculation modules andworkflows developed in the first phase. Additional studies will be conducted on efficient
inverse problem analytical techniques for processes that are not always compatible withcalculation modules.
Concurrently, the (A-2) team will be developing a set of calculation modules capable ofsupporting various processes in order to apply inverse problems to the advanced materials
and processes addressed in Domain C. Utilizing the modules developed here, the teamwill work on streamlining development with the inverse design approach for specificapplication cases of advanced materials and processes while incorporating analyticaltechniques for inverse problems developed in (A-1).

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In order to apply inverse problems at the structural level, as is addressed in Domain B,
the (A-3) team will develop analytical techniques necessary for designing structures fromthe atomic level. The required performance for airframe and engine parts at the structurallevel must satisfy multiple properties. These properties are dependent on internal
structures at various scales from the atomic and molecular level to the structural level.
Here, an advanced technology must be developed to address multiple physicalphenomena simultaneously while linking the different scales of these phenomena.
In the development of an MI integrated system for inverse problems aimed at integrating
the aforementioned core technologies (A4), significant functional enhancements to theintegrated system are needed; namely, the implementation of newly developed
calculation modules for inverse problem techniques and advanced materials andprocesses that can find solutions to inverse problems.
The team must work simultaneously on improvements required for the social
implementation of MI, such as enhanced user-friendliness and strengthened security.
Finally, in (A-5) the development of a structural materials database to be the foundation
for developing structural materials, the team will research and develop a databasestructure specific to structural materials and construct a structural materials database thatcan efficiently accumulate experimental and computational data suitable for application
to inverse problems.
The MI integrated system and structural materials database will be closely linked so that
calculation tools including materials data calculation modules and workflows can beutilized organically to develop structural materials by inverse design.
These efforts are aimed at establishing a next-generation MI foundation that covers
everything from metals and ceramics to polymers and composites using these materials asa matrix for the purpose of optimizing materials and processes based on the desired
performance.

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Figure 4 Domain A: research organization for an inverse design MI foundation(private companies are in red)(A-1) Inverse Design ApproachCo-leaders:Manabu Enoki (the University of Tokyo)
Akira Kazama (JFE Steel Corporation)
Participating organizations: the University of Tokyo; JFE Steel Corporation; Teikyo
University; the National Institute of Informatics; the National Institute for Materials
Science; UACJ Corporation; Kobe Steel, Ltd.; Nissan Motor Corporation; and Showa
Denko K.K.
By integrating the theory, empirical law, numerical calculations, and databases
accumulated in Japan thus far, we have developed a system comprising modules anddatabases for predicting the structure and performance of structural materials using
welded joints of steel as an exercise. Since welding is a complex process involving thesimultaneously occurrence of numerous phenomena that determine the structures of steel
materials, including solidification, transformation, grain growth, and precipitation, thestructural prediction modules cultivated in this exercise are highly versatile and can beextended to processes other than welding such as the manufacture of metal materials.
Performance prediction modules targeting such performance aspects as fatigue, creep,17

hydrogen embrittlement, and fracture toughness were also developed for determining
what time-dependent performance is exhibited by materials and structures at welded
joints possessing complex microstructures in response to applied stress, temperature, andother working conditions. Developing a system for flexibly linking these calculation
modules has enabled us to predict performance consistently. In addition, methods of data
assimilation enable us to estimate material parameters that are difficult to measure.
However, the prediction systems developed thus far fundamentally deal with forward
problems that predict performance from such processing conditions as composition andother material conditions, and processing conditions for manufacturing and use In themeantime, development has been conducted on 1.5 GPa-grade next-generation ultrahigh-strength steel for use in steel materials and 750 MPa-grade high-strength materials
for aluminum alloys. However, since strength has a tradeoff with environmental
resistance and weldability, finding an optimal balance in performance is essential indeveloping materials for practical use. Consequently, to reduce the development time formaterials, a new approach to optimization that links prediction modules individuallydeveloped for each aspect of performance will be needed. Further, the difficult issue of
constructing a physical model for each individual process, such as a manufacturing
technology for powder used in advanced AM, will require a drastic reduction in thenumber of R&D trials and a more efficient technique for searching processes.
Hence, we are conducting R&D on a framework (see Fig. 5) capable of finding an
optimal performance balance and analyzing inverse problems. The framework will bebased on the system developed thus far that primarily targets steel materials andaluminum alloys and uses forward problems for predicting performance. Our approach
will effectively utilize sparse modeling and data-driven information science and data
science. By applying this inverse design approach, we intend to further acceleratematerials development of high-performance steels, aluminum alloys, and heat-resistantalloys that will be increasingly needed for automobiles, aircraft, and other transportationequipment.
Intermediate Goals (for the end of fiscal 2020)
Next-generation high-strength steel MI
Issues related to applying an inverse design MI approach to high-strength steels will beidentified. The study will focus on martensitic structures, which are the base of highstrength steel, and will primarily use data obtained thus far on process conditions,microstructures, properties, and performance.
Next-generation high-strength Al alloy MI
Next-generation high-strength steel MI Through the use of MI, heat-treating processes
will be searched in data collected to date on properties and microstructures in an attempt
to find conditions necessary for producing new high-strength Al alloys.
Joining process optimization MI for high-strength steels
With a focus on welding processes that affect the fracture toughness of high-strength
steels, an inverse design MI approach will be used to search processing conditions for18

improving fracture toughness of high tensile steel. This MI approach will be used inaddition to the performance prediction system developed thus far for fracture toughness.
Joining process optimization MI for heat-resistant steels
With a focus on welding processes that affect the creep performance of high-strength
steels, an inverse design MI approach will be used to search processing conditions for
improving creep performance of heat-resistant steel. This MI approach will be used inaddition to the performance prediction system developed thus far for creep.
Product application MI
Utilizing MI, a database on manufacturing processes will be developed to turn expertise
accumulated by companies into explicit knowledge.
End Goals (for the end of fiscal 2022)
Next-generation high-strength steel MI
A strategy for formulating guidelines will be established for new materials development
applying an inverse design MI approach to high-strength steels. Development will befocused on martensitic structures, which are the base of high-strength steel, using
primarily data obtained thus far on process conditions, microstructures, properties, andperformance.
Next-generation high-strength Al alloy MI
Through the use of MI, a basis will be established for identifying conditions in datacollected to date on properties and microstructures related to heat-treating processes for
new high-strength aluminum alloys.
Joining process optimization MI for high-strength steels
With a focus on welding processes that affect the fracture toughness of high-strength
steels, an inverse design MI approach will be used to find optimal processes for realizing
good fracture toughness of high-tensile steels. This MI approach will be used in addition
to the performance prediction system developed thus far for fracture toughness.
Joining process optimization MI for heat-resistant steels
With a focus on welding processes that affect the creep performance of high-strength
steels, an inverse design MI approach will be used to find optimal processes for realizing
good creep performance of heat-resistant steels. This MI approach will be used inaddition to the performance prediction system developed thus far for creep.
Product application MI
Utilizing MI, a foundation for discovering new manufacturing processes will beestablished to turn expertise accumulated by companies into explicit knowledge.

19

Figure 5 R&D concept for inverse problem analysis(A-2) Process Design
Co-leaders:
Makoto Watanabe (National Institute for Materials Science (NIMS))
Kenichiroh Igashira (Kawasaki Heavy Industries, Ltd.)
Participating organizations: National Institute for Materials Science; Kawasaki Heavy
Industries, Ltd.; Osaka University; Tohoku University; the University of Hyogo; Nagoya
University; Kyushu University; Kobe Steel, Ltd.; Hitachi Metals, Ltd.; Gifu University;
the University of Tokyo; Katayanagi Institute, Tokyo University of Technology; Toho
Technical Service Co., Ltd.; and JAMPT Corporation
Processes, structures, properties, and performance are the four elements of materials
engineering, and materials development essentially involves clarifying their correlations
to linking these elements together. Hence, the development of calculation modules forconnecting these four elements of materials engineering is essential for applying inverse
problems to advanced materials and processes. Here we will take on metal powder-based
molding as the advanced process in order to develop calculation modules required for
applying this technology to the development of advanced heat-resistant materials (see Fig.
6). Specifically, we will construct a calculation module base in order to develop
analytical modules for common physical phenomena and prediction modules forindividual materials, and to apply inverse problems to advanced materials and processes.
The calculation modules for various processes developed here and analytical techniquesfor 3D structures will be utilized to apply inverse problems to the advanced materials andprocesses addressed in Domain C in order to design those materials and processes.
Specific development targets are summarized below.

20Common base modules for materials development
To develop modules for common physical phenomena, such as meltingsolidifying processes and sintering processes for metal powders.
Structural control modules for AM
To develop techniques for designing alloys that purposely utilize nonequilibrium
processes targeting AM and to establish a new technology for proposing alloys
that have both heat-resistance and moldability. To perfect modules by developing
and collecting data on in-line monitoring techniques and comparing and verifying
prediction results.
Analytical modules correlating structures and performance in 3D powder forging
Near-net-shape forging and heat-treating control the three-dimensional shapes andstructures of primary materials obtained by powder sintering and billet formation,and their performance is determined by such factors as creep and fatigue. Here,we will establish a technique for correlating structures and performance as a basefor determining the optimal conditions of 3D powder forging from performance,and particularly from creep-fatigue, which is the superposition of two important
performance aspects in heat-resistant components.
Prediction modules for CMC performance
To collect and organize existing knowledge on performance degradation underconditions simulating the CMC working environment and to apply this knowledge
to the evaluation of CMC component reliability.
Intermediate Goals (for the end of fiscal 2020)
Powder AM
Forward analytical techniques capable of predicting structural formation and cracking in
rapid cooling processes and predicting mechanical properties will be developed for AM
processing of heat-resistant alloys.
Powder manufacturing
Data will be collected on manufacturing conditions and powder properties, such as
particle size distribution, aimed at manufacturing processes for heat-resistant alloy
powders. Machine learning algorithms will be applied to the collected data to extract
issues in optimization. Studies will be conducted on bearings for heavy loads and highspeed rotation targeting the plasma rotating electrode process (PREP), and on the effectof a non-transferred arc plasma torch for achieving fine control of average particle size.
Powder forging (powder metallurgy)
Efforts will be made to improve the NIMS program for predicting superalloy properties,
to clarify issues in the collection and prediction of creep and fatigue performance data,
and to create a database with correlations among powder properties, initial density, load,
sintering behavior, and microstructures.
Powder sintering
A database will be developed with correlations among powder properties, initial density,load, sintering behavior, and microstructures. The diffusion mechanism of additiveelements will be clarified, and the effects that temperature conditions in hot plastic
working have on microstructural changes will be investigated.

21

Advanced forging
Issues will be identified by collecting data on constant-temperature forging of solid
solution strengthened and precipitation hardened alloys, and demonstrating analyticalmodels in small-scale experiments.
CMCs
The simulation of degradation mechanisms for CMCs under high-temperature dynamic
load conditions will be made possible by collecting and organizing existing knowledge
on such mechanisms.
End Goals (for the end of fiscal 2022)
Powder AM
A technology aimed at AM processes for heat-resistant alloys will be developed forpredicting structures and defects in rapid heating and rapid cooling processes andpredicting structures and performances resulting from heat treatments. Techniques fordesigning alloys utilizing nonequilibrium processes will be established.
Powder manufacturing
A MI technology aimed at manufacturing processes for heat-resistant alloy powders will
be developed for accelerating the optimization of manufacturing conditions, which have
conventionally required many experiments and much time and expense,. A new PREP
apparatus will be developed for enhancing cyber-physical affinity in 3D molding.
Powder forging (powder metallurgy)
Techniques targeting the forging of powder-based, heat-resistant alloys will be developed
for analyzing metal powder sintering, forging, and heat-treating processes, and a
prediction technology will be realized for structures and macro-properties.
Powder sintering
Efforts will be made to systematically measure shrinkage behavior and microstructuralchanges in powder compacts at high temperatures, to construct a materials database forthe sintering process, and to establish a sintering analysis system employing this database.
A method of predicting optimal solutions for alloy design and processing conditions willbe established through inverse design MI that combines experiment analyses withcomputational science.
Advanced forging
A high-precision forging analysis technology and a process design technology will be
developed for ingot-based advanced forging.
CMCs
A performance prediction technology will be developed for CMCs under conditions
simulating their working environment, virtual tests will be conducted.

