MIM Special seminar. Hambrug PM conference

Transcription

1 MIM of Japan PE office Kato MIM Special seminar 13 th October 2016 Hambrug PM conference Kato Professional Engineer office Yoshiyuki. Kato P.E. ( Metal & Powder Metallurgy) Zip cord Higashi-Terao Tusrumi Yokohama Japan TeL PMkato@jd5.so-net.ne.jp 1

2 PM of Japan Characteristics of Japanese MIM PE office Kato MIM Special seminar 1 工業会の紹介 The MIM industry of Japan does not have a big at all scale. The development of China and the Indian scale is remarkable. The characteristic of Japanese MIM is the originality of the technique, originality of the application. It is unique. I introduce technical one end of activity and the MIM company of association of Japanese MIM today. 2

3 Statistics of MIM of 2015 MIM Market Market volume of Japan MIM market volume of Japan results and forecast from 2009to 2018) (Mallon JPY) 12,500 PE office Kato 市場規模は大きくないが 成長軌道にある 12,000 11,952 11,627 11,698 11,500 11,238 11,000 10,951 10,951 10,752 10,565 10,547 10,743 10,500 10,000 9, ( 実績 ) 2010 ( 実績 ) 2011 ( 実績 ) 2012 ( 実績 ) 2013 ( 実績 ) 2014 ( 実績 ) 2015 ( 実績 ) 2016 ( 予測 ) 2017 ( 予測 ) 2018 ( 予測 ) 3

4 Statistics of MIM of 2015 MIM application in Japan Application MIM parts of Japan PE office Kato 日本の MIM の特徴は主力市場が無く, 殆どが少量多品種である AV Parts 0.5% Toy Parts 0.4% Other 8.7% Sawing machine 1.0% Robot parts 1.0% Mechanical Parts 23.5% Camera Video parts 1.3% Optical communication 3.1% Watch Parts 3.2% Key Parts 3.6% Medical parts 19.3% Motorcycle 6.3% Communication 10.7% Automotive 17.4% 4

5 Statistics of MIM of 2015 MIM material in Japan Material for MIM Material It's based on sales Money PE office Kato 材料的にはステンレスが視力であるが 多くの材料が使用されている W & Korver Inver Pure Fe 0.4% 0.7% WC 0.03% Others 5.0% High speed steel 2.6% Ti 2.8% Low alloy steel 3.4% Magnetics 8.2% Fe-Ni 9.5% Stainless 65.1% 5

6 Activity of JPMA MIM committee Training Camp for Young MIM guy September Castem Head office PE office Kato It is training camp for MIM young guy They are received know how of planning parts designs from senior MIM guy Those camp is sponsored by JSPM 6

7 Introduction of Japanese MIM Technology MIM Special seminar PE office Kato Today's speech contents Introduction of Japanese MIM technologies 1. Micro MIM Taisei Kogyo 2. Castem 3. NPR 4. Osaka Yakin Kogyo 5. Teibow 6. Micro Injection Machine 7

8 MIM Special seminar 2 太盛工業の紹介 Taisei Kogyo Co,.Ltd Taisei Kougyo is pioneer company of Micro-MIM Technology & parts production 26Micro MIM technology was born in Taisei Kogyou Japan in This company provided this new technology in MIM world. Company history of Taisei Kougyo is same to Micro MIM history. PHONE : +81(0) FAX :+81(0) This is one of our pride 8

9 about us Location: HQ; Neyagawa, Osaka Research Lab; Higashiosaka, Osaka Tokyo Sales Office; European Representative Office ; Thailand Factory; Our research target for 1. Invent new material MIM process 2. Develop brand new processes 3. Challenge to tighter μ-mim processes Micro Gears Forceps Soft magnetic material Taisei は μmim の基礎を築いた Precious metals 9

10 Product overview and our target 1mm Hitherto known MIM Optical connector Dimensional precision 100µm 1µm 1mm Cam Impeller 5mm 1cm 0.01µm Planetary wheel Reactor Micro forceps 1µm 10µm 100µm 1mm 1cm MIM product size 10

11 ATOS Triple Scan Deformation Analysis Using the ATOS Triple Scan and comparing it to the CAD Data, we are able to spot any possible deformation that may have happened during production. -Reduce production start-up times -Optimize component quality -Speed up the time to production 11

