大阪富士工業 List of Products and Services

Osaka Fuji Industries provides high-quality, high-performance "small forged steel quenching rolls" through its unique special induction hardening equipment, which enables high hardness and deep hardening. Since they are forged from unique materials obtained by refining carefully selected raw materials, the steel structure is refined, imparting both toughness and hardness, which are opposing properties, during heat treatment. From cold rolling rolls, hot rolling rolls, and groove rolls to high hardness rolls of around Hs100, we can manufacture rolls according to our customers' diverse applications. 【Product Lineup (Partial)】 <For Cold Rolling> ■ General Rolling Rolls ■ Skin Pass Rolls ■ Backup Rolls ■ Corrosion and Wear Resistant Rolls ■ Rolls for Foil *For more details, please refer to the PDF materials or feel free to contact us.

• others

In powder plasma cladding (PTA) and laser cladding (LMD) that use powder as a filler material, various combinations of materials are possible. However, in powder plasma cladding, when there is a significant difference in density between the matrix metal material (Ni-based alloy: 8g/cm³) and WC (17g/cm³), a bias in the dispersion of WC occurs within the cladding layer. In laser cladding, even with composite alloys that have a large density difference, uniform dispersion can be achieved from the surface. Osaka Fuji Industry is advancing the development of various composite materials in addition to carbide-based composites. Furthermore, based on our experience with powder plasma cladding, we possess a variety of proprietary developed alloys and can propose the optimal materials according to the environment in which they will be used and the required characteristics.

• Processing Contract

■Background of Research and Development The maximum operating temperature of commercially available metal ball bearings is approximately 400°C. In higher temperature environments, ceramic ball bearings are used; however, their application is limited due to issues such as impact resistance/strength (load capacity), size constraints, and cost. This research aims to solve existing problems by raising the operating temperature of metal ball bearings from 400°C to 600°C, thereby extending the lifespan of ball bearings, reducing energy consumption due to decreased rotational driving force, simplifying equipment, and improving equipment utilization rates, ultimately striving for breakthroughs in various industrial production activities.

• Metal bearings

Using laser cladding technology, we conducted surface modification with newly developed materials, resulting in the successful development of foundational technology for brake discs aimed at next-generation high-speed railway vehicles that meet target performance. [Background of Research and Development] Considering the increasing thermal load associated with the further acceleration of railway vehicles, the application of existing steel brake discs is approaching its limits. There is a need to further enhance reliability against thermal loads, which has led to the exploration of methods to form a heat-resistant layer on the friction surface of brake discs. This research and development aims to develop brake discs for next-generation high-speed railway vehicles using laser cladding. This project has been adopted as part of the "FY 2014 Strategic Basic Technology Advancement Support Project." [Research Implementing Institutions] - Railway Technical Research Institute - Nippon Steel & Sumitomo Metal Corporation (now Nippon Steel Corporation) - Osaka University, National University Corporation - Osaka Fuji Industrial Co., Ltd.

• brake

■Background of Research and Development Based on the results of the New Energy and Industrial Technology Development Organization (NEDO) project, Shimadzu Corporation commercialized a high-brightness blue semiconductor laser oscillator with an output of 100W in January 2018. Additionally, Furukawa Electric Co., Ltd. is independently developing a multi-line near-infrared semiconductor laser with an output of 200W across 6 lines, totaling 1400W. This development incorporates a high-output multi-beam (multi-color) processing head based on the results of the Cabinet Office's SIP project (Innovative Design and Manufacturing Technology). The processing head is mounted on a 6-axis articulated robot, and it is expected to be applicable for forming high-quality coatings on industrial parts ranging from small to large sizes.