22

Figure 6 Concept of process design R&D(A-3) Structure Design of Atoms and Molecules
Co-leaders:Tomonaga Okabe (Tohoku University)
Akihiko Ito (Toray Industries, Inc.)
Participating organizations: Tohoku University, Toray Industries, Inc., Subaru
Corporation, the University of Tokyo, the Japanese Aerospace Exploration Agency,
Nagoya University, the National Institute for Materials Science, and Keio University
Utilizing inverse problems to design structures from the atomistic level will require atechnology for linking different scales from atomistic and molecular to structural(multiscale) while handling multiple physical phenomena simultaneously (multiphysics).
Here, using the example of polymer-based composites for aircraft, which have acutemultiphysics and multiscale problems, we will address basic technologies for applying
inverse problems at the airframe (structure) level. In Japan we have so far been successful
in developing multiphysics, multiscale simulation techniques (see the top diagram in
Figure 7) from molecular scale simulations, including crosslinking reactions based on
quantum chemical calculations, to elementary airframe design. Boeing has called thisinitiative “atoms to aircraft.” In the first phase of SIP, Structural Materials for Innovation,
the application of CFRP was possible in everything from quantum chemical calculations(three modules), molecular simulations (four modules), microscale simulations (threemodules), mesoscale simulations (three modules), and macroscale simulations (sixmodules) to structural design (three modules). Development of a forward design tool also23

reached a level applicable to social implementation. The tool is already being
implemented through its incorporation in general-purpose code (Materials Studio, JOCTA, etc.) and its use in corporate materials development.
While utilizing results from the first phase of SIP, simulation tools will be further
developed to make airframe applications of polymer-based composites specificapplication targets that are more readily adopted at development sites. We will develop amultiphysics/multiscale (MP/MS) simulator for comprehensively handling everythingfrom R&D on multicomponent polymer networks to the design and manufacture ofstructural members and optimization based on inverse analysis. Based on these results,
we will propose multifunctional composites or optimal structural components. Items ofdevelopment required for achieving these goals are as follows.
Establish dissipative particle dynamics (DPD) simulation techniques targeting
network polymers
Perform multiphysics analysis using DPD or all-atom molecular dynamics (MD)simulations
Establish a self-consistent field (SCF) theory that considers fiber-fiber interactions
Compare compositional designs and experiments for epoxy network polymers
Propose new materials using both experiments and multiphysics analysis as
training data
Establish multiscale modeling that incorporates the continuum scale
Propose modeling methods for automatic lamination of composite materials andmodeling based on these methods
Achieve optimum multiscale design for auto-laminated structural members to
reduce stress concentration
Among the above items, efforts to characterize multicomponent network polymers aimed
at composites having nano/microscale phase-separated structures, simulation modeling ofphase-separated structure formation occurring during the reaction processes of epoxy
resins in particular, and an attempt to scale-up this process to actual structural members
will be the world’s first ever, ahead of even Boeing. It is critical that Japan establish
software technologies in order to maintain its dominance in such strategic resources ascarbon fibers or composites.

24

Figure 7 R&D concept of structure design for atoms and molecules

25Intermediate Goals (for the end of fiscal 2020)
Modeling the crosslinking process of network polymers in advanced composites foraircraft
Quantum calculations for crosslinking of network polymers will be formulated in a
Gaussian basis and incorporated in curing reactions of polymeric materials to implement
DPD simulations of reactions responsible for the formation of crosslinked networks.
Meso/microscale modeling of advanced composite matrix resins for aircraft
Polymer simulations for reaction-induced phase separation will be developed using the
SCF theory and the density functional theory (DFT) to obtain reproducible results in both
DPD simulations and experiments on reactions.
Integrated analysis tool for multiphysics/multiscale (MP/MS) simulations
An integrated analysis tool for MP/MS simulations on advanced composites for aircraft
will be developed to obtain reproducible results for experiments in Domain B.
Machine learning-assisted tool for inverse design MI
With the support of machine learning, an analytical tool will be developed for multiscale
analysis and hierarchical screening of material properties.
End Goals (for the end of the fiscal 2022)
Modeling the crosslinking process of network polymers in advanced composites foraircraftA modeling tool will be developed for the atomistic or molecular scale that targets matrix
resins in advanced composites for aircraft. More particularly, quantum chemical
calculations for crosslinking processes of network polymers will be formulated andincorporated in curing reactions of polymeric materials to develop DPD simulations ofreactions in the formation of crosslinked networks. The results will be reproduced inexperiments to enable their use at materials development sites.
Meso/microscale modeling of advanced composite matrix resins for aircraft
Coarse-grained simulations of polymers will be developed using SCP and DFT theories
to reproduce phase separation around fibers, and efforts will be made to reproduce theresults of both DPD simulations and experiments on reactions. We will also construct
micromechanical models based on the microscopic scale to establish an analyticaltechnique for composite materials aimed at producing practical multifunctional CFRPs,
and CFRTPs or thin-ply CFRPs formed of a crystalline thermoplastic resin matrix.
Integrated analysis tool for multiphysics/multiscale (MP/MS) simulations
An integrated analysis tool will be developed for MP/MS simulations of advanced
composites for aircraft. The MP/MS analysis tool will be implemented in materials
development or manufacturing technologies at participating companies in collaboration
with Domain B. Implementation of this analysis tool in all integration tools of MI will bepromoted. Multiscale modeling of thermoplastic CFRPs with a short cycle-time will be
performed to develop an AFP manufacturing technology.

26

Machine learning-assisted tool for inverse design MI
Techniques will be established for machine learning-assisted multiscale analysis andhierarchical screening of properties. These techniques will contribute to the multiscale
design of optimal materials and the development of manufacturing technologies throughinverse problem analysis.

(A-4) MI Integrated System
Co-leaders:Satoshi Minamoto (the National Institute for Materials Science)
Junya Inoue (the University of Tokyo)
Participating organizations: the National Institute for Materials Science and the
University of Tokyo
In order to employ an inverse design MI system in materials development, not only will it
be essential to develop the base of an integrated system for solving inverse problems, butalso usability of the system must be improved. Additionally, in order to apply this system
to various actual problems, newly developed workflows and modules must be
implemented in the system in coordination with teams (A-1), (A-2), and (A-3), andsupport will be needed to ensure calculations for materials development go smoothly.
Thus, with the aim of establishing a base for MI systems that can solve inverse problems,development of the integrated system will be focused on the following three research
themes: basic development of an integrated system for inverse problems, development
and improvements in usability, and applications to real problems (Fig. 8).
Basic development of an integrated system for inverse problems
Applying inverse problems to materials having heterogeneity at various levels will
require 1) that physical phenomena be described in great detail in the underlying
technology for solving forward problems going from processes toward performance and2) that calculations based on these descriptions can be executed robustly without such
instabilities as divergence and termination. Also needed are workflows for integrally
resolving the various scales and physical phenomena in real problems.
For this reason, the foundation of the MI system produced in the first phase must be
substantially reinforced to be able to handle inverse problems. Specifically, we must firstupgrade each of the programs and greatly enhance the database functions and thefunctionality of the various application programming interfaces (APIs) developed thus far,including the MI-API (API for connections), DB-API (API for database operations), andvocab-API (API for vocabulary information).
Inverse problems can be solved using AI to fully control robust forward calculation
techniques backed by these detailed physical descriptions. Hence, in order to expand theMI system to a base system capable of handling inverse problems, it will be essential to
implement algorithms for solving inverse problems and to develop new technologies
using AI to control forward calculations. Expanding the base system to handle inverse27

problems will be achieved by developing inverse problem algorithms based on the latest
AI technology and a WF-API (an API for workflow operations) and by incorporatingthese items in the MI system.
In materials engineering, a workflow may be regarded as the manner in which a problem
is solved. Hence, by digitally accumulating and networking these workflows, expertise inareas of materials can be restructured to a form suitable for machine learning. Use of
these so-called digital textbooks will help us rapidly examine methods of solving similar
problems and may lead to the discovery of unexpected paths to solutions. The challenge
lies in how workflows are to be networked. A workflow is essentially concepts and links
connecting those concepts. Concepts are expressed with vocabulary (technicalterminology). Hence, it should be possible to network workflows by structuring theconnections between different vocabulary terms. Based on this idea, we will substantiallyenhance the functionality of vocabulary management developed in the first phase with theaim of building a network of knowledge on materials engineering. Networking
knowledge will be achieved using a framework for describing the relationships among
concepts in order to connect expertise possessed by engineers on different materials anddifferent processing technologies. Doing so will require a vocabulary analysis system anda vocabulary visualization system for extracting knowledge in synchronization withhuman thought while referencing sets of recorded vocabulary and experimental andcomputational data. In short, we must develop a system to search databases on
vocabulary and materials that is fast, user-friendly, and scalable.
Developments and improvements in usability
Since it is vital to gain a clear understanding of the user layer in MI systems for a wide
range of fields, user opinions must be gathered to implement a graphical user interface(hereinafter “GUI”) that each user can intuitively manipulate for solving problems.
Further, in light of the variety of APIs that will be developed, a framework will likely be
developed to facilitate functional development and data collection for individual
problems. AI-driven data analysis functions including error handling, data logging, andvisualization, must be developed in order to implement an interactive GUI that can tap
into the user’s intuition. System expansion will also include enhanced functions forremote access and security-related technologies.
Applications to real problems
In this phase, research achievements developed by teams (A-1), (A-2), and (A-3), such as
workflows, modules, and algorithms for inverse problems, must be incorporated in thesystem in order to complete our tool for developing materials through inverse design. We
will work together to understand and organize input/output for products being
incorporated in order to enhance the program so that it is versatile, robust, and large inscale. The results of these efforts will be implemented in the system.
Intermediate Goals (for the end of fiscal 2020)
System implementation of mathematical techniques for inverse analysis
Several generalized case studies for flexibly implementing techniques developed in (A-1)
aimed at mathematically analyzing inverse problems in a system will be carried out tovalidate system implementation of such techniques.

28Flexible control for repeated calculations in inverse analysis workflows
Control techniques for repeated calculations in workflows required for inverse analysis
and a flexible framework for searching similar workflows will be established by utilizing
the APIs described below.
Implementation of newly developed modules for advanced materials and processes
A large number of new modules are anticipated to be developed for advanced materials
and processes, and their prompt implementation will be essential. At present, recording
information such as vocabulary inventories is complicated. Therefore, we will establish atechnique for simplifying the operations required for implementing modules in the MI
system.
User interface
Public hearings on usability will be held for users during this fiscal year and next. Priority
items will be studied and implemented while ensuring security.
API setA set of APIs will be developed for defining input/output between modules, manipulating
workflows themselves, and other functions. A framework will also be established forproviding users with more flexibility in designing modules that incorporate these APIs.
Remote access control
An infrastructure will be established to enable remote system access and utilization. In
addition, we will create an environment for managing workflows and computational data
uniformly with local systems.
End Goals (for the end of fiscal 2022)
System implementation of mathematical techniques for inverse analysis
Techniques developed in (A-1) for mathematically analyzing inverse problems will be
generalized for flexible use and implemented in the system.
Flexible control for repeated calculations in inverse analysis workflows
A flexible control technology will be established for repeated calculations in workflows
required for inverse analysis.
Implementation of newly developed modules for advanced materials and processes
Newly developed modules for advanced materials and processes will be implemented,
while simultaneously establishing a systems approach for simplifying these operations.
User interface
The user interface will be completed with improved usability and security measures.
API setA set of APIs will be developed for defining input/output between modules, and aframework will be developed to provide users with flexibility in designing modules thatutilize these APIs.

