Kitakyūshū, Japan
Kitakyūshū, Japan

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Hirose M.,Fukuoka Industrial Technology Center | Yamamoto K.,Kurume National College of Technology | Miyahara H.,Kyushu University | Sakata K.,Fujikikosan Corporation | Ogi K.,Oita National College of Technology
Key Engineering Materials | Year: 2011

A series of abrasion tests on high Cr-V-Nb cast irons revealed that the addition of MC type carbide formers, V and Nb, remarkably enhances the abrasion resistance of high Cr cast iron, and the abrasion resistance becomes higher with the increase in MC type carbides [1]. Therefore, hyper eutectic Fe-4.7%C-15%Cr-7%V-5%Nb-5%Mo alloy melt was poured into 30kg and 1kg sand mold castings to distribute different sizes of primary and eutectic carbides in hardenable matrix. The abrasion test specimens cut from each casting were austenitized at 1323K for 1h then cooled in air. These specimens were tempered at 773K for 1h followed by air cooling. The hardness of specimens was 1015-1018HV50. The rubber wheel abrasion test, a typical 3 body type one, was performed on these quenched and tempered specimens with 56-107, 107-150 and 297 μm dia. silica grit. The testing load was 86.3N and 172.5N, and the rubber wheel rotation speed was varied from 1s-1 to 4s-1. Though the higher testing load increases the wear loss, the wear rate expressed by the wear volume/(testing load × wear distance) changes depending on the wear condition and the microstructure. In case of 30kg cast specimen, the silica grit preferentially attack and scrape off the matrix, and the wear rate increases with the increase in the testing load. The fine carbides in 1kg cast specimens effectively protect the matrix from the attack of silica grit, and the wear rate decreases with increasing load which causes silica grit blunt and fracture. However, fine carbides tend to be fractured by silica grit and diminish the protective effect. Based on the worn surface structures, the abrasion mechanism is discussed comparing those of steel and eutectic 25%Cr cast iron.


Sakata K.,FUJIKIKOSAN Corporation | Tagomori K.,FUJIKIKOSAN Corporation | Sugiyama N.,FUJIKIKOSAN Corporation | Oka D.,FUJIKIKOSAN Corporation | And 7 more authors.
Proceedings of the International Thermal Spray Conference | Year: 2015

In order to clarify the bonding mechanism and to control the quality of cold-sprayed coatings, it is necessary to accurately measure the in-flight velocity and impact velocity of a projectile. In this study, the in-flight velocity of an aluminum alloy (A2017) 1 mm sphere shot from a small two-stage light gas gun was measured as being 1 km/s using a laser-cut velocity measurement technique. So as to estimate the impact velocity of the projectile, the projectile was caused to impact targets made of aluminum (A1050), copper (C1012), mild steel (SPCC), and stainless steel (SUS304). After the impact tests, the impact crater shapes of the targets was measured using scanning electron microscopy (SEM), energy dispersive x-ray spectroscopy (EDS), and laser microscopy. The impact velocity of a projectile was estimated from obtained crater depth of the targets. In addition, microstructures of the interface between projectile and target were analyzed by EDS, electron backscattered diffraction (EBSD) and transmission electron microscopy (TEM). © Copyright (2015) by ASM International All rights reserved.


Sakata K.,Fujikikosan Corporation | Tagomori K.,Fujikikosan Corporation | Sugiyama N.,Fujikikosan Corporation | Sasaki S.,Fujikikosan Corporation | And 8 more authors.
Journal of Thermal Spray Technology | Year: 2014

Compared to conventional thermal spray coating, cold spray processing typically employs finer, smaller-diameter metal powders. Furthermore, cold-sprayed particles exhibit fewer surface oxides than thermally sprayed particles due to the absence of particle melting during spraying. For these reasons, it is important to consider the potential for dust explosions or fires during cold spray processing, for both industrial and R&D applications. This work examined the dust explosion characteristics of metal powders typically used in cold spray coating, for the purpose of preventing dust explosions and fires and thus protecting the health and safety of workers and guarding against property damage. In order to safely make use of the new cold spray technology in industrial settings, it is necessary to manage the risks based on an appropriate assessment of the hazards. However, there have been few research reports focused on such risk management. Therefore, in this study, the dust explosion characteristics of aluminum, titanium, zinc, carbonyl iron, and eutectoid steel containing chromium at 4 wt.% (4 wt.% Cr-eutectoid steel) powders were evaluated according to the standard protocols JIS Z 8818, IEC61241-2-3(1994-09) section 3, and JIS Z 8817. This paper reports our results concerning the dust explosion properties of the above-mentioned metal powders. © 2013 ASM International.