• Processing Contract

【Molding】 Size: Φ10mm to Φ600mm, up to 3500mm in length *Can accommodate sizes other than those listed above Features: Thin-walled sleeves (SUS is also acceptable) Sleeves as thin as 4.5mm are possible 【Cutting】 Size: Width 500mm × Height 500mm × Length 500mm, slice thickness 0.06mm to 12mm, cutting thickness 0.7mm to 500mm *Can accommodate sizes other than those listed above Features: Good yield, minimal kerf loss, cost-effective 【Grinding】 Size: Up to 600mm *Can accommodate sizes other than those listed above Features: High-precision flat grinding is possible 【Polishing】 Size: Single-sided processing machine, up to approximately Φ600mm Double-sided processing machine, up to approximately Φ400mm Features: High-precision lapping and polishing are possible

• Processing Contract

We would like to introduce a case study for the paper industry: "Thermal Spraying on Conveyor Pulleys." Conveyor pulleys for raw material transport were traditionally made with rubber lining, but it is now possible to improve durability and safety. We have a proven track record of delivering dimensions ranging from φ200 to 800 × 1,000 to 2,000L, and we also have numerous achievements with carrier rollers and others. 【Thermal Spraying Specifications】 ■ Ceramic (water plasma spraying), WC-based cermet (constrained frame spraying), etc. ■ Improved safety: Ceramic is non-combustible, eliminating concerns about fire hazards. *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other contract services

We would like to introduce a case study for the paper industry: "Pump Screw Plating Repair." In equipment used for transporting sludge and other materials, partial wear occurred due to the intrusion of foreign objects, and repairs were difficult because there were no drawings available, making buildup and thermal spray repairs challenging. Therefore, we measured the highest point during the acceptance inspection. We determined the plating thickness and applied hard chrome plating, followed by buff polishing. 【Process】 ■ Measure the highest point during acceptance inspection ■ Strip the plating and conduct an intermediate inspection (comparison with acceptance inspection) ■ Determine the plating thickness (report existing thickness) ■ Apply hard chrome plating and finish with buff polishing *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements

We would like to introduce a case study for the paper industry: "Filter Shaft Repair and Manufacturing." Due to wear caused by vibration on the filter shaft, we responded with a thermal spray repair. Following the repair results, we received a request for the production of spare parts. We completed the entire process from pickup, preparation, thermal spraying, finishing, to delivery within a short period of 7 days. After the repair, the actual item was sketched and drafted by the ENG Sales Department. 【Processing Overview】 ■ Bearing Tolerance: φ560 +0.044 to +0.088 (n6) ■ Bearing Step: Maintained R4 ■ BRG Nut: 15mm clearance and thread correction *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other contract services

We would like to introduce a case study for the paper industry titled "Extending the Lifespan of Screws Using Lasers." Screw conveyors are used for transporting powders, gravel, high-viscosity liquids, and bulk materials. Due to the nature of the transported materials entering between the screw tip and the inner surface of the case, wear at the tip has become a significant issue. By using laser cladding, it is possible to create a hardened layer on the millimeter scale, greatly extending the machine's lifespan. [Case Overview (Partial)] ■ Screw for ash transport in incinerators (Body size: φ400×5000mm) ■ Issues - Used in a corrosive environment at high temperatures exceeding 850°C - Damage such as cracks in the body and thermal deformation or cracks in the blades occurred, requiring replacement after six months of use. *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other contract services

We would like to introduce a case study for the paper industry titled "Investigation and Production of Screw Breakage Causes." During operation, a screw broke, and the technical center conducted an investigation into the cause. We performed various examinations, including visual inspection, penetrant testing, and SEM observation. Additionally, based on the investigation report, we produced a new screw. 【Investigation Details】 ■ Visual Inspection ■ Penetrant Testing ■ SEM Observation ■ Macro Observation of the Joint Cross-section ■ Micro Observation of the Joint Cross-section *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other contract services

We would like to introduce a construction case study for the paper industry: "Chip Inlet Repair." Corrosion progressed in the equipment used to tilt and transport chips selected from the yard, leading to issues such as the warping of the bottom plate and the loss of support columns. Support columns were fabricated on-site and replaced, along with other corroded parts, and the bottom plate was modified into pieces to allow for replacement only in the areas that had corroded and worn. [Case Overview (Partial)] - Construction Period: 1 month, with 17 workers involved - Chip Inlet Repairs (2 units) - Silo chute replacement work - Conveyor vent pulley replacement work - Correction of kiln equipment receiving roller positions *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other contract services