29

Remote access control
Technologies for remote access control will be established to ensure consistent workflow
control while effectively utilizing computer resources scattered throughout research labs
and companies.
System implementation of data structures for describing structural materials
A framework will be established for reflecting the data structures that were developed in(A-5) to describe structural materials in the system and for looking up data associations.

Figure 8 R&D concept of MI integrated systems(A-5) Structural materials database
Co-leaders:
Masahiko Demura (the National Institute for Materials Science)
Toshihiro Ashino (Toyo University)
Yoshitomi Okazaki (Kobe Steel, Ltd.)
Participating organizations: the National Institute for Materials Science, Toyo University,
Kobe Steel, Ltd., RIKEN, Kansai University, Tohoku University, JFE Steel Corporation,
IHI Corporation, and UACJ Corporation

30

Structural materials have hierarchical heterogeneity, also known as structure, at different
size scales ranging widely from the atomistic to the structural. Structures are located at
nodes linking processes to properties, whereby the process determines the structure, andthe structure determines the properties. Performance can be considered by also
accounting for the application environment. The method of describing hierarchicallyheterogeneous structures is key for the advanced utilization of materials data indeveloping structural materials. In addition, there exists a major bottleneck to digitizing
information on such heterogeneous structures. Material structures are collected as images
using various microscopic techniques. However, the work required to sort these imagesby hierarchical form and to quantify them as digital information must be delegated toexperts with a deep knowledge of structural images and requires a significant amount oftime and cost. One must also bear in mind that models constructed in conventional
materials engineering are based on two-dimensional information of structures due totechnical limitations. By utilizing the original structural information of materials
characterized three-dimensionally, it is expected that one can better understand the
intrinsic connections between processing, structures, properties, and performance.
Based on this awareness, we will carry out R&D on a database structure designed
specifically for structural materials to describe connections among structures, properties,
and performance and handle inverse problems. Specifically, we will develop a method of
describing the internal structures of hierarchically structured materials, from latticedefects to precipitates and crystal structures, while drawing connections between levels.
The focus will be on the internal structures of materials that govern the properties andperformance of structural materials. We will then construct a database linking processing
with properties and performances. Among the four elements of materials science andengineering, “structure” is the element that links processing to properties. Therefore, atechnique will be developed for efficiently compiling databases of 3D information on
structures. The performances and properties of materials are greatly dependent on
structures having 3D geometric features across a wide range of scales from the nanometerscale to a scale on the order of several hundred micrometers, and their structures vary
greatly according to the processes. Hence, quantitative 3D information on material
structures that link performances to processes must be compiled in a database in order todetermine through inverse design the most suitable process from the desired performance.
Here, a technique will be developed for efficiently collecting multiscale 3D information
on structures formed under a variety of processing conditions.
Development of a database structure for structural materials
Utilizing materials data on weld joints for steel and aluminum alloys, we will take thelead in a study on database structures for such materials in industry, academia, andgovernment. To construct a database structure that will aid in the utilization of data forstructural materials, a computer science framework will be utilized fully for describing
hierarchical connections, such as a material ontology. Once data has been collected for
application examples, a similar study will be initiated on advanced materials andprocesses applying inverse design MI. Since international cooperation will be
indispensable for the investigation and implementation of such a study, we will work topromote de facto standards in collaboration with such organizations as Granta MI that arebehind other projects on structural materials databases.

31Development of analytical techniques for multiscale 3D structures
Conventionally, the support of prominent experts has been essential for determining thethree-dimensional shapes of materials, as the shapes are too difficult to guess from asingle sectional image. The creation of a machine learning model capable ofautomatically determining structure from a sectional image through segmentation has
been needed. Such a model would facilitate the collection of multiscale 3D information
on structures. Here, we will construct a system that will be able not only to determine
structures, but also to extract the structure factor in any two-dimensional image
automatically. At the same time, we will develop a technology for analyzing multiscale
3D structures that eliminates the scale gap present in current techniques for observing 3D
structures. One particular target is a technique for observing 3D structures in the
micrometer to submillimeter range, which is the most important range for structural
materials.
Intermediate Goals (for the end of fiscal 2020)
Design and publication of description methods for structural materials data
A method of designing data will be proposed for three or more types of inverse problems.
Acquisition of multiscale 3D structural information between nm and cm
Techniques will be established to enable large-area 3D observations with scanningelectron microscopes and efficient 3D observations with optical microscopes.
Automatic extraction of quantitative information for material structures from 2D
optical/electron microscopy images
A methodology will be established for sequentially generating supervised 2D images
from labeled 3D images and creating a machine learning model for quantifying structures.
Proposal of new descriptors having strong correlations with the performance of structural
materials
New descriptors will be proposed through mathematical science techniques for material
structures.
End Goals (for the end of fiscal 2022)
Design and publication of description methods for structural materials data
A method of describing materials data for structural materials having the following
characteristics will be designed and published in a usable form for the purpose of
establishing de facto standards.
Capacity for representing hierarchies and mutual relationships of materials and being
linked with techniques for analyzing 3D structural information
Readily expandable for new measuring methods and material systems
Capacity for integrally describing information sources of different types, such as
experiments, numerical calculations, and empirical formulae, in coordination withdescriptors developed for MI System ver. 1.0

32

Described with standard technology on the Internet when possible with the aim ofestablishing de facto standards
Acquisition of multiscale 3D structural information between nm and cm
A technology for acquiring multiscale 3D structural information covering size scales
from nanometers to centimeters will be established by integrating various observation
methods in order to handle hierarchically heterogeneous structures for advanced materials
and processes.
Automatic extraction of quantitative information for material structures from 2D
optical/electron microscopy images
A technique will be established for automatically extracting quantitative information ofmaterial structures from two-dimensional images captured in optical/electron microscopy.
Proposal of new descriptors having strong correlations with the performance of structural
materials
New descriptors having strong correlations with the performance of structural materials
will be proposed using mathematical science techniques.

(B)

Carbon Fiber Reinforced Plastic (CFRP)

Co-directors:
Tomonaga Okabe (Tohoku University)
Toshiya Nakamura (the Japan Aerospace Exploration Agency)
Domain B will apply the basic technologies for inverse design MI developed in Domain
A to the development of raw materials and structures in actual CFRPs. Material structuresand processes required for achieving the target performance will be derived in cyberspace(the MI system) and verified in physical space (trial manufacturing and testing). A
reduction in development time and costs will also be verified. Technologies tailored tothe target materials and processes will be developed based on the techniques relevant tocalculation modules, workflows, and data science approaches developed with inverse
design MI. Advanced structural materials and processes for practical use were selected as
application targets because they are anticipated to be conducive to the application of
inverse design MI, be in line with Japan’s strengths, and have high global demand. One
specific example is a molding technology for composite materials.
In light of the purpose of SIP, the effectiveness of inverse design MI in the developmentof materials and processes must be demonstrated according to a roadmap for practicalapplication and commercialization developed by the participating raw material and heavy
industry manufacturers. Specifically, we need a system involving the Japanese industry,
government, and academia to give concerted support for these efforts through inverse
design MI. Such a system is necessary because CRFP-related technological development
is not progressing fast enough to keep up with the performances required by industry.
The primary outcomes of this R&D will be used in the aircraft industry, but the current
production rate is insufficient to manage future needs for small and medium-size aircraft.
Further improvements are needed in production technology, and new approaches to33

utilizing calculation technologies and scientific foundations possessed by government
and academia will be critical.
The development of structural materials has historically followed the pursuit of highspecific strength and heat-resistance. This pattern will continue as long as we keep
pursuing equipment with higher efficiency, lower energy use, and low environmental
impact. Since materials for aircraft in particular have the strictest requirements for thesetwo performance aspects, along with reliability, such materials are most fitting as theoutcomes of R&D on structural materials.
R&D for the three teams in this domain is described below. All R&D will be carried out
in collaboration with relevant sub-teams under team (A3) (see Figure 9). The calculation
modules and databases developed in this domain will be collected in the inverse design
MI system in a manner that will not impede commercialization, and will be utilized to
improve Japan’s overall competitiveness in materials development.

Figure 9 Domain B: research organization for CFRP (private companies are in red)(B-1) Development of Multifunctional CFRP Providing Added Value
Co-leaders:
Kenichi Yoshioka (Toray Industries, Inc.)
Tomonaga Okabe (Tohoku University)
Participating organizations: Tohoku University, Toray Industries, Inc., the University of
Hyogo, Kyoto University, the Kanazawa Institute of Technology, and the National
Institute for Materials Science34

Owing to their improved mechanical properties, carbon fiber composites have been
adopted to produce lightweight components. With the recent focus on reducing overall
weight and costs by imparting functionality to carbon fiber composites, such as flame
retardancy, thermal conductivity, and damping properties, development of functionality
imparting technologies that can be implemented in structural materials for aircraft has
taken on importance. However, the development period for aircraft systems has morethan doubled since the 1990s as the complexity of development has increased. Thus, atechnical approach for reducing the development period is needed. Adding functionality
to composites has also become a widespread issue in internal railway structures,
automobiles, and electric appliances such as computers.
Since functionality is being added as a component of materials development, as describedabove, we will endeavor to utilize MI technology in the initial stages of development forproviding composites with functionality from the perspective of polymer and prepreg
design. The feasibility of implementing these technologies will be established at an earlystage and will be verified through element tests on components.
While prepregs have conventionally been employed to achieve a target performance inmechanical properties, success has been achieved in separating stiffness and toughness
functions in the design of polymers or prepregs. The current development will not only
cover conventional design in the mechanical domain for pursuing improvements inmechanical properties, but will also target structures having at least one functional
domain as the final composite. In this development, functional particles and polymers
will be combined in prepregs in an effort to impart new functionality, such as flame
retardancy, thermal conductivity, and damping properties. Prepregs will be designed withthe support of MI to acquire basic mechanical and functional data for realizing thisobjective. Structural design will be conducted by identifying optimal structures forfunctional particles or polymers needed to implement a functional domain. Parameters
will be acquired during reactions involved in structural formation to confirm correlations
between the actual domain properties and phenomena related to flammability and thermal
conductivity. Based on this experimental data and hierarchical screening for functional
polymers/prepregs, a materials design tool will be constructed with the use of deeplearning.
Finally, we will construct a design database for polymer systems and prepreg systems
comprising multiple functional domains and a mechanical domain having mechanicalproperties required for structural materials, and will design materials that impart multiple
functions while preserving or improving the mechanical properties. Additionally, we will
utilize MI to construct a design tool based on hierarchical screening for multifunctional
polymers/prepregs and will establish a method of predicting material properties withgood accuracy. The effectiveness of the design prepregs will be verified through smallscale element tests simulating composite members.
By using MI technology to implement the cycle between inverse analysis based on end
products, such as airframe structures, and forward analysis based on the molecular designof materials, technologies will be developed to shorten the development period andpredict the properties of resins, carbon fibers, resin-fiber interfaces, and the components(products) themselves. Specifically, we will develop a multiphysics/multiscale (MP/MS)
35

simulator to comprehensively handle everything from the development ofmulticomponent network polymers to the design and manufacture of structural materials,
and to handle optimization based on inverse analysis. From this simulation information,
we will develop a technology for proposing multifunctional composites or optimal
structural members while shortening the development period.

