Patents Assigned to Sanyo Special Steel Co., Ltd.
  • Patent number: 11976344
    Abstract: A Cu-based alloy powder is provided that is suitable for a process involving rapid-melting and rapid-solidification and can produce a shaped article having superior properties. The powder is made of a Cu-based alloy. The Cu-based alloy includes 0.1 to 5.0 mass % of at least one element M selected from V, Fe, Zr, Nb, Hf, and Ta. The balance in the alloy is Cu and inevitable impurities. The powder has a ratio D50/TD of a mean particle diameter D50 (?m) to a tap density TD (Mg/m3) in a range of 0.2×10?5·m4/Mg to 20×10?5·m4/Mg.
    Type: Grant
    Filed: November 6, 2018
    Date of Patent: May 7, 2024
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Tetsuji Kuse, Soichiro Maeda, Yuichi Nagatomi
  • Patent number: 11920226
    Abstract: Provided is a powder suitable for a magnetic member capable of suppressing noise in a frequency range of 100 kHz to 20 MHz. The powder for a magnetic member contains a plurality of particles 2. The main part of the particle 2 is made of an alloy. The alloy contains B. The content of B in the alloy is 5.0 mass % or more and 8.0 mass % or less. The alloy may further contain one or more elements selected from the group consisting of Cr, Mn, Co, and Ni. The content of these elements is 0 mass % or more and 25 mass % or less. The balance of the alloy is Fe and unavoidable impurities. The alloy contains an Fe2B phase. The area percentage of the Fe2B phase in the alloy is 20 mass % or more and 80 mass % or less.
    Type: Grant
    Filed: September 18, 2019
    Date of Patent: March 5, 2024
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Takahisa Yamamoto, Koudai Miura, Toshiyuki Sawada
  • Patent number: 11781204
    Abstract: Provided is a powder for metal molds that is less likely to cause solidification cracking even in a process involving rapid melt-quenching solidification. The powder for metal molds is made of an alloy. The alloy includes C: 0.25 mass % to 0.45 mass %, Si: 0.01 mass % to 1.20 mass %, Mn: more than 0 mass % to 1.50 mass %, Cr: 2.0 mass % to 5.5 mass %, and V: 0.2 mass % to 2.1 mass %. The alloy further includes at least one of Mo: more than 0 mass % to 3.0 mass %, W: more than 0 mass % to 9.5 mass %, and Co: more than 0 mass % to 4.5 mass %. The balance of the alloy is Fe and incidental impurities. The alloy satisfies the expression: (Mn %)3/S %>6.7. The total content of P, S and B in the alloy is 0.020 mass % or less.
    Type: Grant
    Filed: March 22, 2019
    Date of Patent: October 10, 2023
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventor: Yuka Saimen
  • Patent number: 11555227
    Abstract: Disclosed is a Ni—Cr-based brazing alloy including, on the basis of mass %: 15%<Cr<30%; 3%<P<12%; 0%?Si<8%; 0.01%<C<0.06%; 0%?Ti+Zr<0.1%; 0.01%<V<0.1%; 0%?Al<0.01%; 0.005%<O<0.025%; 0.001%<N<0.050%; 0%?Nb<0.1%; and the balance being Ni and incidental impurities. Inequality (1): 0.2?0.24V %/C %?1.0 is satisfied if the alloy contains no Nb, and Inequality (2): 0.2?(0.24V %+0.13Nb %)/C %?1.0 is satisfied if the alloy contains Nb. Also disclosed is an inexpensive Ni—Cr-based brazing alloy containing a trace amount of V for use in the production of stainless steel heat exchangers and other steel articles. The alloy has a low liquidus temperature and high corrosion resistance, and achieves high brazing strength.
    Type: Grant
    Filed: April 18, 2018
    Date of Patent: January 17, 2023
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Toshiyuki Sawada, Shingo Fukumoto
  • Patent number: 11430588
    Abstract: In order to provide a soft magnetic flaky powder having high electrical resistance and high corrosion resistance, and a magnetic sheet including the same, the present invention provides a soft magnetic flaky powder, including a plurality of soft magnetic flaky particles. Each of the plurality of soft magnetic flaky particles contains an Fe-based alloy flaky particle and a coating layer formed on a surface of the Fe-based alloy flaky particle. The coating layer contains one or two or more components selected from chromic acid and a hydrate thereof, and a metal salt of an inorganic acid and a hydrate thereof. The inorganic acid is selected from sulfuric acid, nitric acid, chromic acid, phosphoric acid, hydrofluoric acid and acetic acid. The metal salt is selected from a Na salt, an Al salt, a Ti salt, a Cr salt, a Ni salt, a Ga salt and a Zr salt. The coating layer has a thickness of 10 nm or more.