We would like to introduce a case study of "Staker Repair" for the paper manufacturing industry. It has been over 30 years since installation, and corrosion of the tension bar has progressed, with the turntable experiencing rib loss and a reduction in plate thickness. The Steel Division is responsible for contracted work within various steel companies. A new tension bar was created and installed, and the turntable was repaired by replacing the ribs and welding the plates. [Case Summary (Partial)] ■ Issue: Over 30 years since installation ・Corrosion of the tension bar has progressed, and the turntable has experienced rib loss and a reduction in plate thickness ■ The Steel Division is responsible for contracted work within various steel companies ■ A new tension bar was created and installed ■ The turntable was repaired by replacing the ribs and welding the plates ■ Construction period: 2 months, with 20 workers involved *For more details, please refer to the PDF document or feel free to contact us.

• Other machine elements
• Other contract services

We would like to introduce a case study for the paper industry: "Kiln Retainer Replacement Work." The retainer that holds the tires of the kiln equipment fell off, and welding was performed on-site. The welding material used is NSSW YM-24S (φ1.6), a high-tensile steel of 50kg class. In selecting the material for the retainer, emphasis was placed on toughness (soft steel type with low strength but good ductility), with the strength being covered by the amount of buildup (leg length). 【Case Overview】 ■ Problem: The retainer that holds the tires of the kiln equipment fell off. ■ Welding Material: NSSW YM-24S (φ1.6), 50kg class high-tensile steel. ■ Selection Reason: Emphasis on toughness for the retainer material (soft steel type with low strength but good ductility), with strength covered by the amount of buildup (leg length). *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries is engaged in the construction of power generation systems (boilers) in the paper manufacturing industry. Here, we introduce a case study of the "Protector" for boiler equipment. There were issues with damage to furnace walls caused by high-pressure steam injection from solid fuels and wall blowers, as well as high costs and long construction periods associated with pipe removal, thermal spraying, and buildup work during furnace wall damage. To address this, we implemented special alloy thermal spraying combined with FUSE or CrC-based cermet (high-velocity flame spraying). The thermal spray coating is dense due to re-melting treatment and is suitable for corrosive environments. [Case Overview (Partial)] ■ Construction Example: Protector for Boiler Equipment ■ Construction Location: Damaged areas such as furnace walls *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries is engaged in the construction of power generation systems (boilers) in the paper industry. We would like to introduce a case of "build-up welding for soda recovery boilers." Corrosion occurs due to chlorine, potassium, sodium, sulfur, and other components contained in black liquor, which damages the water pipes inside the boiler. Our company is capable of handling panel fabrication to build-up welding within the factory. We can also perform build-up welding on-site and on the panel replacement sections (joints), and it can be produced at a low cost in Vietnam. 【Case Overview】 ■ Construction Example: Soda Recovery Boiler ■ Construction Location: Side Wall of Boiler Furnace ■ Required Performance: High-temperature corrosion resistance (such as chloride corrosion) ■ Fuel: Waste liquid from pulp production, etc. ■ Specifications: Inconel build-up welding (MIG welding) *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries is involved in the power generation sector (boilers) of the paper manufacturing industry. We would like to introduce a case study on "thermal spraying for fine coal-fired boilers." Severe wear occurred due to solid fuel particles and limestone used for desulfurization inside the furnace. Particularly, intense abrasion was a problem in areas with steps and at the corners of the furnace. To address this, we performed welding with high chromium cast iron in specific areas of the corners for protection. We also conducted smoothing thermal spraying to eliminate the step between the weld and the furnace wall. 【Case Overview】 ■ Project Example: Circulating Fluidized Bed Biomass Boiler ■ Application Area: Boiler furnace wall ■ Required Performance: High-temperature wear resistance, corrosion resistance to corrosive products ■ Fuel: Biomass fuel, wood chips, waste plastics, etc. *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries is engaged in the power generation sector of the paper manufacturing industry (boilers). We would like to introduce a case study on "thermal spraying for fine coal-fired boilers." As a measure to reduce NOx emissions, the promotion of high-temperature sulfide corrosion due to low-oxygen combustion operation and wear damage from high-pressure steam injection from wall blowers were issues. In response, we applied CrC-based cermet (high-speed flame spraying), as well as 50Ni-50Cr (plasma spraying) and Inconel overlay welding (MIG welding). [Case Overview (Partial)] ■ Construction Example: Fine Coal-Fired Boiler ■ Construction Locations: Boiler furnace wall / Bottom of the furnace / Nose ■ Required Performance: High-temperature corrosion resistance (sulfide corrosion) and