Intermediate Goals (for the end of fiscal 2020)
Our aim is to design CFRPs having at least one functional domain. Specifically, withtensile strength and compressive strength of CRFP perforated sheets used in aircraft
structures being typically 480 MPa and 310 MPa, respectively, the objective is to reduceburn length by 35% in a practical evaluation method for flammability, which will be
introduced in this study as an index of flame retardancy, while preventing a drop of morethan 5% in tensile and compressive strength. To realize this objective, we must firstacquire fundamental mechanical and functional data on CFRP structures and the designof resin compositions and prepregs constituting the materials of these structures, therebybuilding this data on mechanical and functional properties in a database. The target levelis TRL 3.
End Goals (for the end of fiscal 2022)
A design database will be constructed for polymer systems and prepreg systems
comprising multiple functional domains and a mechanical domain having mechanicalproperties required for structural materials. Materials will be designed to have multiple
functions (flame retardancy, thermal conductivity, damping properties, etc.) while
maintaining the mechanical properties required for structural materials in particular.
Specifically, assuming that the tensile strength and compressive strength of CFRP
perforated sheets used for structures in aircraft are generally 480 MPa and 310 MPa,
respectively, the goal is to avoid a decrease of more than 5% in these parameters, while
improving thermal conductivity by 10% along the thickness direction of the CFRP and
improving the damping ratio by 10% in oscillation measurements on CFRP.
At the same time, we will construct a tool for utilizing the MI described above fordesigning structural materials based on MP/MS modeling of multifunctional polymers
and prepregs. We will establish a method of predicting material properties in the final
structural materials with high precision. The effects of the designed prepregs will beverified through small-scale element tests simulating CFRP members. The target level is
TRL 5.
These outcomes will be demonstrated by manufacturing prototype prepregs that exhibit
the above properties and conducting evaluations similar to quality assurance tests for
products (fiber content, areal weight, etc.). CFRP panels will then be molded from theseprepregs to confirm whether panels of a sufficient grade can be manufactured under
actual molding conditions, and a full evaluation will be conducted on not only themechanical properties, but also the flame retardancy, thermal conductivity, and damping
properties described above. The evaluation method for flammability introduced in this36

study will be used for evaluating flame retardancy. A common standard of measurement
will be used for measuring thermal conductivity. A conventional method of measuring
CFRP oscillations shown to be effective for sports equipment will be employed forevaluating damping properties.

(B-2) Development of CFRP Design/Manufacturing Automation Technology Using AIassisted Stacking Optimization
Co-leaders:Toshio Abe (Mitsubishi Heavy Industries, Ltd.)
Toshiya Nakamura (the Japanese Aerospace Exploration Agency)
Participating organizations: Mitsubishi Heavy Industries, Ltd., the Japanese Aerospace
Exploration Agency, the High Energy Accelerator Research Organization KEK, Kobe
University, Nagoya University, Kyushu University, the University of Tokyo, Hokkaido
University, and the University of Osaka Prefecture
The entrance of the Boeing 787, which embraced the use of carbon fiber composites, has
spurred rapid introduction and growth of automated manufacturing equipment in recent
years to manufacture composite structures for aircraft. With expectations high on carbon
fiber composites for producing lightweight structures, this trend is becoming manifested
in wind turbines for wind power generation, as well as high-speed rail and high-speed
craft. Europe in particular has made great strides in producing automated fiber placement(AFP) machines capable of high-speed, high degree of freedom fabrication ofcomposites. The introduction of these machines has made it easy for anyone to fabricatecomposite structures. Consequently, Japan’s international competitiveness from previous
accumulated composite technologies is now rapidly declining. In order to once again leadthe world in composite technologies, Japan must innovate and standardize techniques ofmanufacturing suitable for AFP. On the other hand, Japan has world-leading
manufacturers of carbon fibers and other raw materials. We intend to take advantage ofJapan’s competitive edge in these materials to make improvements and modifications incoordination with MI in order to overcome problems and defects. One specific issue withthese materials, shrinkage behavior when curing polymeric materials, is directly linked toshape inaccuracies produced during parts manufacturing. Such inaccuracies are a major
obstacle in the assembly of aircraft structures and a factor in increased production costs.
Further, while AFP improves productivity, the interior quality of products produced by
AFP is inferior to products produced from hand layup by laminate experts due to thelower layup accuracy. This can result in degraded performance in the product’s strengthand stiffness, for example. AFP has functions for placing tape along curves rather thanjust straight lines and for producing optimal designs that make use of the strength ofcarbon fibers. However, the improved productivity is not sufficient to be considered anadvantage, and the gaps and overlaps between tape layers in AFP cause numerous
internal defects that have an adverse effect on structural quality, reducing strength andstiffness.

37

In the meantime, Europe and the United States currently have a monopoly on AFP
machines. Despite the best-performing composites and intermediate base materials
known as prepregs originating in Japan, Japan has been unable to acquire materials
design and molding methods suitable for existing AFP machines, making it more andmore difficult to comply with requests from the machine manufacturers. Emerging
powers such as China have been quick to introduce AFP machines from the West andhave begun to undertake research on the manufacture of relevant materials.
In light of these circumstances, our aim is to enter the next emerging aircraft businesspromptly by using general-purpose AFP machines for the optimal AI-assisted design ofcomposites and by improving molding precision using prepregs already developed inJapan.
In order to overcome Japan’s weaknesses in AFP and other manufacturing automation,
our goal is to introduce general-purpose AFP machines being commercialized in Europe
and America in order to perform optimal AI-assisted design of composites and to
improve molding precision using prepregs that Japan has already developed. Throughthese efforts, we hope to achieve materials technology and high-precision molding
techniques unique to Japan and to enter the next-generation aircraft business promptly.
For this reason, we will link technologies related to the cost-competitiveness of productmanufacturing or the products themselves to MI technology driven bymultiphysics/multiscale (MP/MS) analysis. This will enable us to promote activities toimprove and modify materials, make Japanese products competitive once again, andultimately give a boost to Japan’s aerospace industry. At the same time, we will connect
research findings for composite structural optimization/automation to AI-assisted
automated design and formulation of a system for curing (correcting irregularities, etc.
during molding).
Future development of aircraft is expected to bring fierce competition from othercountries including China, which has been rapidly increasing its market presence intechnology. Seizing a commanding lead in this technological area will require an
innovative technology that can improve productivity in the manufacturing of composites
rivaling that of today’s aluminum structures, while utilizing the virtues of composite
materials. Without inhibiting productivity, we must analyze issues specific to polymericmaterials, such as cure shrinkage, or issues of quality lost in exchange for dramatic
improvements in productivity over traditional hand layup, such as the drop in layup
precision due to the application of AFP. We must also utilize MI technology to improveand modify materials in order to take advantage of the virtues of composites, including
their low weight, high strength, and high stiffness. Utilizing MI technology driven by
MP/MS analysis, multiscale research for material improvement and modification will be
carried out on a wide range of issues, from nanoscale observations of raw materials or
crack paths to the development of new structural types applicable to the relevantmaterials. The aim of the new structural types is to suppress fracture phenomena
appearing on the meter scale, and particularly fracture behavior specific to the relevantmaterials, such as separation and interlaminar crack propagation. Ultimately R&D will be
carried out to transform the design and structures of products employing carbon fiber

38

composites or the products themselves, leading to materials-based innovation that will
become a force in Japan’s high-efficiency, high-productivity manufacturing industry.
Intermediate Goals (for the end of fiscal 2020)
Research results obtained to date will be incorporated in the trial manufacture of panel
structures simulating aircraft structures with stress concentration around holes, and thestructures will be subjected to strength tests.
Evaluation items
Lamination speed, increase in speed
Quality assessment of laminate interior, quality assessment with profile measuring(comparison with standard aircraft quality)
Effects of improved strength over hand layup and general laminates determinedthrough strength tests
Target values
The goal for fabricating laminated structures with curved surfaces utilizing thestrength and qualities of carbon fibers in epoxy composites, which are commonly usedin the aviation industry, is to achieve a strength at least equivalent to that of common
hand layup products and a layup speed five times or greater that of hand layup (0.5kg/hr on average).
The following are specific targets at the midpoint of each research issue
Confirm operation performance of the AFP machine, and adjust device-side
improvement tasks aimed at materials improvement
Adjust issues of improvement and issues for manufacturing large complex-shaped
structural parts for aircraft with the AFP machine
Clarify conditions for matching multi-composites (epoxies and thermoplastics) with an
AFP machine
Identify issues in molding and curing of carbon fiber-reinforced thermoplastics(CFRTP) such as the effects of resin crystallinity and conditions of rising/dropping
temperatures
Establish a basis of molding techniques and summarize challenges for establishing
AFP and in-situ consolidation technologies
Study materials improvement aimed at in-situ consolidation of thermoplastic
composites and set policies for methods of materials improvement
Observe fracture features, focusing on the internal structure of CFRPs, and particularlycomposite structures formed through automated layup, optimize layup for improving
fracture strength based on these observations, and extract goals for new structural
types
Target level for intermediate evaluation (end of March 2020): TRL 3
End Goals (for the end of fiscal 2022)
Demonstration tests and strength tests will be conducted to clarify outcomes andchallenges for elements of this study (materials improvement, AI system development,etc.).

39

Evaluation items
This evaluation has essentially the same items as those in the intermediate year. However,
the efficiency of manufacturing products will be comprehensively evaluated through aprocess of manufacturing panels having assembled structures closer to those in aircraft
and assembling those panels.
Target values
Our aim is to achieve improved strength and speed five times or more that of hand layup
for structural components of airfoils, which are more complex in shape than existing
structures made with epoxy composites. In addition, goals will be set for out-of-autoclave
layup and in-situ consolidation for thermoplastic composites.
The following are specific targets upon completion of each research issue.
Establish a base for optimal layup design and fabrication methods, utilizing AFP
machines for composites
Clarify a strategy for materials improvement utilizing MI based on the challenges
identified for the product quality and manufacturability of automated composite layup
and applicable structures for composites
Establish a basis for techniques of design and manufacturing automation that optimize
multivariate parameters through the integration of multipurpose optimization
techniques and data mining
Optimize composite layup suited to AFP, establish a basis for automated design andmanufacturing methods, and implement and evaluate development tests for verifying
their effects
Establish a basis of methods for AFP and in-situ consolidation of thermoplastic
composites
Calculate manufacturing costs according to improved productivity and lighter
structures based on an evaluation of the demonstration tests, and study and implementa business model
Target level for the completion of SIP (the end of March 2023): TRL 4(B-3) Development of 3D High Degree of Freedom Design Technology by Automatic
Lamination of Thin-Layer CFRP
Co-leaders:
Shigekazu Uchiyama (Subaru Corporation)
Toshiya Nakamura (the Japanese Aerospace Exploration Agency)
Participating organizations: Subaru Corporation, the Japanese Aerospace Exploration
Agency, the Industrial Technology Center of Fukui Prefecture, Tokyo University ofAgricultural and Technology, the University of Tokyo, and Tokyo University of Science
With the global expansion of composites used in aircraft parts, the spread of generalpurpose automated equipment and easy-to-use materials is bringing about an age whenanyone can manufacture products with constant quality and performance. Further, as
40

