ネツレン　高周波熱錬株式会社 List of Products and Services

This is a steering rack bar made using hollow material (pipe). Mass production began in 1997, and we have delivered over 16 million units, primarily for lightweight vehicles with high VGR (Variable Gear Ratio) needs. 【Features】 - It enables weight reduction of up to 50% compared to solid materials. - It supports VGR, improving steering stability and contributing to the downsizing of EPS (Electric Power Steering) motors. We have developed and started mass production of the "Hybrid Rack Bar / Rack Bar combining hollow and solid rack bars for DP-EPS (Dual Pinion Electric Power Steering)." *In 2019, it won the "Mobility-related Parts Award" at the "Super Manufacturing Parts Grand Prize."

• Flight control parts

We manufacture and sell pre-hardened materials with excellent straightness by performing high-frequency heat treatment on various special steel materials, including structural steel, die steel SKD61, high-speed tool steel SKH51, and stainless steel. In response to customer requirements, we deliver products in a form that is closer to a finished product, including centerless grinding, cutting to product length, center hole processing, and chamfering. 【Features of Netsuren Pre-Hardened Materials】 - We deliver straight materials even for steel types with significant heat treatment warping or thin diameter materials, eliminating (or greatly reducing) the need for correction processing. (Example: SUS440C φ2.0x2200L warping below 30μm) - Due to short-time quenching with high-frequency heating, almost no decarburization layer occurs on the surface, allowing for reduced grinding allowance in subsequent processes. (Process shortening, resource conservation) - We also accommodate centerless grinding, providing materials with industry-leading roundness and cylindricity. (Example: AISI4150 roundness below 2μm, cylindricity below 3μm) - Not only surface hardening but also through hardening is possible. - We can also accommodate hollow materials.

• Steel

In conventional heat treatment using furnaces, it was difficult to apply heat to only the necessary parts of the steel material, as heat was applied to the entire steel. However, by utilizing high-frequency induction heating (IH) to selectively high-frequency quench only a portion of the steel (enhancing strength and durability), multiple strengths have been achieved with a single steel rod. By placing high-strength sections in areas where the integrity of structures and components must be ensured, and low-strength sections in other areas, damage control and reduction of materials are possible. Using this technology and product, we have started selling high-strength rebar placed in column and beam joints that contribute to damage control of structures, reduction of rebar quantity, improved workability, and comfortable living spaces, named "Double Stark®." *In 2018, we received the "Super" Monozukuri Parts Award and the Lifestyle-Related Parts Award.

• Steel

This is a technology that allows for the formation of a flange (creating a bulge on the shaft) through plastic processing without cutting or forging the shaft material. It has been successfully applied in gear pump shafts, intermediate shafts, ball screws, etc. 【Features】 - There is no material loss. (It can also handle difficult-to-machine materials such as titanium.) - Processing time can be significantly reduced compared to cutting processes. - Flanging can be performed on large diameter and long products. (Up to φ70mm, up to L600mm) - Since it is not a hot processing method, CO2 emissions can be significantly reduced.

• Processing Contract

We design, manufacture, and engineer equipment and systems to achieve inline induction heating, energy saving, and labor saving in various industrial fields such as the automotive, construction machinery, machine tool, steel, chemical, and home appliance industries. As service bases, we have locations in Kanagawa and Nagoya, as well as overseas in the United States, China, Indonesia, Mexico, and South Korea, providing global support and services. We commercialize high-frequency power supply devices using SCR, IGBT, MOSFET, and SiC semiconductors, with a frequency range of 0.5 to 400 kHz and power output from 2.5 to 2,000 kW. Additionally, we have practical applications for CAE analysis up to metal transformation and "low (constant) deformation contour quenching technology" for gears and shafts, enabling us to provide equipment with high quality stability in heat treatment. *Induction heating (IH) technology uses green electricity as a heat source and contributes to the reduction of CO2 emissions.