high-temperature wear resistance ■ Fuel: Fine coal (contains S, V, Cl) ■ Specifications: - CrC-based cermet (high-speed flame spraying) - 50Ni-50Cr (plasma spraying) Inconel overlay welding (MIG welding) *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industry is engaged in the construction of various rolls for the paper industry. Here, we introduce a case of "thermal spraying on winding drums." The shapes include φ600×4000L and various others, with requirements for slip prevention and grip performance. These are used under conditions for product winding. Thermal spraying was performed with WC-based cermet at specifications of 50μm or more and Ry30–50μm, and it has been in use since February 2011. [Case Overview (Partial)] ■ Product Name: Winding Drum ■ Shape: φ600×4000L and various others ■ Required Performance: Slip prevention, grip strength ■ Usage Conditions: Used for product winding *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries manufactures various rolls for the paper industry. Here, we introduce a case study of "Calendar Roll Production." The dimensions are φ500×3,000L (weight = under 2,000kg). Large items can be produced upon consultation. High hardness and high depth performance were required. Under conditions of high nip, the rolls are used to give the paper surface a glossy and smooth finish, with roll materials being RP53 (general-purpose steel) and RP79 (stainless steel). 【Case Overview (Partial)】 ■ Product Name: Calendar Roll Production ■ Dimensions: φ500×3,000L (weight = under 2,000kg)… Large items can be produced upon consultation ■ Required Performance: High hardness, high depth ■ Usage Conditions: High nip to give the paper surface a glossy and smooth finish ■ Roll Materials: RP53 (general-purpose steel), RP79 (stainless steel) *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries constructs various rolls for the paper industry. Here, we introduce a case of "thermal spraying on calendar rolls." The shapes range from φ200 to 800×2000 to 6000, requiring high hardness, wear resistance, and corrosion resistance. The usage conditions involved high nip to achieve a glossy and smooth surface on the paper. The construction was done using WC-based cermet with sealing treatment, and it has been in continuous use for over 5 years. 【Case Overview (Partial)】 ■ Product Name: Calendar Roll ■ Shape: Various sizes from φ200 to 800×2000 to 6000 ■ Required Performance: High hardness, wear resistance, corrosion resistance ■ Usage Conditions: High nip to achieve a glossy and smooth surface on the paper *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries is engaged in the construction of various rolls for the paper industry. Here, we introduce a case of "thermal spraying on paper dryer rolls." The dimensions are φ1500×5000L, with a requirement for shape restoration. The usage conditions were for a moisture profile device (cardboard) 2 groups #11. The thermal spray specification is 13Cr stainless steel, which has been in use since H23.4. [Case Overview (Partial)] ■ Product Name: Paper Dryer Roll ■ Dimensions: φ1500×5000L ■ Required Performance: Shape Restoration ■ Usage Conditions: Moisture Profile Device (Cardboard) 2 groups #11 *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries is engaged in the construction of various rolls for the paper industry. Here, we introduce a case of "thermal spraying on dryer rolls." The dimensions are φ1500×5000L, with a requirement for rust prevention. The usage conditions were for a moisture profile device (board paper) in group 2, #11. We implemented a thermal spraying specification using a nickel-based alloy spray, sealing treatment, and polishing. 【Case Overview (Partial)】 ■ Product Name: Dryer Roll ■ Dimensions: φ1500×5000L ■ Required Performance: Rust Prevention ■ Usage Conditions: Moisture Profile Device (Board Paper) Group 2, #11 *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industry is engaged in the construction of various rolls for the paper industry. Here, we introduce a case of "thermal spraying on press rolls." The shapes range from φ600 to 1000 × 4000 to 5000, requiring performance in paper release, release properties, and wear resistance. The usage conditions involved compression and dehydration with rolls and felts (blankets). We applied a thermal spray specification using high-strength ceramics with sealing treatment. 【Case Overview (Partial)】 ■ Product Name: Press Roll ■ Shape: Various sizes from φ600 to 1000 × 4000 to 5000 ■ Required Performance: Paper release, release properties, wear resistance ■ Usage Conditions: Compression and dehydration with rolls and felts (blankets) *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Osaka Fuji Industries constructs various rolls for the paper industry. Here, we introduce a case of "Wire Roll Thermal Spraying for Breast Rolls." The shapes range from φ300 to 1000 × 4000 to 7000, requiring wear and corrosion resistance. These were used under conditions for transporting wire that dewaters paper raw materials. We applied a thermal spray specification of ceramics (water plasma spraying method) with sealing treatment, and we have received evaluations indicating that the thermal spray products have been in use for over 15 years. [Case Overview (Partial)] ■ Product Name: Wire Roll Breast Roll ■ Shape: Various sizes from φ300 to 1000 × 4000 to 7000 ■ Required Performance: Wear and corrosion resistance *For more details, please refer to the PDF document or feel free to contact us.