costs keep dropping due to increased sourcing from low-cost countries (LCCs), Japan is
struggling to remain cost-competitive on the level playing field. Technologies forachieving high-performance, low-cost production must be established by developing
materials, design, and manufacturing technologies not bound by past conventions andstandards so that Japan can maintain its dominance in composite technologies. Prior
composites used in aircraft parts have limitations in such aspects as materials, design, andmanufacturing and have not succeeded in demonstrating their true performance. For thisstudy, our goal is to remove these constraints, improve degree of freedom in aspects ofdesign and production, and improve performance so that the properties of composites
approach their true performance.
Specifically, while adopting an MI approach, we will establish and integrate
manufacturing technologies to automate a variable fiber spreading technology for freely
varying the width of composite materials, and an optimal design technology forcomposites having complex structures aimed at continuously varying material width andlayer thickness. With unprecedented structure optimization and low-cost production,
Japan will surpass other countries and maintain its superiority in composite technologies.
Our aim is to design and manufacture lightweight composites that can be competitive
worldwide by promoting the three pillars of materials technology, design and analysis
technology, and manufacturing technology in collaboration with industry, academia, andgovernment. Despite the trend toward low-cost products, we aim to maintain Japan’s
dominance by reducing material costs through the use of lightweight materials andshorter production, including equipment development.
Since the development of composites requires equipment and designs suited to the raw
materials, collaboration among materials, equipment, and airframe manufacturers isnecessary. By nurturing the midstream industry (equipment) currently being dominatedby overseas manufacturers in order to assume comprehensive control over the production
process from the upstream sector to the downstream sector, we can improve development
speed and increase Japan’s competitive strength in composites.
With the aim of achieving social implementation at an early stage, we will reduce thedevelopment period and begin adopting thin-ply CFRPs in 2025. To achieve this, wemust expand our laminating machines ahead of schedule to a practical scale for
manufacturing parts.
Since we also need to extract the benefits of thin-ply CFRP and accelerate technologicaldevelopment of degree of freedom design for further reducing the weight of composite
structures, we will conduct coupon tests (FY2019) for utilizing a tow-steering techniquethat exceeds the original estimates.
Our objective is to optimally design and fabricate composites utilizing MI technology(multiscale calculation and optimal design technologies) linking materials design with
manufacturing. Material production, parts production, and parts performance evaluation
will be compared between the physical space and cyberspace at the development stage tocontinuously improve these technologies. Algorithms for inverse design analysis will also41

be constructed to determine what materials, designs, and manufacturing can achieve therequired parts performance.
Intermediate Goals (for the end of fiscal 2020)
Target TRL: TRL 3, complete basic development of thin-ply prepregs, equipment, anddesigning/manufacturing(i) Development of thin-ply CFRP
Establish process conditions for thin-ply prepreg sheets having improved interlaminarstrength of at least 20 m/min(ii) Development of high degree of freedom AFP (automated laminating machine)
Install automated laminating machine in anticipation of manufacturing actual large
parts, and demonstrate manufacturing
Establish techniques of tow-steering and variable layer width and thickness using theautomated laminating machine(iii) Design and analysis technologies
Complete basic development of a design optimization method for fiber orientation andlayer thickness based on a tolerance database reflecting the strength and fracture
properties of thin-ply CFRP, and begin trial use
Verify effectiveness by conducting a comparison of conventional straight layup
methods for CFRP and a layup method that considers tow-steering and variablewidth/thickness of CFRP for use in aircraft wing structures
End Goals (for the end of fiscal 2022)
Target TRL: TRL 4, complete core technology development using the example ofstructural elements for aircraft wings(i) Development of thin-ply CFRP
Establish process conditions for thin-ply prepreg sheets with improved interlaminarstrength compatible with an AFP machine for high freedom of degree design
Improve strength of thin-ply CFRPs even more than before for use as aircraftcomponents, and fabricate thin-ply prepreg sheets with enhanced interlaminar strengththat are compatible with AFP machines in order to realize a high degree of freedom
layup design technology(ii) Development of high degree of freedom AFP (automated laminating machine)
Establish techniques for steering layup and variable width/thickness of multiple tapelayers using the AFP machine(iii) Design and analysis technologies
Design test pieces using the established method of design optimization for the
structural element level of aircraft wings that achieves the target 10% reduction inweight while maintaining strength and stiffness(iv) Molded articles

42Manufacture actual large parts for structural elements of aircraft wings optimized
through steering of thin tape using AFP
Apply load to the large parts fabricated as structural elements of wings to confirm
their strength and stiffness are equivalent to the analytical results(C)

3D Powder Processing

Co-directors:
Takayoshi Nakano (Osaka University)
Makoto Watanabe (the National Institute for Materials Science)
In Domain C, basic technologies for inverse design MI developed in Domain A will beapplied to the development of actual metal and ceramic-based materials and structures.
Material structures and processes required for achieving the target performance will bederived in cyberspace (the MI system) and verified in physical space (trial manufacturing
and testing). A reduction in development time and costs will also be verified.
Technologies tailored to the target materials and processes will be developed based on
the techniques relevant to calculation modules, workflows, and data science approaches
developed with inverse design MI. Advanced structural materials and processes forpractical use were selected as application targets because they are anticipated to be
conducive to the application of inverse design MI, be in line with Japan’s strengths, andhave high global demand. Specific examples are powder metallurgy processes centeredon additive manufacturing.
In light of the purpose of SIP, the effectiveness of inverse design MI in the developmentof materials and processes must be demonstrated according to a roadmap for practicalapplication and commercialization developed by the participating raw material and heavy
industry manufacturers. The primary outcomes of this R&D will be used in the aircraft
industry because materials used in aircraft are subjected to the harshest conditions and,
consequently, require the highest reliability. Naturally, these results will have a major
ripple effect in the environment and energy industries, for example.
R&D for the five teams in this domain is described below. All R&D will be carried out incollaboration with relevant sub-teams under team (A2) (see Fig. 10). The calculation
modules and databases developed in this domain will be collected in the inverse design
MI system in a manner that will not impede commercialization, and will be utilized to
improve Japan’s overall competitiveness in materials development.

43

Figure 10 Domain C: research organization for 3D Powder Processing(private companies are in red)(C-1)

Development of Additive Manufacturing Process for Ni-based Alloys

Co-leaders:
Kenichiroh Igashira (Kawasaki Heavy Industries, Ltd.)
Takayoshi Nakano (Osaka University)
Participating organizations: Kawasaki Heavy Industries, Ltd., Osaka University, and the
National Institute for Materials Science
AM process technology offers advanced processes for manufacturing parts with threedimensional, complex, and intricate designs that can not be manufactured withconventional methods. AM processes are expected not only to revolutionize design, butalso to have many effective uses owing to the unique properties it imparts to materials.
However, a precise means for exploring materials and processes suited to AM processes
has not been established. Further, there has been increasing demand to reduce greenhousegas emissions in order to realize Society 5.0, and studies are being conducted on
expanding the variety of fuels that can be used in power plants, and particularly in gas
turbines for power generation. For example, when using hydrogen gas as fuel, thecombustion burner must be formed of a nickel-based heat-resistant alloy capable ofsupporting the high burning rate and high combustion temperatures inherent in hydrogengas. There will also be increasing need for more complex designs and more durable
materials.

44

An AM process using Ni-based alloy powder is the best technology for meeting theseneeds. Establishing MI technology for guiding the exploration of materials and processes
may become a source of Japan’s competitiveness.
In view of this situation, a consistent prediction technology developed with the MI
system as a common technology will be utilized in this development in order to establish
a technology for predicting the material properties of Ni-based heat-resistant alloys
molded in AM processes. An inverse design analysis technology developed with the MI
system will be utilized with the aim of establishing a technology based on theseprediction technologies for designing suitable alloys and process conditions that satisfy
the required performance of the parts.
Additionally, a new technology for predicting nonequilibrium phase diagrams
corresponding to the rapid solidification in AM processes will be developed while
utilizing Japan’s background in Ni-based heat-resistant alloys. With this prediction
technology, we will establish an MI technology for nonequilibrium alloy designs specificto AM processes that will be utilized in this study to propose alloys and determine
processes. After the SIP project has ended, this MI technology may be the one thatdifferentiates Japan from other countries in the field.
These MI prediction technologies in cyberspace will be put to use in physical space toselect materials and to develop manufacturing processes. Universities and other institutes
will be responsible for linking cyber to physical and will act as an intermediary withcompanies for parts production. We will install AM processing equipment at participatingcompanies and select materials that match the requirements for combustion burner parts.
We will also focus on establishing processes for manufacturing the parts and techniques
for evaluating components. Demonstrating an improved performance in combustion
burners will be an end goal of this development.
Intermediate Goals (for the end of fiscal 2020)
Overall goal and target TRL for R&D
Mount combustion burner formed by AM for actual combustion tests
Achieve TRL 4
Targets of individual research items(a) Demonstrate fabrication of new Ni-based alloys utilizing MI
Collect experimental data with existing Ni-based alloys for implementing the MI
system (physical space)
Confirm consistency between forward analysis simulation data and the above
experimental data for existing Ni-based alloys (link between cyberspace and physicalspace)(b) Verify improved durability of combustion burner
Establish a manufacturing technology for combustion burners formed through AM
using commercially available material (or refined versions thereof)

45

Establish a technology for evaluating material properties suited to AM materials
End Goals (for the end of fiscal 2022)
Overall goal and target TRL for R&D
Successfully conduct continuous burning of four hours or longer in combustion tests
performed in an actual pressurized environment using a combustion burner
manufactured by AM
Achieve TRL 5
Targets of individual research items(a) Demonstrate fabrication of new Ni-based alloys utilizing MI
Collect experimental data for new Ni-based alloys (physical space)
Confirm consistency between forward analysis simulation data and the above
experimental data for the new Ni-based alloys (link between cyberspace and physicalspace)
Demonstrate manufacturing of new Ni-based alloys with required mechanicalproperties for AM material(b) Verify improved durability of combustion burner
Establish a manufacturing technology for combustion burners formed through AM
using the new Ni-based alloys
Confirm improved durability of the new Ni-based alloys using a technique for
evaluating materials manufactured by AM(C-2) Development of Ni-based Powder Metallurgy Processing for High Performance
Aircraft Engine Disk
Co-leaders:Shinya Imano (Mitsubishi Hitachi Power Systems, Ltd.)
Toshio Osada (the National Institute for Materials Science)
Participating organizations: Mitsubishi Hitachi Power Systems, Ltd., the National
Institute for Materials Science, Honda R&D Co., Ltd., Mitsubishi Heavy Industries AeroEngines, Ltd., Hokkaido University, and Tohoku University
Disk materials used in commercial aircraft engines have been forged of high-strength
nickel-based alloys, such as Inconel 718 (IN718) and Waspaloy. Both alloys haveexcellent strength at elevated temperatures and good manufacturability and reliability.
However, in order to handle the rising combustion temperatures, powder-processed Nibased alloys used as disk materials (hereinafter called “PM disk superalloys”) are being
adopted for high-pressure turbine disks whose operating environment is particularly
severe, and applications for these superalloys are expected to continue to expand. A highquality powder manufactured under high vacuum and inert gas is subjected to sintering
under pressure or superplastic forming at high temperatures to form the PM disk
superalloy into a disk shape. Members sintered using Ni-based alloy powder are also used46

in molds and other components. PM disk superalloys possessing excellent strength athigh temperatures have become more and more indispensable in recent years for highperformance aircraft engines. However, since production requires special advanced
technologies, their manufacturing costs are prohibitive outside of a limited number ofmanufacturers in Europe and America. This research is aimed at developing purely
domestic low-cost processes surpassing those being used in Europe and America. These
processes will be applied to actual aircraft parts by improving and integrating Japan’s
latent strengths in powder manufacturing technology and forging technology for highstrength Ni-based alloys.
The main processes required for producing PM disk superalloys are powder
manufacturing, billeting forming, and near-net-shape forging. In this study, MI will beutilized to develop low-cost processes using existing facilities in Japan. In addition to
reducing process costs, a study will be conducted on further lowering costs by using
byproduct powders generated in the powder manufacturing process for molds andstationary components of aircraft engines and industrial gas turbines. The aim of thisstudy is to reduce manufacturing costs to at least two-thirds the current costs, while
ensuring performance is at least equal to conventional process materials.
The first three years of the study (2018–2020) will be dedicated to establishing anddemonstrating technologies with simulated members through implementation items (i)–(vii) provided below. Target materials are domestically produced materials that are
utilized in the latest engines for mid-size commercial aircraft. Additionally, PM disk
superalloys in engines for military aircraft and castings/forgings commensurate to PM
disk superalloys will be trial manufactured and evaluated as needed for comparison. In
the latter two years of this research, manufacturing and evaluation aimed atcommercialization will be conducted on parts formed for use on actual aircraft according
to items (viii)–(xii) provided below.
Implementation items(i) Establish powder manufacturing/classification technology, (ii) establish canning and
HIP technologies, (iii) establish billet forging technology, (iv) establish near-net-shapeforming technology, (v) research and examine evaluation techniques, (vi) establish
techniques for developing and repairing mold materials, (vii) trial manufacture andevaluate simulated materials for actual aircraft, (viii) trial manufacture high-pressure
disks for mid-size commercial aircraft, (ix) begin collecting data on acquiringcertification to advance MI, (x) trial manufacture of high-pressure disks for small aircraft,(xi) begin collecting data on acquiring certification to advance MI, and (xii) study
applications for next-generation commercial aircraft
In this study, physical aspects will be compiled by private companies possessing basic
technologies of the relevant processing, while cyber aspects will be compiled byuniversities or national research institutes with a track record in studying MI technology.
Many manufacturers of aircraft engines will participate in establishing development goals
and evaluating development technologies for the physical side.
While this study will target a wide range of manufacturing processes, a new target will be
the development of MI technology for the efficient elimination of prior particle