    Type: Grant
    Filed: December 18, 2017
    Date of Patent: August 30, 2022
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Tetsuji Kuse, Koudai Miura, Toshiyuki Sawada
  • Patent number: 11377726
    Abstract: A method of making a sputtering target in which an atomized powder including, in at. %, 10 to 50% of B, 0 to 20% in total of one or more elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, Ru, Rh, Ir, Ni, Pd, Pt, Cu, and Ag, and a balance of one or both of Co and Fe, and unavoidable impurities is provided. Fine particles are removed from the atomized powder to obtain a powder having a particle distribution where the cumulative volume of particles having a particle diameter of 5 ?m or less is 10% or less, and the cumulative volume of particles having a particle diameter of 30 ?m or less is 5-40%. The obtained powder is sintered to form a sputtering target comprising a sintered body. The sputtering target comprises hydrogen of 20 ppm or less.
    Type: Grant
    Filed: August 6, 2020
    Date of Patent: July 5, 2022
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Hiroyuki Hasegawa, Noriaki Matsubara
  • Patent number: 11276516
    Abstract: There is provided a magnetic powder for high frequency use including, in percent by mass, 0.2 to 5.0% C and at least one selected from Group IV to VI elements, Mn, and Ni in a total of 0.1 to 30%, the balance being Fe or/and Co, inclusive 0% for Co), and incidental impurities, wherein the saturation magnetization exceeds 1.0 T and satisfies Expression (1): Co%/(Co%+Fe%)?0.50. According to the magnetic powder, there is provided a metal magnetic powder having a saturation magnetization exceeding 1.0 T and also having a high FR of 200 MHz or more and a magnetic resin composition including the metal magnetic powder.
    Type: Grant
    Filed: October 26, 2017
    Date of Patent: March 15, 2022
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Toshiyuki Sawada, Kodai Miura
  • Patent number: 11273490
    Abstract: Provided is an Fe-based metal powder that is suitable for a process involving rapid melt-quenching and solidification, and that provides a shaped article having superior properties. The metal powder for shaping is made of an Fe-based alloy. The Fe-based alloy contains: Ni in an amount of 15.0% to 21.0% by mass; Co in an amount of 0% to 10.0% by mass; Mo in an amount of 0% to 7.0% by mass; Ti in an amount of 0.1% to 6.0% by mass; Al in an amount of 0.1% to 3.0% by mass; and the balance composed of Fe and incidental impurities.
    Type: Grant
    Filed: October 9, 2018
    Date of Patent: March 15, 2022
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Tetsuji Kuse, Shingo Fukumoto
  • Patent number: 11081267
    Abstract: A flaky powder for high frequency application is provided, wherein the flaky powder contains 1.5 to 3.0 mass % C, 10 to 20 mass % Cr, 0.03 to 0.30 mass % N, and the balance being Fe and incidental impurities, and has an average particle diameter of 200 ?m or less, an average thickness of 5 ?m or less, an average aspect ratio of 5 or more, a saturation magnetization of more than 1.0 T, and a frequency (FR) of 200 MHz or more at which tan ? reaches 0.1. Based on the flaky powder, a novel magnetic flaky metal powder having a saturation magnetization exceeding 1.0 T and exhibiting a high FR of 200 MHz or more, and magnetic sheets including the magnetic flaky metal powder are provided.
    Type: Grant
    Filed: October 23, 2017
    Date of Patent: August 3, 2021
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Toshiyuki Sawada, Kodai Miura
  • Patent number: 10872716
    Abstract: In order to provide a soft magnetic flaky powder that is used primarily in a member for an RFID and that has the high real part ?? of a magnetic permeability and the low imaginary part ?? of the magnetic permeability even when having an average particle diameter of 30 ?m or more, and a method for producing the soft magnetic flaky powder, the present invention provides a soft magnetic flaky powder obtained by flattening-treatment of a soft magnetic powder, in which an average particle diameter is more than 30 ?m, a coercive force measured by applying a magnetic field in the longitudinal direction of the flaky powder is in a range of 240 to 640 A/m, a saturation magnetization is 1.0 T or more, and an aspect ratio is 30 or more, and a method for producing the soft magnetic flaky powder.
    Type: Grant
    Filed: November 9, 2015
    Date of Patent: December 22, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Fumihiro Maezawa, Toshiyuki Sawada
  • Patent number: 10844476
    Abstract: An object of the present invention is to reduce particles generated in sputtering, and in order to achieve such an object, there is provided a sputtering target material including in at. %: 10 to 50% of B; and the balance of at least one of Co and Fe, and unavoidable impurities, in which the intensity ratio [I [(CoFe)3B]/I [(CoFe)2B]] of the X-ray diffraction intensity [I [(CoFe)3B]] of (CoFe)3B (121) to the X-ray diffraction intensity [I [(CoFe)2B]] of (CoFe)2B (200), the intensity ratio [I (Co3B)/I (Co2B)] of the X-ray diffraction intensity [I (Co3B)] of Co3B (121) to the X-ray diffraction intensity [I (Co2B)] of Co2B (200), or the intensity ratio [I (Fe3B)/I (Fe2B)] of the X-ray diffraction intensity [I (Fe3B)] of Fe3B (121) to the X-ray diffraction intensity [I (Fe2B)] of Fe2B (200) is 1.50 or less.
