大阪富士工業 List of Products and Services

In the field of power generation, thermal spray coatings are applied as a countermeasure against damage to furnace evaporator tubes in commercial power generation facilities. The forms of damage vary depending on the fuel and the atmosphere inside the furnace, and the factors can be broadly categorized into two types: high corrosion and erosion wear. 【Overview】 <Construction> ■ Depending on the shape and area of the products to be treated, automatic thermal spraying by robots in our factory or manual thermal spraying on-site is carried out. <Thermal Spray Repair> ■ For areas where damage has progressed since the start of operations, localized repair thermal spraying is also performed. *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

Paper-making rolls are subject to significant impact, wear, and corrosion due to the manufacturing process, requiring strong abrasion resistance, impact resistance, and corrosion resistance. Our company has extensive experience with various shapes and types of paper-making rolls. Please feel free to consult us when needed. 【Project Overview】 ■Shape: φ330–800×5, 600–8,000 ■Material: Cast iron ■Usage Conditions: Paper machine (wire part, press part) ・Temperature: Room temperature ・Board material: Nylon wire, wet paper ・Others: Corrosion due to white water ■Required Performance: Abrasion resistance, paper release properties, corrosion resistance ■Conventional Measures: Rubber lining ■Thermal Spray Specifications: Material "Alumina-based ceramics," Spray method "Water plasma method" *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

The equipment and machinery used in steelmaking facilities operate under harsh conditions, such as high temperatures and corrosive environments specific to the steelmaking process. Therefore, the materials and surfaces used in these applications require strong performance in wear resistance, heat resistance, and corrosion protection. Thermal spraying is utilized as an essential technology for extending the lifespan of such materials and surfaces. 【Construction Examples (Excerpt)】 ■ Conveyor Pulley ■ Coke Oven and Ascending Pipe ■ CDQ Boiler Tube ■ Acid Cleaning Bridle Roll ■ Support Roll *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

Aircraft technology requires absolute safety and reliability. In recent years, aircraft jet engines with a maximum operating temperature of 1,600°C have been put into practical use. As a result, the demand for precision in thermal barrier coatings has increased to protect components from even harsher environments and ensure component lifespan. The "combustion chamber and turbine blades" are parts that make up the engine, which is the heart of the aircraft, while the "landing gear" refers to the three takeoff and landing devices used by the aircraft during takeoff and landing. [Reference] - Coating methods: Plasma spraying, HVOF spraying - Coating materials: Ceramics, cermets - Coating thickness: 0.5 to 0.7 mm - Requirements: Thermal insulation, high-temperature corrosion resistance, (high-temperature) wear resistance *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

Recently, the application of thermal spraying to chemical storage facilities and piping has become more common. Various materials such as ceramics and Hastelloy demonstrate effectiveness in this field. By forming a coating with low porosity that is resistant to chemicals on the material, we extend the lifespan of the material and equipment. 【Application Example】 <Hydrochloric Acid Sleeve> ■Spraying Method: Plasma Spraying (Inner Diameter Spraying) ■Spraying Material: Ceramics ■Coating Thickness: 0.3 to 0.4 mm ■Required Performance: Chemical Resistance *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

In the late 1970s, we energetically conducted salt spray tests and coastal exposure tests, establishing anti-corrosion thermal spraying technology. In the 1980s, we equipped ourselves with automatic thermal spraying devices that could be operated on-site, and began undertaking anti-corrosion thermal spraying for crude oil tanks and others. By 2011, we had performed thermal spraying on dozens of tanks. From the late 1990s to the present, thermal spraying of various bridge components, including the Fukuhoku Bridge, has become active. We aim to improve the quality and cost aspects of these components by developing construction techniques using automatic thermal spraying. We are continuously making improvements to accommodate even more complex shapes. [Examples of thermal spraying on tanks (aluminum anti-corrosion thermal spraying)] - Kerosene tanks - Naphtha tanks - Gasoline tanks - Crude oil tanks - Propane tanks *For more details, please refer to the PDF materials or feel free to contact us.