• Other surface treatment equipment

The 'High-Strength Shear Reinforcement Bar Ulbon 1275' is a deformed PC steel bar certified by the Minister of Land, Infrastructure, Transport and Tourism, with a yield point of 1275 N/mm² and a tensile strength of 1275 N/mm². Compared to conventional ordinary rebar (SD bar), it can achieve design stresses up to four times greater, significantly reducing the amount of rebar used and contributing to improved work efficiency, cost reduction, and shortened construction periods on site (resource conservation, CO2 reduction). Additionally, by accommodating the high-strength requirements of columns and beams in reinforced concrete (RC) structures, it enables the construction of super-tall buildings over 60 meters. * A design method using bond-splitting reinforcement bars has been established, allowing for reinforcement of up to 1.5% as P_w + P_b (bond-splitting reinforcement ratio) based on plastic theory shear strength formulas and patented methods by Netsuren.

• Steel

The "High Strength Shear Reinforcement Bar Ulbon 1275" is a deformed PC steel bar certified by the Minister of Land, Infrastructure, Transport and Tourism, with a yield point of 1275 N/mm² and a tensile strength of 1275 N/mm². Compared to conventional ordinary rebar (SD bars), it can achieve a design stress up to four times greater, significantly reducing the amount of rebar used and contributing to improved work efficiency, cost reduction, and shortened construction periods at job sites (resource conservation, CO2 reduction). With the addition of the new bar diameter U11.8 to the lineup, further design options tailored to various member cross-sectional widths have become possible. The new bar diameter U11.8 demonstrates effectiveness in column sections of 1,100 mm square for heights of 30 to 60 m (levels 10 to 20), allowing for approximately a 10% further reduction in rebar quantity compared to conventional diameters. * The new bar diameter U11.8 has obtained certification from the Minister of Land, Infrastructure, Transport and Tourism and evaluation from the Japan Architectural Center (general construction method and welded joint method).

• Steel

The 'High-Strength Shear Reinforcement Bar Ulbon 1275' is a deformed PC steel bar certified by the Minister of Land, Infrastructure, Transport and Tourism, with a yield point of 1275 N/mm² and a tensile strength of 1275 N/mm². Compared to conventional ordinary rebar (SD bars), it can achieve a design stress up to four times greater, significantly reducing the amount of rebar used and contributing to cost and schedule reductions for customers (resource conservation, CO2 reduction). This time, we obtained performance evaluation from the Better Living Foundation for the calculation formula of the required bond length for the cutoff of the second main bar of beams using 'Ulbon 1275'. By using this new calculation formula, it has become possible to reduce costs (shortening the length of the second main bar and reducing the number of joints) and shorten construction time (reducing installation and inspection work hours). - It is possible to reduce the number of joints by 30-50% compared to conventional methods. - The reduction in joint locations leads to decreased installation and inspection work hours. - We have prepared a calculation tool (utilizing CSV data) for calculating cutoff lengths. *Cost comparisons with other products can be calculated. Please feel free to contact us.

• Steel

This is a spiral shear reinforcement bar used as shear reinforcement for cast-in-place piles. The only high-strength shear reinforcement bar that has received certification and general evaluation from the Minister of Land, Infrastructure, Transport and Tourism is "Ulvon 1275(R)." 【Features】 - Reducing the pile cross-section allows for cost reduction and shorter construction periods. - Using high-strength shear reinforcement bars significantly improves deformation capacity. - The diameter of the shear reinforcement bars can be reduced compared to using ordinary rebar, resulting in a decrease in the amount of rebar used. Additionally, the workability of the concrete is improved. - Since on-site welding is not required, work can be carried out even in rainy weather, ensuring consistent quality. - The strength of the piles is increased, and performance is enhanced.