• Paper Converting Machinery
• Other machine elements
• Other contract services

Laser coating, known as "laser cladding," which uses a laser as a heat source, is a high-performance surface modification technology that utilizes the excitation heat reaction of the laser irradiation area. It allows for precise control of output and minimizes thermal impact on the base material. 【Research Examples】 <Mortar Pool Type Laser Coating> By supplying powder while forming a mortar pool on the base material and melting it, functional surfaces such as wear resistance and corrosion resistance are created on the component's surface. <Non-Mortar Pool Type Laser Coating> By directly heating and melting raw material powder with multiple laser beams, the melting of the substrate surface is suppressed. There is minimal thermal deformation or alteration of the coating components. High output and combinations of lasers with different wavelengths are also possible. *For more details, please refer to the materials. Feel free to contact us with any inquiries. ★Research and development are also being conducted on "brake discs for high-speed rail" and "ultra-heat-resistant ball bearings" utilizing this technology. For more information, please refer to the basic information or materials.

• Surface treatment contract service

Our company has been engaged in the processing of various materials such as ceramics, resins, glass, magnetic materials, sintered products, and difficult-to-machine materials through "molding, cutting, grinding, and polishing." If requested, we can provide integrated processing from material procurement to the desired product. Of course, it is also possible to supply the processing target material and only undertake the processing. In particular, our processing using the multi-wire saw we own allows for a cutting method that minimizes kerf loss, thereby reducing material waste. Additionally, the high cutting precision is a significant advantage. This method can be said to be skilled at efficiently turning materials into products. Our company also handles not only cutting but also grinding, polishing, and precision processing. If you have any concerns about processing methods, please feel free to consult us. 【Features】 ■ Molding: Thin-walled sleeves (even in SUS), with the thinnest sleeve possible at 4.5mm ■ Cutting: High yield, low kerf loss, and cost-effective ■ Grinding: High-precision flat grinding is possible ■ Polishing: High-precision lapping and polishing (mirror finish) are possible *For more details, please refer to the PDF document or feel free to contact us. You can also check the available sizes in the PDF.

