CODEN : HIKGE3 ISSN 0916-0930 VOL. 30 2014 2 VOL. ® 30 2014 VOL. 4 30 2014 VOL. 30 2014 Hiroshi HARADA Senior Scientist, High Temperature Materials Researches, National Institute for Materials Science Chuya Aoki • Toshihiro Uehara • Hironori Kamoshida • Shinya Imano • Takashi Sato Akihiro Toji • Toshihiro Uehara • Takashi Tsuyumu Nobuyuki Kitai • Yutaka Matsuura • Rintaro Ishii • Mitsutoshi Natsumeda • Jun Hoshijima Nobuhiro Arai • Yoshihiro Nakamichi • Keijiro Hayashi Kumiko Masuda • Hideaki Takahashi • Hidenori Tanaka Kanako Suzuki • Seiji Kojima • Mikio Ohkoshi • Yoshihiro Nakatani • Takahiro Sato • Takao Nishikawa • Toshiyuki Suzuki • Tetsuya Sueoka Takahiro Sugiyama • Hideki Nonen • Izumi Fukasaku • Hiroshi Ishikawa • Takashi Kumakura 5 6 7 Application of Ni Based Superalloy USC141TM for Boiler Tubes of 700ºC-Class A-USC Power Plants Chuya Aoki Toshihiro Uehara Shinya Imano Hironori Kamoshida Takashi Sato The creep rupture properties and microstructural changes during creep tests in solution treated Ni based superalloy USC141 were investigated in order to use this alloy for 700℃ class A-USC boiler tubes. The creep rupture strength at 700℃ for 100,000 hours in solution treated USC141 was estimated as about 180 MPa, which is almost the same as that of solution treated and aged alloys. This happened because precipitation strengthening occurred during the creep test. This predicted creep rupture strength is much higher than the 100,000 hours’ 100 MPa strength required for boiler tubes. As a result, we tried to produce USC141 boiler tubes and are evaluating the various properties required for approval of USC141 boiler tube material. 8 Table 1 Typical chemical composition of USC141 Fig. 1 Creep rupture strength of USC141 after aging (a) creep rupture strength as a function of rupture time (b) creep rupture strength as a function of Larson-Miller parameter Fig. 2 FE-EPMA, backscattered electron images in solution treated (a) low magnification (b) high magnification 9 Fig. 3 Creep rupture strength of USC141 in solution treated and after aging (a) creep rupture strength as a function of rupture time (b) creep rupture elongation as a function of rupture time (c) creep rupture strength as a function of Larson-Miller parameter 10 Fig. 4 SEM Images of γ’ particles after creep rupture test in solution treated test temperature (a) 700℃ (b) 750℃ (c) 800℃ Fig. 5 Equilibrium calculation of USC141 by JMatPro Fig. 6 Correlation between mean radius of γ’ particles and creep rupture life in solution treated Fig. 7 FE-EPMA, backscattered electron image and elemental map images after creep rupture test at 700℃ in solution treated 11 Fig. 8 TEM analysis of Mo compound (a) dark field image and [001] zone axis SAD pattern (b) [001] zone axis SAD pattern of μ phase-Fe7W6 (simulation) Table 2 EDX analysis of Mo compound and equilibrium calculation of μ phase by JMatPro Fig. 9 Appearance of USC141 trial tube 12 Chuya Aoki Toshihiro Uehara Hironori Kamoshida Shinya Imano Takashi Sato 13 Reduced Use of Nickel in High-Strength Superalloy for Exhaust Engine Valves Akihiro Toji Toshihiro Uehara Takashi Tsuyumu The superalloy NCF5015 was developed to meet the need for exhaust engine valves for high strength, good durability, and low cost. Our original alloy design method was used to reduce the nickel content in nickel based superalloys to approximately 55%. Even with the reduction in nickel content, NCF5015 has a higher high-temperature strength than conventional superalloy NCF751 for exhaust engine valves, and keeps its good properties after long time exposure at high temperature. Engine valves made of this alloy are now being used in the engines of passenger cars. 14 Fig. 1 Isothermal section of Fe-Ni-Cr system phase diagram at 800℃ and location of matrix composition of experimental and conventional alloys Table 1 Design factors and chemical composition for experimental alloys 15 Fig. 2 Microstructure of alloy No.3 (a) standard heat treatment (b) long time heat treatment Fig. 3 Effects of several factors on high-temperature fatigue strength after standard heat treatment 16 Table 2 Normal chemical composition of valve alloys Fig. 4 Effects of several factors on charpy impact value after 800℃×400 h exposure Fig. 6 Hot hardness of valve alloys Fig. 5 Effects of several factors on hot workability Fig. 7 0.2% yield strength of valve alloys 17 