• Steel

Since its establishment in 1946, Netsuren has commercialized high-efficiency and highly reliable high-frequency power supply devices as a pioneer in induction heating, leveraging advanced technology and extensive experience for various applications. The Netsuren MK series high-frequency power supply devices offer a wide range of outputs (2.5 to 2,000 kW) and frequencies (0.3 to 400 kHz) using SCR, IGBT, MOSFET, and SiC semiconductors. 【Features】 - Industry-leading stability and high reliability - High efficiency, compact design, and reduced cooling water requirements - Easy maintenance and inspection, comprehensive after-sales service - Excellent safety design (reliable protection circuits)

• Other surface treatment equipment

The "Pre-Grout PC Steel Bar," developed to prevent insufficient grout filling at construction sites, is shipped from our controlled factory with the PC steel bar coated in grout and a sheath. This eliminates the need for sheath placement and grout work at the construction site, contributing to improved work efficiency, shortened construction periods, and enhanced reliability of structures. We also provide coupler sheaths treated for rust prevention for use at the connection points. 【Features】 - The surface of the PC steel bar is coated with pre-grout resin and high-density polyethylene sheath, providing excellent corrosion resistance (tested for salt spray and alkali resistance). - The elimination of sheath placement and grout work at the site contributes to labor reduction. - The use of PC steel bars as tensioning materials offers excellent self-support and connectivity, improving work efficiency. - It is possible to select pre-grout resins suitable for various environments (moisture-curing type, heat-curing type).

• Steel

PC steel bars are high-strength steel bars used in prestressed concrete, which improves the properties of concrete that is weak in tension by applying compressive forces in advance, thereby significantly enhancing the strength of concrete structures. They are used to continuously compress the concrete at a high stress level of 80% of the yield point. Netsuren PC steel bars have been widely used for over half a century in various applications including foundation concrete piles, concrete poles for power transmission and communication, concrete sleepers for railways, sewer systems, and box culverts for utility trenches, as well as in bridges and buildings. 【Features】 - Manufactured under one of the best quality control systems in the country, they possess stable mechanical properties and relaxation characteristics. - The ends are processed with rolled threads, allowing for anchoring. - Unbonded PC steel bars with a special asphalt-based polymer coating on the surface are also available.

• Steel

Neji-Bon(R) is a fully threaded PC steel bar that has a thread shape similar to that of mechanical joints used in reinforced concrete construction and provides mechanical properties equivalent to PC steel bars. 【Features】 - Since the thread rolling process is not required, it can be cut to any desired length on the construction site and fixed in place. - It can be supplied as a set with fixation accessories. - Upon request, we also offer epoxy resin coating with excellent rust prevention properties.

• Steel

The NAPP method involves placing pre-tensioned hollow PC steel rods, called "NAPP units (R)," within a formwork, and after pouring and curing the concrete, releasing the tension to introduce prestress into the concrete. The tension is introduced at our factory, which is strictly managed, and delivered to the site. At the construction site, prestress can be applied without the use of reaction abutments or hydraulic jacks, and the complicated management of tension, sheath placement, and grouting is not required. This method particularly enhances efficiency in work environments where it is difficult to introduce prestress, such as at high altitudes. ■ Examples of NAPP method implementation Reinforcement of external cable anchorage, reinforcement of misalignment areas, reinforcement of PC steel anchorage, shear reinforcement, and lateral tightening. ■ Examples of NAPP anchor method implementation Widening of existing bridge abutment edges, reinforcement of external cable anchorage, and reinforcement of bridge substructures (widening of low slabs).

• Steel

As a pioneer in high-strength spring steel wire for cold forming, we supply globally (Production bases: Japan, China, the United States, Europe). Netsuren "ITW(R)" imparts the necessary mechanical properties to carefully selected materials through high-frequency quenching and high-frequency tempering, and conducts quality assurance over the entire length through eddy current testing for defects and monitoring of heat treatment temperatures. We manufacture in units of one coil, ensuring uniform wire diameter and strength throughout the entire length. Additionally, the variation between product coils is kept to a minimum. [Features when formed into springs] - Variation in shape is minimized. - High strength allows for the formation of springs with a small D/d ratio. - Both durability and resistance to deformation are at the highest level. - High operating stress can be achieved, enabling weight reduction. - Spring manufacturing through cold forming significantly reduces CO2 emissions compared to hot forming.