12 The World s Smallest Check valve Less than 0.2mm thickness 12

13 X-ray CT: Radiolucent finding Nikon Metrology:MCT225 SEM image X-ray source Spot size:3um, length measurement error:9+l/50um 13

14 MIM Special seminar 3 Castem の紹介 Akira Yoshida

15 Introducing CEO: Takuo Toda Metal Components Manufacturer Founded in 1970 ISO 9001:2008 Certified CASTEM Group 6 Sales Ofices in Japan Sales Ofice in Houston, TX 2 Plants in Philippines 2 Plants in Thailand Plant in Bogota, Colombia The characteristic of this company supports many kinds in small quantities and coexistence of lost wax and MIM 15

16 Important Numbers Revenue (billion of JP yen) 5.5 Employees: 1,127 (Apr. 2016) Capital: 1 billion yen (1M US$) Clients: 1,600~2, # of New Mold per month: 70 16

17 Variety of Clients 17

18 Variety of Metal Parts 18

19 How We Manufacture Metal Parts Investment Casting <Lost-Wax> in 30-45Days Metal Injection Molding 19

20 R&D Joint R&D with Product Development 20

21 IRON CAFe I n Akihabara, Tokyo 21

22 CSR 22

23 Where to reach US Contact info Ofice: (713) Fax: (713)

24 MIM Special seminar 4 NPR の紹介 NPR is the company which mass-produced automotive Rocca arms of chromium molybdenum steel for the first time in MIM in the world. The demand is a car of Honda. 24

25 Composition of NiFreeT wt% Ti Ta Sn 遺伝子突然変異誘導性ラビットの皮内反応性テスト V79Cells による植民地化テストモルモット最大化テスト (GMPT) 材料媒介発熱性テスト鋭敏な全体的な毒性試験筋肉内移植テスト (4 週 ) 溶血テスト Biocompatibility Test Study Compliance: ISO Result 1 Gene Mutation Inducibility Passed 2 Intracutaneous Reactivity Test On Rabbit Passed 3 Colonization Test with V79Cells Passed 4 Guinea Pig Maximization Test (GMPT) Passed 5 Material Mediated Pyrogenicity Test Passed 6 Acute Systemic Toxicity Test Passed 7 Intramuscular Implantation Test (4 weeks) Passed 8 Hemolysis Test Passed 25

26 Physical Properties (MPa) <Tensile Strength> (GPa) <Young s Modulus> (%) NiFreeT Ni-Ti SUS316L Pt-W NiFreeT Ni-Ti SUS316L Pt-W <Elastic Limit> <Relative Permeability> NiFreeT Ni-Ti SUS316L Pt-W NiFreeT Ni-Ti SUS316L Pt-W 26

27 Transmission X-Ray Imaging Visibility <Imaging Conditions> Apparatus; Transmission X-Ray Imaging System OEC9600 (Dicom View) Sample; Outside Diameter 1.27mm, Inside Diameter 1.07mm, Length 2.0mm Pt Catheter NiFreeT 27

28 Processing Properties Assessment of Processing Properties Press-Formability Weld Brazing NiFreeT Good OK OK Ni-Ti High Proficiency is Required NG (Impossible) NG (Impossible) Under Development NiFreeT Gas-atomized powder Metal Injection Molding Additive Manufacturing Implants(Custom-made) (MRI compatible, Low Yaung s Modulus and Radiopaque) 28

29 Story of NiFreeT Contact Information Hiroshi MATSUSHIMA TEL (Japan) TEL (USA) 29

30 MIM Special seminar 5 大阪冶金興業の紹介 Introduction of Osaka Yakin Kogyo 30

31 Business contents Vacuum heat-treatment Vacuum brazing Gas nitriding High temperature gas nitriding Since 1941 Various metal (Tool steel, Ti alloy, Heat-resistant materials) High density(pressurization sintering furnace) Gas atomizer(metal powdery development) Since 1989 Original metal powdery development. Complicated shape Vacuum heat-treatment Since