• Welding Machine

Thermal spraying is utilized in various applications. In addition to repairing parts of various machinery and industrial products such as rolls, shafts, bearings, casings, and rollers, we also carry out decorative applications. There are coatings that not only repair the surfaces of base materials like SS and stainless steel but also dramatically extend their lifespan. We accept orders for custom pieces. Please feel free to consult with us. *For more details, please refer to the PDF materials or feel free to contact us.

• Welding Machine

Thermal spraying is a type of surface modification technology that involves heating metals or ceramics to a molten or semi-molten state, then colliding and depositing them onto a material surface to form a coating. The "melt" in thermal spraying refers to the act of melting, while the "spray" corresponds to the collision and deposition. Therefore, to create a good thermal spray coating, a high-temperature state is necessary to achieve sufficient melting, along with a high-speed state for spraying the particles. In the film formation process of thermal spraying, the molten particles collide with the substrate and simultaneously flatten out. Some particles may also splatter as droplets. The coating is formed as the molten raw material particles layer upon each other. 【Various Thermal Spraying Methods】 ■ Water Plasma Spraying ■ Gas Plasma Spraying ■ High-Speed Flame Spraying ■ Arc Spraying ■ Flame Spraying *For more details, please refer to the PDF document or feel free to contact us.

• Plating Equipment

The thermal spraying method, which involves the unique process of melting and projecting solid materials, has characteristics that are not found in other surface modification technologies. The advantages of thermal spraying include a wide range of choices for spraying materials and material properties, high coating formation speed, and the ability to perform on-site applications. Additionally, it allows for coating formation while keeping the material temperature low, operates as a dry process, and has a minimal environmental impact. **Advantages of Thermal Spraying** - Wide range of choices for spraying materials and material properties - High coating formation speed - Wide range of choices for the dimensions of the sprayed material - On-site application is possible - Coating formation can be achieved while keeping the material temperature low - Operates as a dry process with minimal environmental impact *For more details, please refer to the PDF document or feel free to contact us.*

• Plating Equipment

When we talk about "thermal spraying," it is often thought of as just the coating process. However, the original purpose of thermal spraying is to provide useful value on the surface of the product for the necessary duration, according to the client's (customer's) requests. Therefore, it is essential to have sufficient planning not only for the coating process but also for other processes. 【Basic Processes】 ■ Pre-consultation and specification creation ■ Pre-treatment ■ Coating formation ■ Post-treatment ■ Inspection *For more details, please refer to the PDF document or feel free to contact us.

• Plating Equipment

Chrome plating can be broadly divided into decorative and industrial uses. Decorative plating often takes advantage of its luster, while industrial plating typically focuses on its material properties. Additionally, a key difference is that the thickness of the plating is greater (as specified by JIS to be 2μm or more) compared to decorative plating. The characteristics of chrome plating include a high hardness, which significantly improves wear resistance when applied to machine parts and tools. 【Advantages of Thermal Spraying】 - Unlike plating, it is not limited by the constraints of a processing tank, allowing for the treatment of large products that cannot fit into a tank (partial treatment is also possible). - The processing time is quick, and because it is a dry process, no drying time is required. - The film thickness can range from approximately 0.5mm to 50mm, allowing for both thin and thick film applications. *For more details, please refer to the PDF document or feel free to contact us.*

• Plating Equipment

Our company has developed its technical capabilities primarily in the manufacturing and repair of steelmaking equipment and machining. We have enhanced our unique surface modification technologies, such as special overlay welding and thermal spraying, based on this expertise. Currently, we are expanding our diverse surface modification technologies beyond the steel industry to a wide range of sectors, including the paper industry, energy industry, semiconductor and IT industries, aerospace industry, and construction industry. We combine three strengths: "quality power" that builds trust, "technical power" that creates the future, and "development power" that fosters enthusiasm. With the concept of "high-quality manufacturing," we respond to our customers' needs. [Business Activities] ■ Various operations in the steel production process, machining, various welding and thermal spraying, engineering, industrial machinery design and manufacturing, and slicing processing. *For more details, please refer to the PDF document or feel free to contact us.

• Welding Machine

The surface modification technology that contributes to reducing the life cycle cost of high value-added machinery and equipment is cladding welding and thermal spraying technology.