47

boundaries, which are a major problem in powder processing. Here, a technology forpredicting microstructural changes during high-temperature deformation in the formingof billets will be key. As before, the early stage of this study will involve the explorationof conditions for forming billets based on experimentation, and MI technology will beestablished based on the data obtained through this exploration. In the latter half of thestudy, the MI technology established early on will be utilized to further optimize
conditions of billet formation by introducing inverse analysis techniques developed with
the MI system. An MI technology for a billet-forming process that supports inverse
problems will be established for use in post-SIP development. A common MI technology
developed for the MI system will be actively applied to other methods with the aim ofestablishing efficient development processes. Specifically, outcomes of development with
the MI system will be utilized in powder sintering processes and near-net-shape forging,
and workflows will be developed to link multiple development processes. Moreover, a
study will be conducted on reducing development time with MI.
Intermediate Goals (for the end of fiscal 2020)
The trial manufacture of simulated components for mid-size commercial aircraft engines
will be completed using PM disk superalloys produced domestically and produced
overseas. The goal is to obtain properties in a fracture study on simulated parts formed ofdomestically produced PM disk superalloys that meet or exceed the target mechanicalproperties set by manufacturers of aircraft engines.
The target for mechanical properties is set to 95% that of process materials in Europe
and America.
TRL 4 is the target for raw materials.
Data related to manufacturing processes for PM forged disks is provided to the MIside as needed, and intermediate results from the MI-side are reflected in the
manufacturing process for the purpose of optimization.
End Goals (for the end of fiscal 2022)
Trial manufacturing of parts for small aircraft engines using domestically produced PM
disk superalloys will be completed. Once a fracture study on prototypes formed fromdomestically produced PM disk superalloys indicates that the target mechanicalproperties and costs set forth by aircraft engine manufacturers have been attained, we will
begin considering applications for domestic materials formed with domestic processes in
next-generation aircraft engines. Trial manufacturing of parts simulating high-pressure
turbine disks for mid-size commercial aircraft produced overseas will be completed using
processes developed domestically.
The target for mechanical properties of PM disk superalloys produced domestically is
at least 95% that of European and American process materials, and the target cost is
no more than 66% of processing costs in Europe and America.
TRL 5 is the target for raw materials.
Relevant data in the fracture study will be shared with the MI system, and theconsistency of predictions by tools developed with the MI system will be studied. The
data from this study will be utilized to improve the precision of the prediction tools.

48

(C-3) Development of Powder Additive Manufacturing Process for Titanium Alloys
Co-leaders:Satoshi Takahashi (IHI Corporation)
Naoyuki Nomura (Tohoku University)
Participating organizations: IHI Corporation, Tohoku University, Osaka Titanium
Technologies Co., Ltd., and JAMPT Corporation
Below is a description of the R&D content that will be implemented with the assistanceof MI. In this R&D, metal powder manufacturers, mold manufacturers, heavy industry
manufacturers, and universities will collaborate to research and develop techniques forthe manufacture of metal powders, additive manufacturing (AM), and the evaluation ofcomponent performance. To enable integrated production domestically, a system will beestablished for manufacturing AM parts from titanium alloy components with which
Japan has been competitive globally. Our goal is that this system will help build a supply
chain for the purpose of supplying aircraft components and medical materials, forexample.
(i) Development of an economical technology for manufacturing Ti powder
In order to reduce processing costs for manufacturing materials, we aim to reduce thecost of feedstocks, which are the leading cause of increased costs in manufacturing
processes for titanium alloy powders. In this research, new processes will be introduced
at the feedstock production stage. We will study how to optimize the process and develop
a manufacturing process for titanium alloy powders.
(ii) Development of AM processes
New powders may have different properties from existing high-cost powders. Therefore,
we must conduct a study for creating a fabrication process suited to their properties in the
AM process and, by reflecting the findings back to the new powders, establish acompetitive AM process for titanium alloys.
(iii) Establishment of an evaluation method and guidelines for powders used in AM
Since newly developed powders have different properties from current expensive
powders, their use in powder bed AM processes may yield differences in recoating
behavior and conditions of the powder bed, which can affect properties of the fabricatedarticle. In this research, we will study recoating behavior through experiments andsimulations in order to identify what factors affect conditions of the powder bed and tolearn what properties are required for the new powders, leading to more efficientdevelopment.
(iv) Property evaluation and application demonstration of parts manufactured by AM
AM parts differ greatly from those produced in current manufacturing methods (castingor forging) in their surface roughness, material properties, and product shape, forexample. Thus, in order to adopt AM parts in actual aircraft, we must learn thesediffering characteristics and reflect them in their design. In this study, the mechanical49

properties of AM components will be evaluated to obtain a simple database. We will also
conduct microstructure observations and evaluate associations among characteristics of
Ti powders, fabricating conditions, and microstructures of the metal.
Development in item (i) will be coordinated with an MI technology for new powder
design to accelerate property evaluation of lower-cost powders and to reflect thoseevaluations in the AM process.
In this study, powder manufacturing, evaluation of powder properties, evaluation of
spreading ability, and evaluations of the properties of parts manufactured by AM will be
conducted in collaboration with organizations in the domestic supply chain for AM
processes with the aim of improving Japan’s competitiveness in a coherent AM processfrom the upstream sector to the downstream sector. Establishing a recoating simulation
technique (MI technology) for the AM process in particular will lead to methods andguidelines for evaluating the Ti alloy powder used in AM and will enable uniform
evaluations of the powder and the entire AM process.
Intermediate Goals (for the end of fiscal 2020)
We will conceptualize an economical fabrication process for Ti alloy powders, set up
facilities, and begin trial manufacturing and provision of powders to the facilities(TRL 2).
Fabrication conditions will be established to enable the manufacture of simulated parts
having shapes proposed by IHI, using conventionally produced Ti alloy powders, andactual components will be fabricated (TRL 2).
The properties of current and economical powders will be evaluated.
Properties required for economical powders will be identified.
Data on the properties of components fabricated with conventional Ti alloy powders
will be acquired, evaluated, and organized.
End Goals (for the end of fiscal 2022)
Manufacturing processes for economical Ti alloy powders will be demonstrated withthe goal of reducing feedstock costs by 20% (TRL 2).
Material and fabrication recipes will be formulated for economical Ti alloy powders
and actual components will be manufactured (TRL 3).
Design guidelines will be formulated for economical powders (TRL 3).
Properties of components fabricated using both conventionally produced Ti alloy
powders and economically produced Ti alloy powders will be evaluated, and theresults will be compiled in a database (TRL 2).

(C-4) Development of Powder Manufacturing Process and Basic Technologies for High
Performance TiAl-based Alloy Turbine BladesCo-leaders:
Masao Takeyama (Tokyo Institute of Technology)
Akira Fukushima (Mitsubishi Heavy Industries Aero Engines, Ltd.)

50

Participating organizations: Tokyo Institute of Technology, Mitsubishi Heavy Industries
Aero Engines, Ltd., Kobe Steel, Ltd., Osaka Yakin Kogyo Co., Ltd., and Osaka
University
Titanium aluminide (TiAl alloy) is an intermetallic chemical compound having excellent
specific strength and heat-resistance and shows promise for use as a material in lowpressure turbine (LPT) blades in aircraft engines. TiAl has reached the implementation
stage in the GEnx engine of the Boeing 787 and the PW1100G engine of the Airbus
A320neo. These engine parts are manufactured by machining castings or forgings, but the
low yield and the inclusion of the machining process is viewed as problematic factors that
increase costs of blade parts.
In the meantime, metal injection molding (MIM) has attracted attention as a low-cost
manufacturing method for the mass production of small metal parts. A feature of MIM is
its ability to manufacture net-shape parts. Thus, use of this technique to manufacture
blade parts could reduce manufacturing costs by eliminating the machining step for theblade surface.
Hence, the MIM technique has been considered a candidate for producing low-costtitanium aluminide blades. However, TiAl is inherently a brittle material and, thus,
overcoming it’s low fracture toughness will be a challenge. There is also a concern thatthe fracture toughness of this material may drop even further due to the increasing
inclusion of oxygen and other components during the MIM process. To overcome thesechallenges and concerns, we must determine the chemical and phase compositions andthe morphologies of materials capable of achieving high fracture toughness despite thepresence of oxygen and other components. We must then set manufacturing parameters
for producing high-grade, low-cost TiAl ingots for the MIM process and for reducing
contamination from oxygen and other components that occurs during this process.
Unlike conventional materials development centered on experimental techniques, thisR&D will address the above challenges utilizing MI technology to simulate alloy design
and performance predictions with the aim of optimizing process parameters.
Actual LPT blades are large members exceeding 200 mm in length. Consequently, theseblades are difficult to manufacture with conventional MIM technology. One issue in the
MIM process is the control of deformation in such large structures. To resolve this issue,
MI technology will be utilized to establish a process incorporating injection and sintering
simulations.
The aim of materials development for TiAl is to search for material compositions having
excellent heat-resisting properties aimed at improving the performance and heatresistance of the engine. In powder-based MIM, the composition can be freely designed
without the restrictions inherent in casting and forging. Taking advantage of thisknowledge, we will utilize MI technology to design a TiAl alloy for MIM having
excellent properties at high temperatures.
Utilization of MI technology
The following are five challenges in this R&D that will be resolved using MI.

51

(i) Determine the chemical/phase compositions and the morphology of a material
for MIM that will improve toughness(ii) Develop a manufacturing technology for high-grade, low-cost TiAl ingots to be
used in MIM(iii) Optimize the MIM process to improve toughness(iv) Control deformation of large structures in MIM(v) Determine chemical/phase compositions and morphology of materials to be usedin MIM for improving properties at high temperatures
Here, alloy design and performance prediction technologies will be applied to overcome
challenges (i) and (v). AI-assisted data science techniques will be used to optimize
processes in (ii) and (iii). Various simulation techniques will be used to control
deformation in (iv). Knowledge from universities that are global leaders in technologicalfields specific to TiAl alloys will be further advanced and utilized to accelerate
development in alloy design and performance prediction.
The data science-based inverse analysis technology developed as a common technology
with the MI system will be utilized for the MIM process in an attempt to optimize theprocess. We will also promote technology transfer so that MIM manufacturers
themselves can master this technology. Additionally, a technique for optimizing thesintering process will be established for controlling deformation in MIM utilizing MI
technology for powder sintering developed with the MI system, and this technology will
be utilized to develop actual components.
Intermediate Goals (for the end of fiscal 2020)(i) MIM: An alloy for use in powder processes aimed at achieving sufficient fracture
toughness and tensile strength for application to turbine blades will be designed
using the MI system (a prototype) and verified (TRL 3).
(ii) Electron-beam AM: A process map will be created using the MI system to link
fabrication conditions with microstructures and mechanical properties (TRL 3).
End Goals (for the end of fiscal 2022)(i) MIM: A process for manufacturing large blades meeting an airfoil profile that canachieve near-net shape will be designed based on the MI system, and strength
feasibility of an actual blade will be confirmed using a blade prototype (TRL 4–5).
(ii) Electron-beam AM: An AM process will be optimized using the MI system and a
prototype turbine blade will be manufactured (TRL 4).