32 Location Miki factory (100 Employees) Head office (5 Employees) 32

33 Research and development of titanium aluminide alloy No. R&D 1 R&D 2 Year 1997~ ~2005 Powder Materials (at%) Others SHS powder (Self- propagating High-temperature Synthesis) 150Ti-50Al 225Ti-75Al 355Ti-45Al 450Ti-47.4Al-2.6Cr Gas atomized powder 450Ti-47.4Al-2.6Cr 16 th Plaansee seminar2005 約 107mm (360 /39 分割 9.2 ) 33

34 Appearance of Gas atomizer Electrode High frequency induction coil Nozzle EIGA 50 / 500 Schematic of gas atomizer 34

35 Apparent density of sintered specimens 50Ti-47.4Al-2.6Cr(at%) Atomized powder SHS powder Sintered temperature / Apparent density /Mg m -3 Relative density /%

36 Microstructure of sintered specimens used atomized powder A:lamellar B:β phase C:γ phase Typically microstructure 50Ti-47.4Al-2.6Cr(at%) 50μm Intensity /cps 8000 :γ(tial) :α (Ti 3 Al) :β θ /degree Result of X-ray diffraction Volume fraction of the phases α 2 γ β Volume fraction / %

37 Chemical composition of sintered specimens 50Ti-47.4Al-2.6Cr(at%) Atomized powder Chemical composition /mass% Al Cr O N C Ti Raw material Bal. Powder Bal. Specimen Bal. SHS powder 1/7 Chemical composition /mass% Al Cr O N C Ti Specimen Bal. 37

38 Result of tensile test of specimens 50Ti-47.4Al-2.6Cr(at%) Tensile strength / MPa Elongation /% Tensile strength (Atomized) Elongation (Atomized) Tensile strength (SHS) Elongation (SHS) 0 R.T Testing Temperature / 0 38

39 Strong point(mim of the Osaka Yakin Kogyo) Powder Gas atomizer self-developing it is possible. Vacuum furnace management Binder For Iron based alloy For Titanium alloy For Big parts (400g over) There are many choices. Temperaturecontrol Pressurization sintering Max 6Mpa High density Quality stability Inspection, analysis Since 1970~ Experience more than 40 years. Calibration in our factory (Thermocouple, others) We have much inspection, analyzers. The supply of MIM parts of the high-quality high relative difficulty is possible 39

40 MIM Special seminar 6 テイボーの紹介 MIM Technical Sales Dept. Shinya Ishikawa Hamamatsu City Phone s.ishikawa@teibow.co.j 40.j

41 Products Lineup Pen Nibs Medical Cosmetic MIM We lead pen nibs market in the world, holding world s top share, 50 %

42 Production of hollow product undercut

43 MIM Special seminar 7 セルビックの紹介 Super small injection Machine of Made in Japan 43

44 The ejection molding machine that is the smallest in the world for MIM and CIM 44

45 The ejection molding quantity is 3cc 45

46 Molding screw of the special shape 46

47 Specification of Super small injection Machine Specification Clamp force Closing speed Plunger Diameter Injection Speed Injection Volume Screw diameter Plunger strork PL space Ejection strork Type of Mold Unit Drive Comsumption of Electricity Powder Size of Macine Weight of Machine Type of Machine Cmobdel-061 1t/ cm3 50mm/sec 6Φ ー 8Φmm 45mm /Sec 0.6cc -1.0cc Φ80X20mm 20mm 25mm Max 15mm 60mmX100mmX65mm Servo motor and 3po;eX150W 170W/Hr AC100W 120x20X282mm 17kgs They prepare other type of machine Type of machine Injection volume Injection Machine weight Mobile cc-2.98cc 37kgs Mobile cc 95kgs 47

48 Inventor of this machine Mr. Takeuchi Contact President Mr. Takeuchi Address: Jib cord Choume Hatanodai Sinagawa word Tokyo Tel: t: hiro@sellbic.com 48

49 A conclusion and thanks PE office Kato Japanese MIM does not have a main market MIM steps forward in small quantities in the many kinds... extremely a variety of fields. The quality such as the dimensions precision is superior characteristics of MIM made in Japan. The MIM industry of Japan pursues a unique technique and product in the world of MIM. We will expect cooperation with the world MIM industry in future. Thank you for your attention 49