• others

The PTA welding method is one of the most competitive welding methods in our overlay welding business.

• others

Shielded metal arc welding is the most common welding method.

• others

Our company undertakes slicing processing (cutting processing) for various materials, including silicon wafers for solar cells. Utilizing various equipment, including multi-wire saws, we actively respond to customer needs for "processing expensive materials efficiently with minimal kerf loss," ranging from continuous production for mass production to lot production and individual production for research and development. If you are struggling with the costs or yield of cutting processing in your manufacturing or development operations, please feel free to consult Osaka Fuji Industry.

• Glass

PTA welding

• Steel

Toriballoy is a material that combines the wear resistance of superhard alloys with the corrosion resistance of Hastelloy C. Our company has established construction techniques for this large component using automatic overlay (powder plasma welding method).

• Processing Contract

Since it is low-temperature thermal spraying, the sprayed material does not undergo any alteration. Thermal spraying of ceramics is possible in rod and tube shapes. Compared to arc spraying, it achieves a finer surface roughness and a high-hardness coating. Additionally, there is less loss of chromium and carbon. As a key player in on-site thermal spraying, we have numerous achievements in anti-corrosion spraying with materials such as aluminum and zinc. ● For more details, please download the catalog or contact us.

• Processing Contract

Compared to gas thermal spraying, it features greater adhesion and tensile strength, as well as higher spraying efficiency. By utilizing two different metals or alloy materials, a pseudo-alloy coating is formed. Any metal that can be drawn into wire can be sprayed. Because it is a low-temperature spraying process, the substrate does not undergo alteration or change. The pores within the coating provide excellent oil retention properties and significantly improve wear resistance. For more details, please download the catalog or contact us.

• others

A mixture of hydrocarbon-based gases or hydrogen gas and oxygen is burned in an internal combustion chamber, and the combustion gases are transformed into high-temperature supersonic combustion gas jets (Mach 5 or higher) through four concentrated injection ports. Then, powdered material is fed into the center of the gas jet using nitrogen gas, where it is melted and accelerated while colliding with the material within the nozzle and the highly concentrated combustion gas jet. As a result, it is possible to form a dense and high-quality thermal spray coating. ● For more details, please download the catalog or contact us.

• others

In an operating gas such as argon or helium, a voltage is applied between a tungsten cathode and a copper nozzle anode, generating a direct current arc that dissociates and ionizes the operating gas, continuously producing a plasma arc. This is then constricted by a cooled nozzle, ejecting a high-temperature, high-speed jet of over 15,000°C. By feeding powder into the plasma jet and accelerating it while melting, it is possible to spray high melting point materials such as ceramics. Furthermore, the plasma jet stream can blow molten particles onto the material at high speed, allowing for the formation of high-quality spray coatings compared to other spraying methods, and there is a wide variety of spray materials available. ● For more details, please download the catalog or contact us.

• others

The mechanism of this device is designed so that the high-pressure water flow supplied to the torch creates a cylindrical over-water flow inside. In this state, when a voltage is applied between the carbon cathode and the iron rotating anode, a direct current arc is forcibly generated, causing the water on the inner surface of the over-water flow to evaporate and become plasma after decomposition, continuously generating a plasma arc. This plasma arc is constricted by the swirling cylindrical water flow, increasing energy density, and due to the rapid thermal expansion of the plasma, a stable plasma jet flame at high temperature and high speed is ejected from the nozzle. The maximum temperature of the plasma jet flame can reach approximately 30,000°C, making it easy to spray even high-melting-point ceramics. ● For more details, please download the catalog or contact us.

• others

Osaka Fuji Industrial's cladding welding business is conducted at the Amagasaki factory in Kansai, the Wakayama factory, and the Omigawa factory in Kanto. This brochure introduces an overview of our cladding welding business, focusing on the facilities at the Amagasaki, Omigawa, and Wakayama factories. Additionally, we also present an overview of the thermal spraying business at the Senboku factory. As one of the surface treatment technologies, our cladding welding business, which holds unknown potential, will continue to develop in the future. ● For more details, please download the catalog or contact us.

• others