• Processing Contract

In laser coating known as "laser cladding," which uses a laser as the heat source, the excitation heat reaction from the laser irradiation area is utilized, and since the output can be precisely controlled, it becomes possible to minimize the thermal impact on the base material. 【Research Overview】 <Mortempool-type Laser Coating> ■ Using a laser as the heat source, a mortempool is formed on the base material while supplying powder into it for melting and solidification. ■ Functional surfaces such as wear resistance and corrosion resistance are formed on the surface of the component. ■ Low dilution coating of base material components. <Non-mortempool-type Laser Coating> ■ By directly heating and melting raw material powder with multiple laser beams, the melting of the substrate surface is kept to a minimum. ■ There is almost no thermal deformation or alteration of the coating components. ■ Since multiple laser beams are used, it is possible to achieve high output and combinations of different wavelength laser beams. *For more details, please refer to the PDF materials or feel free to contact us. Other related materials are also available for download.

• Processing Contract

"Laser cladding" is a laser coating technology that allows for buildup construction while minimizing thermal effects on the base material. By utilizing the excitation heat reaction from the laser irradiation and precisely controlling its output, it suppresses cracking of the base material due to hardening in the heat-affected zone and phase transformation caused by welding thermal effects. Coatings using high-performance materials can also be finished beautifully. Currently, we are providing introductory materials for research projects in which our company is participating. You can view various application technologies of laser cladding. [Research Examples] <Mortem Pool Type Laser Coating> By supplying powder while forming a mortem pool on the base material and melting and solidifying it, a functional surface with wear resistance and corrosion resistance is formed on the component's surface. <Non-Mortem Pool Type Laser Coating> By directly heating and melting raw material powder with multiple laser beams, the melting of the substrate surface is minimized. There is almost no thermal deformation or alteration of the coating components. High output and combinations of different wavelength laser light are also possible. *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

"Thermal spraying" is a surface modification technology that creates a coating by accelerating and colliding material particles that have been heated to a molten or semi-molten state. Compared to plating and vapor deposition, the film formation speed is fast, and it is possible to spray a variety of materials (metals, cermets, ceramics, etc.). Our company offers surface modification tailored to the operating conditions of manufacturing sites, such as for corrosive environments, wear environments, and heat resistance purposes. If you have any concerns, please feel free to contact us. 【Features】 ■ Capable of spraying a variety of materials (metals, cermets, ceramics, etc.) ■ Capable of spraying diverse materials (metals, ceramics, carbon materials, etc.) ■ Applicable to both large and small products, with few dimensional shape constraints ■ Low heat input to the product during spraying (approximately below 200°C) ■ Faster film formation speed compared to plating and vapor deposition *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

In power generation facilities, we primarily perform overlay welding and thermal spraying on boiler tubes. For factory construction, we provide high-quality products through automatic welding and automatic thermal spraying. In particular, we are capable of large-scale thermal spraying. With automatic thermal spraying, we can accurately trace shapes like pipes using robots. In on-site thermal spraying work, we have introduced large dust collectors, which improve the furnace environment and significantly shorten construction time through continuous work. There are many applications for power generation facilities, including pulverized coal-fired boilers and heavy oil-fired boilers, so please feel free to contact us when needed. 【Features of Thermal Spraying】 ■ Capability for large-scale work ■ Automatic thermal spraying ■ Introduction of large dust collectors *For more details, please refer to the PDF materials or feel free to contact us.

• Processing Contract

We propose surface modification tailored to the operating conditions of each customer's manufacturing site through thermal spraying, build-up welding, and LMD. In the case of "wear (powder and sliding environment) components," examples include seawater pump sleeves and powder transport screws, where a hard coating is formed on the base material to extend the product's lifespan. Additionally, there are application examples for "composite environment (corrosion and wear) components" and "composite environment (high-temperature corrosion and wear) components." Please feel free to contact us for inquiries. 【Application Examples for Wear (Powder and Sliding Environment) Components】 ■ Paper rolls ■ Seawater pump sleeves ■ Powder transport screws ■ Conveyor pulleys ■ Thin plate bridle rolls *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