• Spring

Netsuren "ITW(R)" imparts the necessary mechanical properties to carefully selected materials through high-frequency quenching and high-frequency tempering, conducts flaw inspections along the entire length using eddy current testing, and ensures quality assurance along the entire length by monitoring heat treatment temperatures. It is manufactured on a per-coil basis, achieving uniform wire diameter and strength throughout the entire length. Additionally, the variation between product coils is kept to a minimum.

• Spring

This is a steel rod that has been softened to below 1200 MPa in the surface layer, which is the starting point for delayed fracture, in relation to high-strength steel materials (tensile strength reference: 1200–2200 MPa), thereby reducing the risk of delayed fracture (patent obtained). By applying this technology, the delayed fracture characteristics (hydrogen embrittlement resistance) of high-strength steel materials and high-stress components can be significantly improved, and the softening of the surface layer enhances machinability, making machining easier. It has been mass-produced for high-stress spring steel wire, high-strength deformed PC steel rods, etc.

• Steel
• Special Steel

The irregular PC steel bar "Ulbon(R)" is a high-strength PC steel bar that excels in adhesion performance with concrete and spot weldability. Due to its excellent performance and ease of use, it has received high praise in the pile and pole industry and is widely used as a tensioning material. 【Features】 - Under appropriate working conditions, using a spot welding automatic assembly machine for rebar cage assembly does not significantly reduce mechanical properties. - It has very little relaxation and remains stable even over long periods. - The surface of the steel bar is shaped with spiral grooves along its entire length, providing excellent adhesion to concrete. - When unwound, the coil material becomes straight, eliminating the need for straightening work. - The cross-sectional shape is uniform along its entire length, allowing for direct rolling screw processing. - Our warm forging system enables head processing without reducing mechanical properties, allowing for economical fixation.

• Steel
• Other metal materials

This is an advanced version of the high-frequency power supply device "MK16A type." By digitizing the control mechanism (FPGA: field-programmable gate array), it becomes possible to accommodate a wider variety of production compared to the existing model. It is also capable of recording operational data independently of the power supply unit, thus meeting customer demands for "preventive maintenance." It can be manufactured in a wide output range (50 to 1200 kW) for small to large components.

• Other power sources

This is a general-purpose vertical single-axis machine. Custom-made design and production tailored to customer needs, including compatible models, is also possible. If production as a standard Netsuren machine is feasible, we will also propose cost advantages. It can be combined with various output high-frequency power supplies, allowing for heat treatment and heating equipment that meets customer specifications.

• Other machine elements
• Other processing machines

This is a device for measuring the cooling capacity of the quenching liquid that is used regularly. The cooling capacity of the quenching liquid changes with daily use. By using Netsuren's "Cooling Capacity Measurement Device," you can manage daily cooling capacity as well as determine the timing for replacing the quenching liquid.

• Analytical Equipment and Devices

We contribute to the stable operation of our customers with a comprehensive after-sales service menu even after the equipment is delivered. We also offer preventive maintenance options such as regular inspections of high-frequency power supplies. We provide global support, including two locations in Japan and facilities in the United States, China, Indonesia, Mexico, and South Korea.

• Other machine elements
• Other processing machines

We provide a reliable quality assurance system for various parts, such as engines and undercarriage components, where "safety" is prioritized. Our contract processing has support bases in four domestic factories (Ibaraki, Aichi, Hyogo, Okayama) and three overseas countries (China, Indonesia, Mexico), enabling us to accommodate our customers' global expansion.

• Other Auto Parts
• Engine parts

We handle various parts from light vehicles to large trucks. We have established a mass production system and are producing with a consistent quality assurance system. We also accommodate heat treatment and painting processes. *Prototype production is also available, so please feel free to contact us.

• Drive system parts

We can also perform high-frequency heat treatment on oversized components. We cater to a wide range of heavy and large industrial machinery, including construction machinery. (Large double helical gear Φ1180mm, approximately 26t) *We will accommodate your requested heat treatment specifications.

