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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
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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
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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
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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 °
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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
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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
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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
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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.
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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
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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
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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
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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
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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.)
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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
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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
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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
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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)
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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
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Amorphous Laminated Block Core
Table. 1 Block core dimensions
Fig. 1 Amorphous laminated block core
Fig. 2 Core loss characteristics
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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
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