The welding and thermal spraying we perform are both processes aimed at surface modification. Surface modification refers to changing the surface state of a material from its base material to impart new functions and enhance the overall value of the material. It is effective for wear resistance, heat resistance, corrosion resistance, shape recovery, and reaction prevention, allowing for the extension of the material's lifespan. "Laser Cladding (LMD)" is a build-up welding method that fuses welding material to the base material using optical energy. Please feel free to consult us if you have any concerns. 【Effects of Surface Modification】 ■ Wear Resistance ■ Heat Resistance ■ Corrosion Resistance ■ Shape Recovery ■ Reaction Prevention *For more details, please refer to the PDF document or feel free to contact us.

• Processing Contract

"EC Pro-Sarmet" is a high-temperature wear and corrosion-resistant material for boiler evaporation tubes, showing minimal reduction in coating hardness even at high temperatures of 500°C, and exhibiting good high-temperature hardness. It has excellent wear resistance against erosion. The coating demonstrates superior followability during bending deformation, contributing to improved handling and workability on-site. Results from a four-year follow-up study in evaluation tests on actual boilers confirmed the superiority of this newly developed material. 【Features】 ■ Improved wear resistance ■ Enhanced crack resistance ■ Capable of thick film formation *For more details, please refer to the PDF document or feel free to contact us.

• Other metal materials

The joint research department aims to develop processing technologies that combine the advanced laser processing techniques of Osaka University’s Institute of Laser Engineering with the materials science and manufacturing technologies of Osaka Fuji Corporation, adding various advanced functions to a wide range of structures from fine to long. We are conducting research and development on surface treatment methods for functional materials using laser cladding techniques and exploring the application range of laser technology, ultimately aiming to apply the developed technologies for the practical implementation of next-generation functional processing technologies. [Research Content] ■ Beam profile control technology ■ High-brightness blue semiconductor laser *For more details, please refer to the PDF document or feel free to contact us.

• Other processing machines

Our company has conducted research and development on a blue and near-infrared wavelength multi-beam "Laser Coating System." Based on the results of the New Energy and Industrial Technology Development Organization (NEDO) project, Shimadzu Corporation commercialized a high-brightness blue semiconductor laser oscillator with an output of 100W in January 2018. Additionally, Furukawa Electric Co., Ltd. is independently developing a multi-line near-infrared semiconductor laser with an output of 200W across 6 lines, resulting in a total laser output of 1400W. This has led to the introduction of a high-output multi-beam (multi-color) processing head based on the results of the Cabinet Office's SIP project (Innovative Design and Manufacturing Technology). The processing head is mounted on a 6-axis articulated robot, and it is expected to be applicable for forming high-quality coatings on industrial parts ranging from small to large sizes. 【Features】 ■ Total laser output of 1400W ■ Introduction of a high-output multi-beam (multi-color) processing head ■ Processing head mounted on a 6-axis articulated robot ■ Applicable for forming high-quality coatings on industrial parts from small to large sizes *For more details, please refer to the PDF document or feel free to contact us.

• Other processing machines

Wear has various types and causes. To impart wear resistance through thermal spraying, it is necessary to consider the characteristics of such wear. Wear resistance through thermal spraying is a very effective method for surface treatment of high-load bearing parts, where conventional surface modification techniques have been insufficient. 【Types of Wear】 ■ Wear that occurs when two metals come into contact, causing the softer metal to be torn and move to the harder one, repeatedly falling off as wear particles. ■ Wear caused by foreign substances interposed on the wear surface, which scrape away the surface. ■ Wear that occurs when one side of the friction surface has a significantly higher hardness than the other, leading to hard surface protrusions scratching the opposing friction surface. ■ Wear that occurs due to fatigue from vertical loads or repeated friction between two solid surfaces against the tiny irregularities on the surface of the thermal spray coating, resulting in damage or delamination of the coating. *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