• gear

We accommodate a variety of vehicles, from light cars to large trucks. We have also established a mass production system and are producing under a consistent quality assurance system. *Prototype production is also available, so please feel free to contact us.

• gear

We can also perform high-frequency heat treatment on oversized components. We propose various heat treatment methods for oversized parts, including mobile quenching and single-shot quenching. (Large wheel component Φ1600mm) *We will accommodate your requested heat treatment specifications.

• roller

We provide integrated manufacturing not only for conventional heat treatment processes but also for material procurement to finishing processes. We can accommodate your requests, including handling only specific processes if needed. Additionally, we can support integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, we can also expect a reduction in CO2 emissions in terms of transportation.

• roller

We provide integrated manufacturing not only for conventional heat treatment processing but also for material procurement to finishing processes. We can accommodate your requests, including handling only specific processes if needed. Additionally, we can manage integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, we can also expect CO2 reduction in transportation.

• gear

Since its establishment in 1946, Netsuren has been a pioneer in induction heating, receiving requests for "surface heat treatment processing" that contributes to the improvement of the mechanical properties of steel components from various industries such as automotive, construction machinery, machine tools, and steelmaking, thanks to its advanced heat treatment technology and extensive track record. We have four domestic factories (in Ibaraki, Aichi, Hyogo, and Okayama) and bases in three overseas countries (China, Indonesia, and Mexico), enabling us to support our customers' global expansion. We also accommodate various prototype requests, so please feel free to consult with your nearest sales office.

• Other machine elements

By incorporating the preceding and subsequent processes into conventional heat treatment contract processing, we can handle everything from material procurement to processing, various heat treatments, finishing, and assembly, delivering "completed parts." Since everything is completed solely by Netsuren, we provide a consistent quality assurance system and reduce our customers' "multi-process management." We primarily operate from two domestic factories (Ibaraki Prefecture and Hyogo Prefecture). For any inquiries regarding various projects, please feel free to consult your nearest sales office.

• Other machine elements

We provide integrated manufacturing not only for conventional heat treatment processing but also for material procurement to finishing processes. We can accommodate your requests, including handling only specific processes if needed. Additionally, we can support integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, CO2 reduction in transportation can also be expected.

• roller

When using water-soluble quenching fluids, the cooling rate can change due to thermal degradation and contamination. If management is conducted solely with a concentration meter, it may not necessarily align with the quality of the quenching process. Our cooling capability measurement service can assist in high-quality cooling fluid management by measuring the "cooling rate" with our specially developed measurement equipment. This can be utilized as data for improving quality assurance levels and determining the timing for coolant replacement.

• Contract measurement
• Contract Analysis
• Heating device

Butted processing allows for flexible adjustment of the thickness of pipe materials through inner and outer diameter drawing. It enables inner diameter slimming without cutting! This contributes to weight reduction and material cost savings. Additionally, even in thin sections, performing IH heat treatment provides high strength and high toughness, achieving high bending fatigue strength. Example) "Before processing" Weight: 704g Total length: 300mm ↓ "After butted processing" Weight: 576g Total length: 300mm - Reduction rate: 49% - Wall thickness (thinning): -31.9% - Weight reduction: 18.2%

• Steel
• alloy
• Special Steel

This is a equipment sales plan available for a fixed fee (monthly or annually). Please consult with us.

• Heating device

This is a subscription plan for the Netsuren equipment you are currently using. Please feel free to consult us regarding the details.

• Heating device

The Mild Carburizing Process was developed in 2006 by Aisin Corporation (formerly Aisin AW Co., Ltd.) and is a heat treatment technology that has already been mass-produced for gears, bearing races, shafts, and more. By combining vacuum carburizing and high-frequency quenching, it leverages the advantages of both processes and exhibits the following features: - Enables longer lifespan, as well as miniaturization and weight reduction of components - Simplifies the finishing process - Reduces material costs and improves machinability - Contributes to carbon neutrality *The Mild Carburizing Process is a patented technology of Aisin Corporation. Our company conducts heat treatment contract processing under license.

• Engine parts
• Heating device
• Metal bearings