Fig. 8 Tensile strength of valve alloys Fig. 10 Charpy impact value of valve alloys after 800℃×400 h exposure Fig. 11 Hot workability of NCF5015 Fig. 9 Fatigue strength of valve alloys 18 Akihiro Toji Toshihiro Uehara Takashi Tsuyumu 19 Relation between Nd2Fe14B Grain Alignment and Coercive Force Decrease Ratio in Nd-Fe-B Sintered Magnets Nobuyuki Kitai Yutaka Matsuura Mitsutoshi Natsumeda Rintaro Ishii Jun Hoshijima It was found that the coercive force of Nd-Fe-B sintered magnets decreases as the Nd2Fe14B grain alignment improves. It was expected that the coercive force of perfectly aligned magnets would reach 0.7 of the coercive force in isotropically aligned magnet. The Magnetic Domain Wall Model is more appropriate than the Stoner-Wohlfarth Model for explaining the coercive force. The alignment distribution of Nd2Fe14B grains in Nd-Fe-B sintered magnet was also measured by electron backscattering diffraction (EBSD). The alignments and the coercive force decrease ratios were calculated using these alignment distributions. These data were compared against the results obtained from the magnetization measurements. The calculated alignments using the alignment distribution functions were close to the values of magnetization measurements. However, it was found that the calculated coercive force decrease ratios were different from the the results obtained from the magnetization measurement. The Authors considered reason for this phenomenon. 20 Table 1 Composition and coercive force of magnets used in this experiment (Nd-Fe-B magnet: atom%, ferrite magnet: chemical composition) Fig. 1 Alignment dependence of coercive force decrease ratio 21 Fig. 2 Inverse pole figure from electron backscattering diffraction (EBSD) (a) isotropically aligned magnet (b) aligned magnet (aligned surface) (c) aligned magnet (perpendicular to aligned surface) (d) color gauge Fig. 3 Grain diameter distribution and average diameter obtained from EBSD (a) isotropically aligned magnet (b) aligned magnet (aligned surface) (c) aligned magnet (perpendicular to aligned surface) Fig. 4 Definition of angle θ 22 Fig. 5 Angular dependence of coercive force based on S-W model (a) angular dependence of Nd2Fe14B crystal particle coercive force based on S-W model (b) perfectly aligned magnet (c) aligned magnet (d) isotropically aligned magnet Fig. 6 Angular dependence of coercive force based on D-M model (a) angular dependence of Nd2Fe14B crystal particle coercive force based on D-M model (b) perfectly aligned magnet (c) aligned magnet (d) isotropically aligned magnet 23 Fig. 7 Pole figure using electron backscattering diffraction(EBSD) (a) Sample 4 (Dy: 0.0%) alignment field: 0.14 MA/m (b) Sample 4 (Dy: 0.0%) alignment field: 1.35 MA/m (c) Sample 5 (Dy: 2.1%) alignment field: 0.14 MA/m (d) Sample 5 (Dy: 2.1%) alignment field: 1.35 MA/m 24 Fig. 8 Data based on misorientation distribution figure by EBSD and calculated alignment distribution using EBSD data and Gaussian distribution (a) f (θ) (alignment field:0.14 MA/m) (b) f (θ) (alignment field: 1.35 MA/m) (c) P (θ) (alignment field:0.14 MA/m) and Gaussian distribution with standard deviateσ=19 ° (d) P (θ) (alignment field:1.35 MA/m) and Gaussian distribution with standard deviateσ=12 ° 25 Fig. 9 Expected coercive force using EBSD data and the gaussian distribution function. (Experimental data in this figure was obtained by magnetic properties measurement) 26 Nobuyuki Kitai Yutaka Matsuura Rintaro Ishii Mitsutoshi Natsumeda Jun Hoshijima 27 Examination of Method for Shrinkage Prediction by Overheating of the Mold with Casting Simulation Nobuhiro Arai Yoshihiro Nakamichi Keijiro Hayashi It may be surmised that shrinkage, including that of exhaust system parts (Hercunite®-S), occurred due to overheating of the sand mold during melt pouring. The developmental state of the shrinkage was investigated by the casting experiments using the test pieces to verify this inference. Also, the casting simulation parameters were modified by the measured thermal property of various molds. The casting simulation using these parameters permitted shrinkage prediction by overheating of the mold. In addition, the accuracy of shrinkage prediction by casting simulation for exhaust system parts was improved by appling this improved parameter. 