    Type: Grant
    Filed: September 16, 2016
    Date of Patent: November 24, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Hiroyuki Hasegawa, Noriaki Matsubara
  • Patent number: 10804014
    Abstract: Provided is a flaky soft magnetic powder composed of an Fe—Si—Al alloy containing Si: 5.5 to 10.5 mass %, Al: 4.5 to 8.0 mass %, and Fe and incidental impurities: balance, wherein the flaky powder exhibits a ratio (D50/TD) of 35 to 92 where D50 represents the average particle size (?m) of the powder and TD represents the tap density (Mg/m3) of the powder, and the flaky powder exhibits a coercive force of 239 to 479 A/m as measured under application of a magnetic field in an in-plane direction of the flaky powder. The flaky soft magnetic powder exhibits superior sheet formability and has high magnetic permeability.
    Type: Grant
    Filed: February 28, 2017
    Date of Patent: October 13, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Tetsuji Kuse, Kodai Miura, Fumihiro Maezawa, Toshiyuki Sawada
  • Patent number: 10669614
    Abstract: A sputtering target material, wherein the strength of a sputtering target material can be enhanced without using pure Ta to prevent cracking during sputtering and generating particles and to suppress an irregular composition of a sputtered film, is provided. The present invention provides a sputtering target material containing, in at %, 35% to 50% of Ta with the balance being Ni and an inevitable impurity, wherein the sputtering target is composed only of a Ni2Ta compound phase and a NiTa compound phase, and a microstructure in each of the Ni2Ta compound phase and the NiTa compound phase has a maximum inscribed circle diameter of not more than 10 ?m.
    Type: Grant
    Filed: May 22, 2017
    Date of Patent: June 2, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Hiroyuki Hasegawa, Yumeki Shinmura
  • Patent number: 10586637
    Abstract: In accordance with the present invention, there are provided: a soft magnetic flattened powder having an average particle diameter, excellent sheet moldability, and a high magnetic permeability; and a method for producing the soft magnetic flattened powder. The soft magnetic flattened powder according to the present invention includes an Fe—Si—Al-based alloy, an average particle diameter D50 being 30 to less than 50 ?m; a coercive force Hc measured by applying a magnetic field in the longitudinal direction of the flattened powder being 176 A/m or less; the ratio of a tap density to a true density being 0.18 or less; a specific surface area BET value being 0.6 m2/g or more; the amount of contained oxygen being 0.6 mass % or less; and the BET value and oxygen value of the soft magnetic powder satisfying expression (1): [oxygen value/BET value?0.50 mg·g/m2 (excluding zero)].
    Type: Grant
    Filed: September 29, 2015
    Date of Patent: March 10, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Fumihiro Maezawa, Toshiyuki Sawada
  • Patent number: 10576539
    Abstract: Provided is a flaky soft magnetic powder including an Fe—Si—Al alloy having an oxygen content of 0.6 mass % or less, a manganese content of 0.1 mass % to 1.0 mass %, and the balance incidental impurities. The flaky soft magnetic powder has an average particle size of 43 to 60 ?m and exhibits a coercive force Hc of 106 A/m or less as measured under application of a magnetic field in an in-plane direction of the flaky soft magnetic powder. The ratio of the tap density to the true density of the flaky soft magnetic powder is 0.17 or less. Also provided is a method of producing the flaky soft magnetic powder. The use of the flaky soft magnetic powder can produce a magnetic sheet having particularly high magnetic permeability.
    Type: Grant
    Filed: March 8, 2016
    Date of Patent: March 3, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Fumihiro Maezawa, Toshiyuki Sawada
  • Patent number: 10543571
    Abstract: A Ni—Cr—Fe-based alloy brazing filler material to which Cu is added, and which has a low melting temperature, and is inexpensive and excellent in corrosion resistance and in strength, for use in manufacture of stainless-steel heat exchangers or the like, specifically, a Ni—Cr—Fe-based alloy brazing filler material, including, in mass %, Cr: 15 to 30%; Fe: 15 to 30%; Cu: 2.1 to 7.5%; P: 3 to 12%; and Si: 0 to 8%; and the balance being Ni and unavoidable impurities, wherein the total content of Cr and Fe is 30 to 54%, and the total content of P and Si is 7 to 14%.