Sakata K.,Fujikikosan Corporation | Tagomori K.,Fujikikosan Corporation | Sugiyama N.,Fujikikosan Corporation | Takenouchi M.,Fujikikosan Corporation | And 2 more authors.
Proceedings of the International Thermal Spray Conference | Year: 2012

In order to minimize environmental burden, green technologies should be important in the 21st century. High-performance catalyst layer would make significant contribution through reforming of hydrocarbon fuels, removal of toxic molecules such as CO and NH3 from exhaust gas, reduction of nitrogen oxide (NOx) formation in combustion, and efficient conversion of chemical energy to thermal energy in small scales. Among various kinds of catalyst support, nano-porous alumina (Al2O3) developed with anodic oxidation of aluminum (Al) layers attracts much attention due to its extremely-large specific area, easy controllability of porosity and coating thickness, and large bond strength with the substrate. In our previous studies, we have developed a micro-scale catalytic combustor with a palladium (Pd) /nano-porous Al2O3 catalyst layer, aiming at micro thermophotovoltaic power generation system, which could realize higher energy density than Li-ion batteries. In this paper, we use kinetic- and plasma-spraying for the deposition of Al, and examine the effect of the Al deposition methods on the nano-pore density. It is found that a large number of dislocations in the kinetically sprayed Al particle provide much higher nano-pore density by anodic oxidation. It is also found that nano-porous Al2O3 layer kinetically sprayed and anodized has better characteristics as the catalyst support. Copyright 2012 ASM International® All rights reserved.


Sakata K.,Fujikikosan Corporation | Tagomori K.,Fujikikosan Corporation | Sugiyama N.,Fujikikosan Corporation | Takenouchi M.,Fujikikosan Corporation | And 3 more authors.
Journal of Thermal Spray Technology | Year: 2013

Of the various catalyst supports that have been developed, nanoporous alumina prepared by anodic oxidation of aluminum layers has attracted particular interest because of its extremely high specific area, easy controllability of porosity, coating thickness, and high bond strength with substrates. In the present study, kinetic- and plasma-spraying methods are employed to deposit aluminum, and the effect of the deposition method on the nanopore density after anodic oxidation is examined through scanning electron microscopy, transmission electron microscopy, and electron backscatter diffraction observations. It is found that nanopore densities in the kinetically sprayed aluminum layers are much denser than in plasma-sprayed layers. It is hypothesized that this is attributed to the dense dislocation because of large internal stress during the deposition process. © 2012 ASM International.


Sakata K.,Fujikikosan Corporation | Tagomori K.,Fujikikosan Corporation | Sugiyama N.,Fujikikosan Corporation | Sasaki S.,Fujikikosan Corporation | And 5 more authors.
Proceedings of the International Thermal Spray Conference | Year: 2013

Cold-spray processing typically employs finer and smaller-diameter metal powders than those of the conventional thermal spraying powders. Furthermore, cold-sprayed particles exhibit fewer oxides than thermally sprayed particles due to the absence of particle melting during spraying. For these reasons, it is necessary to give extra attention to dust explosion and dust fire when using the cold spray, for industrial and R&D purposes. The dust explosion properties of metal powders used for the cold spray were examined for the purpose of not only preventing the dust explosions and fires, but also protecting the workers' safety and health. In order to utilize this new technology of cold spray for industrial use, it is necessary to manage the risks based on risk assessment. However, there are few research reports focused on such risk management. Therefore, in this study, the dust explosion properties of aluminum, titanium, zinc and iron based alloy powders were evaluated by JIS Z 8818: "Test method for minimum explosible concentration of combustible dusts", IEC61241-2-3(1994-09) Section3: "Method for determining minimum ignition energy dust/air-mixtures", and JIS Z 8817: "Test method for explosion pressure and rate of pressure rise of combustible dusts". This paper reports on the dust explosion properties of the above-mentioned metal powders.


Patent
Nissan Motor Co. and Fujikikosan Corporation | Date: 2014-05-14

A high durability roller, a manufacturing method thereof and a power transmission device with the high durability roller are provided. The roller for a power transmission device that comprises a plurality of rollers in contact with each other directly or with lubricant between them, includes: a metal base having a Youngs modulus of 220 GPa or less; and a coating that is formed on a surface of the metal base, includes hard particles and a metal component composed of at least either simple metal or alloy, and has a Youngs modulus of 250 GPa or more. The power transmission device includes the roller. The method of manufacturing the roller includes: forming the coating on the surface of the metal base by thermal spraying using a thermal spray material that comprises the hard particles and the metal component composed of at least either simple metal or alloy.

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