(C-5) Realistic Simulation of Ceramic Matrix Composites Targeted for High
Temperature Components in Jet Engines
Co-leaders:
Yutaka Kagawa (Tokyo University of Technology)
Naohiro Shichijo (Tokyo University of Technology)
Takahiro Sekigawa (Mitsubishi Heavy Industries Aero Engines, Ltd.)52

Participating organizations: Tokyo University of Technology, Mitsubishi Heavy
Industries Aero Engines, Ltd., IHI Corporation, Kawasaki Heavy Industries, Ltd., theUniversity of Tokyo, and the Japan Aerospace Exploration Agency
Ceramic matrix composites (CMCs) are lightweight materials with excellent heatresistance. CMCs are expected to replace current high-temperature structural materials(superalloys) in the near future for use as aircraft engine components. One type of CMC
formed of continuous SiC fibers embedded in an SiC matrix (also known as SiC/SiC) has
become the subject of active R&D worldwide owing to its particularly excellent
properties.
The most important issue with regard to commercializing CMCs as aircraft engine
components is to guarantee their performance and safety for long-term use at hightemperatures. In recent years, simulation techniques have been used frequently inmaterials development, and their use is anticipated in the development of CMC
components for aircraft engines. However, current simulation techniques are inadequate
because CMCs have a far more complex composite structure than those of monolithic
ceramics and metal materials, and their deformation and fracture phenomena is governedby factors too numerous to count. Yet, if the materials can be tested in cyberspace using
MI, the ability to test components being designed using inverse problems would greatly
strengthen Japan’s international competitiveness.
In this study we will develop modules as a foundation for using MI in the development of
CMC components. A virtual test environment will be created so that these modules canbe linked in cyberspace to predict the behavior of CMCs in their operating environment,
and will drive the development of CMCs as aircraft engine components. Our ultimate aim
is to use virtual tests to design optimal members and to develop techniques for inspecting
CMCs.
The following are four specific subjects that will be targeted in this R&D.
(i) Basic technologies and an integrated platform
R&D will be conducted on core technologies required for solving specific issues in thedevelopment of CMC components. Specific core technologies will include thevisualization and recognition of CMC microstructures through machine learning,
prediction of CMC properties, high-temperature testing for CMCs, and reliability
assurance.
(ii) Processing conditions for ensuring performance of CMC components
A simulation system will be developed to assist in setting conditions for manufacturing
processes used to fabricate CMCs.
(iii) Evaluation of risk and defect distribution for ensuring CMC performance
A technique will be developed for recognizing and evaluating defect distribution during
the manufacturing of CMCs.
(iv) Degradation prediction and risk evaluation for ensuring CMC performance53

A model will be constructed for predicting performance degradation under conditions
simulating the CMC operating environment, and a method will be developed forevaluating risk in the deployment of CMC components.
Intermediate Goals (for the end of fiscal 2020)(i) Basic technologies and an integrated platform
Technologies for recognition and visualization of CMC microstructures, acquisition of
CMC properties, high-temperature testing of CMCs, and accelerated testing of CMCs
will be provided for use in R&D on subjects (ii)–(iv).
(ii) Processing conditions for ensuring performance of CMC components
Multiphysics simulations will be implemented for CMC matrix manufacturing processes
using the reactive melt infiltration (RMI) method based on an understanding of basic
processes used to manufacture a CMC matrix using the RMI method.
(iii) Extraction of risk and defect distribution for ensuring CMC performance
The automatic recognition of microstructures in CMC materials based on structural data
for such materials acquired with X-ray computed tomography will be achieved using
machine learning.
(iv) Prediction of performance degradation and determination of risk in CMC
components
A model will be constructed to predict degradation of mechanical properties for CMC
materials under high temperatures, and the model will be evaluated through materials
testing under similar conditions.
End Goals (for the end of fiscal 2022)(i) Basic technologies and an integrated platform
The outcomes in research subjects (ii)–(iv) will be integrated to ensure safety in thedesigns of CMC components.
(ii) Processing conditions for ensuring performance of CMC components
Simulations of CMC matrix manufacturing processes using the RMI method will bemade feasible for preforms having expected shapes of actual components.
(iii) Extraction of risk and defect distribution for ensuring CMC performance
Structural data will be acquired for CMCs during manufacturing and after mechanicalload is applied from X-ray computed tomography, and the distribution of defects that canaffect defect expansion will be automatically recognized based on structural changes
identified through machine learning.
(iv) Prediction of performance degradation and determination of risk in CMC
components
A model will be constructed for predicting the lifetime of CMC materials under hightemperatures and mechanical load and will be made applicable to materials with realistic
shapes.

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3. Implementation structure(1) Program Director, Deputy Program Director, and management agency
PD Yoshinao Mishima will be in charge of establishing and promoting the R&D plan,
while Deputy PD Tetsuo Mohri will assist the PD. A promotion committee composed ofrelated ministries and agencies and specialists will perform general coordination, with the
PD serving as chair and the Cabinet Office as secretariat. This research subject will be
carried out through funding provided by the Japan Science and Technology Agency (JST).
JST will serve as the management agency in assisting the PD, Deputy PD, and promotion
committee. In conformance with the R&D plan, JST will hold an open recruitment for
Principal Researchers, execute contracts, manage funding, oversee R&D progress,
implement self-inspections from a technical perspective using peer reviews, report theresults of these self-inspections to the PD, etc., and conduct related studies and analyses.
(2) Selection of Principal Researchers
Based on the R&D plan, JST will conduct a call for proposals and recruitment to selectresearch topics and the Principal Researchers that will implement these research topics.
However, such selections need not be made publicly if there are sufficient grounds not to
do so and if those reasons are specifically stated in the R&D plan.
JST will, in consultation with the PD, the Cabinet Office, and the promotion committee,
determine the method of screening selections, such as screening criteria and judges. In
principle, the PD, officers from the Cabinet Office, and outside experts will participate in
the screening. key project personnel of researchers who have submitted a research
proposal will not participate in the screening of that research topic. A definition of“stakeholders” will be clearly specified in the application guidelines established by JST.
Once the research topics have been determined through selection, the topics along with
their research entities and participants will be specified in this plan.
(3) Measures to optimize the research system
Companies corresponding to Tier 1 or Tier 2 suppliers of the aircraft industry andcompanies that supply raw materials directly to original equipment manufacturers(OEMs) will participate in teams established under this subject “Materials Integration”
for Revolutionary Design System of Structural Materials, with teams configuring a
vertical integration system that outputs materials for aircraft. With this system, an inverse
design MI system will be developed in Domain A while being applied to advanced
structural materials and processes in Domains B and C in order to accelerate the use andapplication of MI in companies (social implementation of MI). This will be accomplishedby collecting data on cutting-edge materials for aircraft components and utilizing thisdata in inverse design MI to develop materials and processes that meet the required
performance for social implementation, thereby achieving a vertical integration system
driven by inverse design MI.

55

Note: Tier 1 denotes manufacturers that supply parts directly to companies manufacturing
finished aircraft or aircraft engines, while Tier 2 denotes manufacturers that supply parts
to Tier 1 companies.
The Cabinet Office will have flexibility to make changes to the research structure or takeother measures deemed necessary by the PD, depending on the progress of the research
topics, research results of technical surveys conducted by related organizations, andchanges in social circumstances. Specific considerations will include changing or adding
research topics and replacing or adding Principal Researchers. In order to promote more
spirited personnel exchange and facility sharing, as well as the development of humanresources and sustained research, R&D centers will be established to allow forcollaboration among universities, national research and development agencies, andcompanies.
The Deputy PD will assist the PD in exit strategies and intellectual property strategies,
expertise on materials science, and cross-ministerial and industry-academia-government
collaboration. The Deputy PD will also be in charge of specific R&D items and domains
and will assist the PD in implementing R&D in these domains.
Co-leaders established in each R&D domain will be selected from both industry andacademia, and coordination within and among domains will be achieved through close
cooperation between industry and academia. Activities of the domains will be conveyed
through symposiums and other events. JST will support the activities of co-directors andwill build a network among the participating organizations.
(4) Coordination with government ministries and agencies
Coordination among government ministries and agencies is essential for establishing adata infrastructure to support inverse design MI and for its expansion to wide-ranging
materials. With SIP leading the way, MEXT is responsible for developing the materials
data infrastructure and METI for expanding the outcome areas through the promotion
committee and conferences for promoting the projects. All of these efforts will lead to theimplementation of an integrated materials development system for supporting Society 5.0.
(5) Commitment from industry
This project anticipates contributions (both human and material) from industry.
Contributions in materials development for (B) Application of inverse design MI to
actual structural materials (see the Appendix) is expected to account for 20% of the total
R&D expenses (including contributions from the national government and industry) for
the first through third years of the project, and approximately 30% the total for the fourthand final years. Further, the matching funds will be reviewed in accordance with the
Cabinet Office’s matching funds system for SIP.

56

4. Matters related to intellectual properties(1) Intellectual property committee and subcommittees○ An intellectual property committee will be established in the management agency,
while an intellectual property subcommittee will be set up at the organization(trustee) to which the Principal Researcher belongs for each research subject or joint
research item constituting the subject.
○ Intellectual property subcommittees will determine policies for the publication of
papers and the application and maintenance of patents (hereinafter called “IP rights”)
concerning the outcomes of research and development undertaken by theorganization at which the relevant subcommittee was established, and will makeadjustments pertaining to the licensing of IP rights as needed. Intellectual property
subcommittees will submit reports concerning such paper publications and IP rights
to the intellectual property committee.
○ The intellectual property committee will in principle be composed of the PD or an
agent of the PD, key project personnel, and experts. The intellectual property
subcommittees will comprise members of the participating organizations of therelevant research subjects.
○ Details of operating methods for the intellectual property committee andsubcommittees will be determined by the management agency or the organizations
establishing intellectual property subcommittee.
(2) Arrangement concerning IP rights○ he management agency will determine in advance through an agreement with thetrustee the handling of confidentiality, background IP rights (IP rights that Principal
Researchers and the organizations to which they belong had possessed prior toparticipating in the program, or that they obtain without the use of SIP operating
expenses after participating in the program), and foreground IP rights (IP rights
generated through the use of SIP operating expenses during the program).
(3) Licensing of background IP rights○ The IP rights holder can grant a license for a background IP right to another program
participant under terms and conditions determined by the rights holder (or “inaccordance with the agreement with the program participant”).
○ For cases in which measures taken by the IP rights holder, including said terms andconditions, may interfere with the promotion of SIP (including not only the researchand development, but also practical use and commercialization of the outcomes), theintellectual property committee will make adjustments to obtain reasonable solutions.
(4) Handling of foreground IP rights○ In principle, the provision of Article 17, Paragraph 1 of the Industrial Technology
Enhancement Act will apply to foreground IP rights, which will be vested in theorganization (trustee) to which the Principal Researcher who is the inventor belongs.