    Type: Grant
    Filed: December 28, 2018
    Date of Patent: January 28, 2020
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Toshiyuki Sawada, Shingo Fukumoto
  • Patent number: 10273838
    Abstract: Provided is a valve seat insert made of an iron-base sintered alloy, in which a base matrix part that includes a base matrix phase and hard particles, has a base matrix part composition containing, in % by mass, 0.5%-2.0% of carbon and 10%-70% in total of one kind or two or more kinds selected from nickel, cobalt, chromium, molybdenum, vanadium, tungsten, manganese, silicon and sulfur, with the balance being iron and unavoidable impurities, and Co-base hard particles having a composition containing, 1.0% or less of C, 25%-50% of Mo, 5%-15% of Cr, Si as an impurity in a content adjusted to be 0.3% or less, with the balance being Co, and having a Vickers hardness of 500 to 1,500 HV, are dispersed as hard particles in the base matrix phase in an amount of 10%-60% by mass with respect to the total amount of the valve seat insert.
    Type: Grant
    Filed: December 21, 2016
    Date of Patent: April 30, 2019
    Assignees: NIPPON PISTON RING CO., LTD., HONDA MOTOR CO., LTD., SANYO SPECIAL STEEL CO., LTD.
    Inventors: Satoshi Ikemi, Hiroshi Oshige, Seisuke Takaki, Tomoki Okita, Keisuke Ishii, Toshiyuki Sawada, Hiroyuki Hasegawa
  • Patent number: 10265767
    Abstract: It is an object of the present invention to provide an alloy powder that has high hardness and high corrosion resistance and can be produced from inexpensive raw materials, as well as to provide a shot material for shot peening, a powder metallurgical composition, and an iron-based sintered alloy using the alloy powder, and, in order to achieve such an object, there are provided an alloy powder including, in mass %, C: 0.6% or more and 2.4% or less, Cr: 36% or more and 60% or less, Mn: 0.1% or more and 10% or less, Mo: 0% or more and 10% or less, Si: 0% or more and less than 2%, Ni: 0% or more and 15% or less, Co: 0% or more and 5% or less, W: 0% or more and 5% or less, V: 0% or more and 5% or less, Nb: 0% or more and 5% or less, and the balance of Fe and unavoidable impurities, as well as the shot material for shot peening, the powder metallurgical composition, and the iron-based sintered alloy using the alloy powder.
    Type: Grant
    Filed: May 25, 2016
    Date of Patent: April 23, 2019
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventor: Toshiyuki Sawada
  • Patent number: 10060013
    Abstract: There is provided a steel, having an excellent rolling fatigue life, wherein an oxygen content in the steel is 8 ppm or less, a sulfur content is 0.008 mass % or less, and an Al content is 0.005 to 0.030 mass %, the number of non-metallic inclusions having an inclusion diameter of 20 ?m or more and less than 100 ?m, detected per steel material volume of 1000 mm3 by ultrasonic flaw detection, is 12.0 or less, the number of non-metallic inclusions having an inclusion diameter of 100 ?m or more, detected per steel material weight of 2.5 kg by the ultrasonic flaw detection, is 2.0 or less, the mass % ratio of (MgO)/(Al2O3) in the average composition of MgO—Al2O3-based oxides present in the steel is regulated into a range of 0.25 to 1.50, and the number ratio of the MgO—Al2O3-based oxides to all oxide-based inclusions is 70% or more.
    Type: Grant
    Filed: August 7, 2014
    Date of Patent: August 28, 2018
    Assignee: Sanyo Special Steel Co., Ltd.
    Inventors: Takeshi Fujimatsu, Norimasa Tsunekage, Ichiro Takasu
  • Patent number: 10058922
    Abstract: The object of the present invention is to provide a compact for producing a sintered alloy which allows a sintered alloy obtained by sintering the compact to have improved mechanical strength and wear resistance, a wear-resistant iron-based sintered alloy, and a method for producing the same. The wear-resistant iron-based sintered alloy is produced by: forming a compact for producing a sintered alloy from a powder mixture containing a hard powder, a graphite powder, and an iron-based powder by powder compacting; and sintering the compact for producing a sintered alloy while diffusing C in the graphite powder of the compact for producing a sintered alloy in hard particles that constitute the hard powder. The hard particles contain 10% to 50% by mass of Mo, 3% to 20% by mass of Cr, and 2% to 15% by mass of Mn, with the balance made up of incidental impurities and Fe, and the hard powder and the graphite powder contained in the powder mixture account for 5% to 60% by mass and 0.5% to 2.
    Type: Grant
    Filed: July 31, 2015
    Date of Patent: August 28, 2018
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, FINE SINTER CO., LTD, SANYO SPECIAL STEEL CO., LTD
    Inventors: Nobuyuki Shinohara, Kimihiko Andou, Yoshihisa Ueda, Yusaku Yoshida, Masaru Sugimoto, Toshiyuki Sawada, Shingo Fukumoto