28 Fig. 2 The temperature measurement points of the test piece and the mold (enlarged view of the evaluation portion) Fig. 1 Shape of a test piece (a) top view (b) side view Table 1 Casting conditions Fig. 3 Sections of the evaluation portion of a test piece (a) run-off: small (b) run-off: large 29 Table 2 Results of shrinkage analysis of a test piece Fig. 4 Temperature curve of the test pieces and the molds (a) casting temperature (b) mold temperature Table 3 Comparison of temperature curves of the test pieces and the molds between measured value and analysis 30 Fig. 6 Comparison of measurement result of specific heat and analysis setting value Fig. 5 Schematic drawing of apparatus for measurement of thermal conductivity (a) overall view (b) detail view of temperature measuring part 31 Table 5 Results of shrinkage analysis with improvement parameter Fig. 7 Comparison of measurement result of thermal conductivity and analysis setting value Table 4 Comparison of temperature curves of the test pieces and the molds between measured value and analysis (improvement parameter) 32 Fig. 8 Photograph of the exhaust system parts for cars produced at Hitachi Metals, Ltd. Nobuhiro Arai Yoshihiro Nakamichi Keijiro Hayashi 33 Improvement of Earthquake Energy Absorption in Exposed-Type Column Bases Kumiko Masuda Hideaki Takahashi Hidenori Tanaka Exposed-type column bases, which is widely used in steel frame buildings, do not have adequate absorption energy for earthquake. The structure calculation for a building that uses exposed-type column bases must be established with a higher ultimate resistant force than other types of column bases. Therefore, we developed exposed-type column bases named HIBASE-NEO which improved about energy absorption, and confirmed their high energy absorption by conducting full-scale experiments and dynamic response analyses. In this report, the energy absorption and the evaluation method for rotational rigidity and strength are discussed. 34 Fig. 1 Exposed-type column base composition Fig. 2 Slip-type hysteresis and mechanism (a) hysteresis (b) mechanism Fig. 3 Improved slip-type hysteresis and mechanism (a) hysteresis (b) mechanism 35 Table 1 List of specimens Table 2 Material characteristics Fig. 4 Example of specimen (a) top view (b) sectional view (c) dimensional drawing Fig. 5 Loading apparatus 36 Fig. 6 Bending moment-rotation relationship Fig. 7 Calculated and experimental rotational rigidity Table 3 List of calculated and experimental bending moment at yield times of anchor bolt Table 4 List of calculated and experimental rotational rigidity 37 Table 5 List of dynamic response analysis parameters Fig. 8 Example of analysis model (a) 2-story series (b) 4-story series (c) 6-story series 38 Fig. 9 Comparison of the first-story column base energy absorption of the improved slip-type column base hysteretic behavior and sliptype column base hysteretic behavior (a) 2-story series (b) 4-story series (c) 6-story series Kumiko Masuda Hideaki Takahashi Hidenori Tanaka 39 Visual Connection Identifier for LC Type Connector Kanako Suzuki Seiji Kojima Yoshihiro Nakatani Takao Nishikawa Mikio Ohkoshi Takahiro Sato Toshiyuki Suzuki Tetsuya Sueoka To address the need for efficient installation work such as removal and, MACs (Moves, Adds and Changes) of optical fiber, we have developed new technologies for the easy recognition of the operating status of optical telecommunication line that allows the installation work to be completed swiftly. We have developed LC duplex optical visual connection identifiers which are a major component in the data center in the USA. With optimized GI optical fiber, an attenuation of 0.43 dB and return loss of less than −40 dB are achieved. Furthermore no degradation of BER as a 10 Gbps data signal is confirmed. Also we have developed a detector for the LC duplex optical visual connection identifier which has excellent performance with −22.8 dBm detection sensitivity and less than the minimum communication optical power of −20 dBm. 40 Fig. 1 Structure of visual connection identifiers (a) SC type (b) LC type Table 1 Target specifications of visual connection identifier for duplex LC type and optical distinction Fig. 2 Appearance of visual connection identifiers for LC type (a) body (b) body with optical fiber 41 Fig. 4 Measurement result of optical loss of fusion splice Fig. 3 Appearance of optical distinction (a) SC connector measurement (b) LC connector