Corrosion has various atmospheres, and there are different types such as acid corrosion and electrochemical corrosion. When there are corrosion atmospheres that cannot be completely prevented by the characteristics of the base material alone, or when the material is too expensive to use as a base even if it has resistant properties, surface modification through thermal spraying is very useful. Additionally, rust prevention has been promptly introduced in our company since the establishment of the thermal spraying division, responding to such needs. Currently, we have gained high trust in terms of achievements and management, and we are conducting thermal spraying work throughout Japan. [Types of Corrosion] ■ Uniform Corrosion ■ Localized Corrosion (Electrochemical Corrosion, Crevice Corrosion, Pitting Corrosion, Intergranular Corrosion, Erosive Corrosion) *For more details, please refer to the PDF materials or feel free to contact us.

• Welding Machine

In recent years, heat-resistant components have been required to have even higher heat resistance performance for the purpose of improving the efficiency and longevity of equipment. To reduce maintenance costs and enhance performance, thermal spray coatings with excellent heat resistance and high-temperature oxidation resistance have become essential in various fields such as gas turbines, jet engines, boiler components, and steelmaking. Our company, with many years of experience as a partner to major blast furnace manufacturers, possesses extensive know-how and a proven track record in heat resistance and high-temperature oxidation. *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

In general, metals are inferior to ceramics in terms of hardness. However, even when a very hard substrate is required, there are cases where ceramic molded products cannot be made or where ceramics cannot be used due to cost considerations. In such cases, surface modification through thermal spraying is effective. By forming a hard ceramic or cermet coating on the surface of the substrate, it can be made harder than the original hardness of the substrate, ensuring durability and other properties. *For more details, please refer to the PDF document or feel free to contact us.*

• Welding Machine

When operating equipment such as industrial machine parts, wear and damage due to friction between metal components and impacts are inevitable. One effective method in such cases is repair through thermal spraying. Unlike welding, thermal spraying can use ceramics and cermets (composite materials made from a mixture of metals and ceramics) to form coatings, and it does not require specific base material properties, allowing for a wide range of applications. The properties that can be added to the surface of machine parts include high hardness, heat resistance, corrosion resistance, and impact resistance, among others. Additionally, for products that have experienced significant wear, thermal spraying can also be performed to restore dimensions (depending on the product shape and spraying materials). 【Examples】 ■ Crank flange outer diameter repair ■ Case inner diameter repair *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

The impact-resistant coating is an effective layer for areas where objects repeatedly collide or where force is applied. By applying the impact-resistant coating to the surface, the strength of the substrate can be increased, preventing the substrate from being damaged. Our company conducts a test called the drop ball test to measure impact resistance. In the drop ball test, 500 objects similar to marbles are dropped in a concentrated manner onto the measurement area as one set, and the number of sets until abnormalities are confirmed in the coating is used to determine the quality of impact resistance. *For more details, please refer to the PDF materials or feel free to contact us.

• Welding Machine

Thermal spraying can impart excellent electrical properties to equipment. The possibilities are endless, such as forming a non-conductive coating on a substrate with good conductivity to create insulation, or forming a metallic coating that can be inductively heated on a non-metallic substrate. *For more details, please refer to the PDF document or feel free to contact us.*

• Welding Machine

Large ceramic pipes are ceramic molded products that apply water plasma spraying. Our products are extremely resistant to thermal expansion and contraction. We can manufacture various shapes and dimensions of ceramic parts such as "pipes," "tiles," and "crucibles" under the WAPLOC brand. 【Product Lineup】 ■ Pipes ■ Tiles ■ Crucibles *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

The importance of thermal spraying in the semiconductor and IT industries is increasing, and our company has been accumulating achievements in this area. Due to the nature of the products, many cannot be disclosed, so here we will explain the equipment designed for thermal spraying of semiconductor components, which require a clearer construction environment. We are conducting daily research to meet high-quality and high-level requirements. 【Construction Equipment】 ■ A clear thermal spraying environment with dedicated equipment to avoid contamination ■ Fully automated construction using highly reliable robots ■ New thermal spray gun *For more details, please refer to the PDF materials or feel free to contact us.

• Welding Machine