57

○ In the event of an invention made by a subcontractor, etc., IP rights may be vested in
the subcontractor, etc., only with the approval of the intellectual property committee.
In such cases, the intellectual property committee may attach conditions to theapproval.
○ If the rights holder of an IP right has little intention of pursuing commercialization,
the intellectual property committee may recommend that an individual who is morecommitted to commercialization be given possession of the IP right or granted
license for the IP right.
○ For any individual withdrawing from the project during the participation period, themanagement agency, etc., will require that the individual assign free of charge, or
grant a license for, all or part of the outcomes obtained with the use of SIP operating
expenses during that individual’s participation period (or all of the outcomes sincethat individual initially participated in the project, in the event of participation overmultiple years) at the time of withdrawal.
○ In principle, the rights holder will be responsible for the costs of application andmaintenance of the IP rights. In the case of joint application, the percentages ofownership and cost burden will be determined through discussions between the joint
applicants.
(5) Licensing of foreground IP rights○ The rights holder can grant a license for a foreground IP right to another program
participant under terms and conditions determined by the rights holder (or “inaccordance with the agreement with the program participant”).
○ The rights holder can grant a license for a foreground IP right to a third party underterms and conditions determined by the rights holder, provided that such terms andconditions are not more advantageous than those for other program participants.
○ For cases in which measures taken by an IP rights holder, including said terms andconditions, may interfere with the promotion of SIP (including not only the researchand development, but also practical use and commercialization of the outcomes), theintellectual property committee will make adjustments to obtain reasonable solutions.
(6) Approval for transfer of, and establishment and transfer of an exclusive license for,foreground IP rights○ Under the provision of Article 17, Paragraph 1, Item 4 of the Industrial Technology
Enhancement Act, any transfer of, or any establishment and transfer of an exclusive
license for, foreground IP rights will require the approval of the management agency,
except in cases of transfer due to a corporate merger or division, and cases of transferof, or establishment and transfer of an exclusive license for, IP rights to a subsidiaryor parent company (hereinafter collectively referred to as “cases of IP rights transfer,etc., due to mergers, etc.”).
○ Cases of IP rights transfer, etc., due to mergers, etc., will require the approval of the
management agency, etc., under contract with the management agency, etc.
○ Even after IP rights transfer, etc., due to mergers, etc., the management agency, etc.,
may be able to possess a license for the IP rights, including the right for sublicensing. Unless this condition is accepted, the transfer will not be permitted.

58

(7) Handling of IP rights at the time of termination○ With regard to IP rights, etc., that no one wishes to possess when the research anddevelopment is terminated, the intellectual property committee will discuss a courseof action (abandonment or succession by the management agency, etc.).
(8) Participation by overseas organizations, etc. (such as foreign companies, universities,
and researchers)○ Participation by an overseas organization, etc., will be permitted when suchparticipation is necessary for carrying out a research task.
○ From the perspective of appropriate executive management, only an overseasorganization, etc., with a point of contact or an agent in Japan capable of processing
paperwork related to acceptance of the research and development will in principle bepermitted to participate in the project.
○ In the case of participation by an overseas organization, etc., IP rights will be sharedby the management agency, etc., and the overseas organization, etc.
5. Matters related to assessment(1) Assessing entities
The Governing Board will invite external experts to perform assessments whilereferencing reports of self-inspections conducted by the PD and JST based on national
and international peer reviews. The Governing Board may hold assessments individuallyby research area or subject. Note that particular care must be taken when receiving
external assessments to avoid any disclosure of information.
(2) Timing of assessments○ Assessments will include preliminary assessments, end-of-year assessments, andfinal assessments.
○ Once a fixed period (three years, in principle) has elapsed after termination of the
program, tracking assessments may be performed, as needed.
○ In addition to the above, assessments may be performed in the middle of a fiscal year,
if necessary.
(3) Assessment items and criteria
Based on the “General Guideline for the Evaluation of Government Research andDevelopment (R&D) Activities” (established by the Prime Minister on December 21,2016), assessment items and criteria are given below from the perspective of assessing
necessity, efficiency, and effectiveness. Assessments are performed not merely todetermine whether the goals have been attained, but will also include an analysis of thecauses and factors of such attainment or nonattainment and a proposal of measures for
improvement.
(i) Significance and consistency with the organizational objectives of SIP.

59

(ii) Appropriateness of the goals (particularly the technology outcomes) and degree ofprogress made in the schedule toward attaining the goals.
(iii) Whether or not proper management is being made; particularly, how effective
collaboration is being demonstrated among government ministries and agencies.
(iv) Strategic relevance, and degree of achievement, toward practical use andcommercialization.
(v) Expected effects or ripple effects in the final assessment. Whether or not postprogram methods for follow-up have been specified clearly and adequately.
(vi) Status of meeting the requirements listed in the attachment.
(vii)Status of achieving TRLs in each research topic.
(4) Methods of reflecting assessment outcomes○ Preliminary assessments in connection with the R&D plan will be conductedannually and reflected in the plan beginning from the fiscal year following thecommencement of research.
○ Each end-of-year assessment will involve refining or adding to the research subject
and research topics as needed.
○ Final assessments will be performed in connection with actual outcomes up to thefinal fiscal year, and will be reflected in the post-program follow-up.
○ Tracking assessments will be performed in connection with the progress of practicaluse and commercialization of the outcomes of each task, and measures for
improvement will be proposed.
(5) Disclosure of outcomes○ In principle, assessment outcomes will be made available to the public.
○ The Governing Board that performs assessments will be held privately since theassessments may involve undisclosed research and development information.
(6) Self-inspections(i)

Self-inspection by Principal Researchers

The PD will select Principal Researchers to perform self-inspections. (In principle, theprimary researchers or research institutes of each research item will be selected.) The
selected Principal Researchers will conduct self-inspections on the progress of R&D andefforts toward practical use and commercialization.
(ii)

Self-inspection by the PD

While referencing the results of self-inspections by the Principal Researchers and, whennecessary, the opinions of third parties and peer reviews by national and international
experts, the PD will personally inspect the actual results of the PD, JST, and eachPrincipal Researcher and the future plan in accordance with the assessment items andcriteria provided in 5(3). The PD will summarize not only determinations of whether
goals were attained, but also an analysis of the cause and factors of such attainment or
nonattainment and measures for improvement. Based on the results of the inspection, thePD will determine whether each research entity should continue their research, and60

provide necessary advice to the Principal Researchers. In this way, the research structure
can be improved autonomously. Particular care must be taken when receiving external
assessments to avoid any disclosure of information. On the basis of these results, the PD
will prepare materials for the Governing Board with the support of JST.
(iii)

Self-inspection by the management agency

Self-inspections by JST will be conducted to determine whether paperwork procedures
related to budget execution have been performed properly.
6. Exit Strategies
This research subject has two major aims for social implementation.
(1) Use of MI systems in corporate R&D (Domain A)(2) Practical application and commercialization of materials developed with MI systems(Domains B and C)
To achieve these goals, R&D will be conducted with the following strategies.
(1) Use of MI systems in corporate R&D○ The starting point of the inverse problem is set to numerical values of a target
performance required by participating companies, i.e., potential users, and theeffectiveness of the MI system is confirmed through solutions in cyberspace anddemonstrations in physical space. Here, indices for evaluating the obtained solutions
objectively are set to define success or failure.
○ We will develop a distributed computation and control technology for seamlessly
linking a system operated by a centrally located MI center with calculations in a local
corporate environment over the Internet. Ensuring information security is one of themost important issues. By using distributed computations and control, calculations
with classified data can be performed in-house, enabling the use and application ofcompany-held data. In order to promote such use, a standard data description format
will be designed and widely shared (even if the actual data cannot be). These efforts
are hoped to encourage the use and application of data that lies dormant incompanies.
○ In order to promote the use of MI at companies, the establishment of consortiums
and venture businesses will be studied and implemented. (Since venture businesses
may take on overseas institutes as clients, sufficient care must be made to ensure thebusinesses are consistent with improving Japan’s international competitiveness.) MI
centers will serve as the core of these operations. In addition to the activities
described above, the centers will work to popularize MI through development of
human resources, and publicity and outreach activities.
(2) Practical application and commercialization of materials developed with MI systems○ Cutting-edge materials and processes for aircraft fuselages and engines and industrial
power plants are envisioned as applications for MI, and practical applications and61

commercial products for research achievements will be found through collaboration
with material and heavy industry manufacturers.
○ While only disclosed in the non-public edition, Table 1 shows the end goals set byeach participating company. If these goals are achieved, the target TRL is also
expected to be attained, enabling a smooth transition to the stage of development anddemonstration aimed at practical use and commercialization following theconclusion of SIP.
○ For aircraft, the close relationship between participating Tier 1 and Tier 2 companies
and OEMs will be utilized to formulate methods of standardization, planning, andevaluation, as well as their accreditation, and to acquire certification. For industrial
power plants, the participating companies are OEMs themselves. Thus, theirtechnologies can be applied to actual aircraft, provided they meet their own
companies’ standards. While our long-term goal is to commercialize private aircrafton the global market, we will work to promote applications for our own products at
an earlier stage as a form of social implementation.
7. Other important matters(1) Legal basis
This project will be implemented in accordance with “3. Basic policy concerning theexpense for creation and maintenance of science, technology and innovation” (May 23,
2014, Council for Science, Technology and Innovation) of Article 4, Paragraph 3, Item 7of the Act for Establishment of the Cabinet Office (Act No. 89 of 1991), and the
Operational Guidelines for the Cross-ministerial Strategic Innovation Promotion Program(May 23, 2014, Governing Board of the Council for Science, Technology andInnovation).
(2) Flexible plan modifications
This plan may be revised according to circumstances, from the perspective of producing
the earliest and maximal outcomes. The following is a history of modifications made todate (the date and main details of the modification).
December 13, 2018 The R&D plan was approved by the Governing Board of theCouncil for Science, Technology and Innovation and confirmed by the Director-Generalfor Science, Technology and Innovation, Cabinet Office.

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(3) Successive Generations of Project Director, Deputy Project Director, and theManager
1. Program Director

KISHI, Teruo

MISHIMA, Yoshinao(April 2018 – March 2019)(May 2019 - Present)

2. Deputy Program Director

MISHIMA, Yoshinao

MOHRI, Tetsuo(April 2018 – March 2019)(May 2019 - Present)

3. Assigned Director

CHISHIMA, Hiroshi(April 2018 – September 2018)

TONOUCHI, Toshio(October 2018 – Present)

4. Assigned Personnel
HOSODA, Naoe (March 2018 – June 2018)YANAGIDA, Masatoshi (July 2018 – June 2019)
SAHARA, Ryoji (July 2019 – Present)
Deputy Assigned Personnel
TAMAGAWA, Akiko(April 2019- Present)

63

Attachment
Requirements for subjects initiated through the supplementary budget for FY 2017(1) Is aimed at the realization of Society 5.0(2) Places emphasis on areas needing a productivity revolution(3) Entails not mere R&D, but R&D that will transform society(4) Is an area important for resolving problems in society and improving Japan’s
economic and industrial competitiveness(5) Has clear exit strategies aimed at practical use, commercialization, and social
implementation (with precise plans for commercialization in five years)(6) Has institutional exit strategies, such as intellectual property strategies, international
standardization, and regulatory reforms(7) Involves transdisciplinary efforts requiring collaboration among government
ministries and agencies(8) Includes comprehensive R&D covering the transition from basic research to practicaluse and commercialization(9) Promotes an establishment of cooperative areas and a clear distinction between
competitive areas (implements an open and closed strategy)(10) Establishes a system of industry-academia-government collaboration having a builtin matching funds component and a structure linking R&D outcomes to practical use
and commercialization by participating companies

Appendix

Financial planning and estimation

FY 2018

Total: 2,500 million yen

Accounting breakdown
1. R&D budget (including general and administrative expenses and overhead
expenses): 2,400 million yen
Breakdown by R&D item(A) Technological development for inverse design MI (participating ministries:
MEXT and METI)(B) Application of inverse design MI to actual structural materials (participating
ministries: MEXT and METI)
2. Promotional expenses (personnel, assessments, conferences, etc.): 100 million yen
Total: 2,500 million yen

FY 2019

Total: 2,080 million yen
64Accounting breakdown
1. R&D budget (including general and administrative expenses and overhead
expenses): 1,953 million yen
Breakdown by R&D item(A) Technological development for inverse design MI (participating ministries:
MEXT and METI)(B) Application of inverse design MI to actual structural materials (CFRP;
participating ministries: MEXT and METI)(C) Application of inverse design MI to actual structural materials (3D powder
processing; participating ministries: MEXT and METI)
2. Promotional expenses (personnel, assessments, conferences, etc.)
yen
Total: 2,080 million yen

65

127 million