measurement 42 Fig. 5 Measurement result of insertion loss Fig. 7 Test result of environment (a) temperature cycling test (b) high-humidity temperature test Fig. 6 Measurement result of return loss Fig. 8 Measurement set up for BER of 10 Gbps 43 Fig. 11 Module of visual connection identifier (19-inch) Fig. 9 Measurement result of BER ( 2 m optical fiber length) Fig. 10 Measurement result of BER (100 m optical fiber length) Fig. 12 Monitoring system for SC type connector (a) tablet (b) mobile PC (c) 19-inch patch panel 44 Kanako Suzuki Seiji Kojima Mikio Ohkoshi Yoshihiro Nakatani Takahiro Sato Takao Nishikawa Toshiyuki Suzuki Tetsuya Sueoka 45 Analysis of the Intra-pair Skew Generation Factor in Copper Cable for 25 Gbit/s/ch Transmission Takahiro Sugiyama Hideki Nonen Hiroshi Ishikawa Izumi Fukasaku Takashi Kumakura Conventional copper cable has an intra-pair skew of about 10 ps/m, which makes it difficult to use copper cable for a 25 Gbit/s/ch interconnect. The new structure cable “OMNIBIT®” features a low skew and is expected to become a next-generation cable. We investigated the factor of intra-pair skew particularly the “rise-time skew” of these cables. As a result, it became clear that the intra-pair skew was related to the differences at propagation time between the differential mode and the common mode. Because the new structure cable did not have the differences in propagation time, it was confirmed that the intra-pair skew of OMNIBIT cable did not easily become as it dose in conventional cable. 46 Fig. 2 Twinax structure (a) spiral shield (b) longitudinal shield Fig. 1 Port setting of S-parameter Table 1 Cable specification and analysis condition 47 Fig. 3 Mixed mode S parameter in the case where the balanced twinax cable Fig. 5 Cross-section and electric field distributions of twinax cable (a) cross-section (b) electric field distribution of differential mode (c) electric field distribution of common mode Fig. 4 Impulse response and step response in the case where the balanced twinax cable Fig. 6 Mixed mode S parameter in the case where the unbalanced twinax cable has a longitudinal shield 48 Fig. 8 Mixed mode S parameter in the case where the unbalanced twinax cable has a spiral shield Fig. 7 Impulse response and step response in the case where the unbalanced twinax cable has a longitudinal shield Fig. 9 Impulse response and step response in the case where the unbalanced twinax cable has a spiral shield 49 Fig. 11 Mixed mode S parameter at the structure of the one batch extruded insulator covering two conductor type Fig. 10 OMNIBIT Cable (structure of the one batch extruded insulator covering two conductor type) Fig. 12 Impulse response and step response at the structure of the one batch extruded insulator covering two conductor type Table 2 Cable specification and analysis conditions for OMNIBIT 50 Takahiro Sugiyama Hideki Nonen Izumi Fukasaku Hiroshi Ishikawa Takashi Kumakura 51 Amorphous Core for Energy Efficient Transformer Table 1 Core loss and apparatus power for single phase model core ® based on Metglas 2605HB1M and grain-oriented electrical steel Fig. 1 Amorphous core AMTC series Fig. 2 Core loss vs. induction for single phase core based on Metglas ® 2605HB1M and grain-oriented electrical steel (measured by Hitachi Metals, Ltd.) 52 Fig. 3 Apparatus power vs. induction for single phase core based ® on Metglas 2605HB1M and grain-oriented electrical steel (measured by Hitachi Metals, Ltd.) Ni-Based Amorphous Brazing Materials Table 1 Product line-up for MBF Fig. 1 Preformed MBF Fig. 2 Appearance of MBF Fig. 3 Application for MBF (a) exhaust gas recirculation (b) heat exchanger (c) metallic catalytic substrate 53 High Accuracy Resistance Alloy Fig. 1 Relationship between temperature and electrical resistance change ratio of metal material Table 1 Line-up of resistance alloys 54 Fig. 2 Relationship between electrical resistivity and TCR of resistance alloys Cu Cored Pb-Free Solder Ball for Solder Jointing Fig. 2 Cross section view of solder and Cu cored solder bumps Fig. 1 Cu cored solder balls (a) SEM image (b) cross section view Table 1 Specification of Cu cored solder Fig. 3 Particle size destribution of Cu ball 55 Indexable 4-Flute Ball End Mill 56 Fig. 1 Ball Precision Multi Flutes ABP4F type Fig. 2 Structure Fig. 3 Performance comparison when cutting flat surfaces Fig. 4 Tool life comparison when cutting vertical walls High-Efficiency Ball Nose End-Mill for Hardened Steels Fig. 1 Epoch high hard ball (a) appearance (b) cutting edge Fig. 2 Special tip shape Fig. 3 Sintered HSS bottom cutting (HAP40: HRC 64) (a) EHHB-ATH (b) Conventional Fig. 4 Cold tool steel high-efficiency contouring example (SLD: HRC 60) (a) EHHB-ATH (b) Conventional 57 Mn-Zn Ferrite with Low Loss at High Temperature for Vehicles Fig. 1 Ferrite cores for transformers Fig. 2 Relationship between saturation magnetic flux density (Bs) and core loss (Pcv) Fig. 3 Temperature dependence of saturation magnetic flux density (Bs) 58 Fig. 4 Temperature dependence of core loss (Pcv) 5 mm Square-Sized High Performance Isolator for LTE Base Stations Table 1 Specification of ESI-5CM series Fig. 1 Appearance of developed isolator Fig. 2 Configuration of developed isolator Fig. 3 Electrical characteristics of LTE band 41 (example) (a) insertion loss (b) isolation 59 Amorphous Laminated Block Core Table. 1 Block core dimensions Fig. 1 Amorphous laminated block core Fig. 2 Core loss characteristics 60 Fig. 3 Comparison of gap loss Reduced Rare Earth Material Linear Motor Fig. 1 Appearence of ALTO-MAXTM Velocity characteristics (ALT-400S) Fig. 2 Structure comparison of linear motor TM (a) conventional type (b) ALTO-MAX Table 1 Principal specifications Fig. 4 Thermal characteristics 61 Light-Weight Suspension Parts Made of High-Strength and High-Toughness Ductile Cast Iron 62 Fig. 1 Characteristic of bending load and deformation of ® NMS 600CM Fig. 2 Impact value of NMS®600CM of specimens with a casting surface Fig. 3 Examples of commercialization of weight-reduced suspension arm made of NMS®600CM (a) lower arm for light duty truck (b) upper arm for passenger car Fig. 4 Load-displacement by bench test of upper arm for passenger car (existing product of our company vs weightreduced product made of NMS®600CM) Ultra High-Temperature Mass Flow Meter Table 1 Basic specifications of the developed product Fig. 1 Ultra high-temperature mass flow meter Fig. 2 Evaluation results for life of sensor wire coatings Fig. 3 63 Earthquake Absorbing Floor System for Data Center Fig. 1 Product structure of earthquake absorbing floor system SKID Ⅱ (a) appearance of product (b) detailed figure of main parts Fig. 2 Structure of bearing aconventional 64 bnew type Fig. 3 Results of vibration test Rolling Stock Cables Compliant with European Norm Table 1 Line up of POLYENEX®, cables compliant with European Norm Fig. 1 Appearance of EN cables POLYENEX® Fig. 2 Comparison of mechanical property Fig. 3 Comparison of smoke emission (light transmittance) 65 Woven Coaxial Cable-Micro Thin Type (0.2 mm Pitch) Fig. 1 FCBAND® coaxial cable (a) appearance (64 coaxial type) (b) concept illustration (c) enlargement (d) cross-section Table 1 64 coaxial FCBAND® properties Fig. 2 Proposed case for probe head (a) diagnostic ultrasound system (b) probe cable 66 Rubber Roller Using Continuous Vulcanizing Technology Table 1 Specifications of rollers for photocopy machine Fig. 1 Rollers for photocopy machine Fig. 2 Electrophotographic process Fig. 3 Continuous vulcanizing equipment 67 High PDIV Rectangular Enameled Wire for HEV/EV Inverter-Fed Motors Fig. 2 Structure of high PDIV rectangular enameled wire Fig. 1 Generation of partial discharge between wires Table 1 General characteristic example of high PDIV rectangular enameled wire Fig. 3 Characteristic of thermal degradation at 240ºC 68 Electric Parking Brake Harness Table 1 Fig. 1 Fig. 2 Fig. 3 69 Small Connector for Car Accessories Fig. 1 (a)developed connector (b) current connector Table 1 Basic specifications 70 High Voltage Compact Connector for HEV/EV Table 1 Characteristics of compact connector Fig. 2 High voltage compact connector (a) cable connection type (b) terminal block type Fig. 1 Terminal structure of connector (a) conventional structure (b) developed structure 71 Mold Connector for ABS Sensor Fig. 1 Mold connector for ABS sensor Fig. 2 Problem of current water proof connector attachment for ABS sensor Table 1 Reliability assessment result Fig. 3 Comparison of costs of current and development products 72 Ethernet Switch for Service Providers Fig. 1 Appearance of Apresia12000 series Fig. 2 Network architecture with Apresia12000 series Table 1 Specification of Apresia12000 series Fig. 3 Summary of CCM-FLR function 73 74 75 76