Patents by Inventor Atsuo Ota
Atsuo Ota has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11884995Abstract: There is provided a Co-based alloy material, having a chemical composition including: Al of 0.1 to 10 mass %; W of 3 to 45 mass %, the total content of Al and W being 50 mass % or less; O of 0.007 to 0.05 mass %; and the balance being Co and impurities, wherein in ? phase crystal grains as a matrix phase of the Co-based alloy material, segregation cells within an average size of 0.15 to 1.5 ?m are formed, wherein in the segregation cells, ?? phase grains within a size of 0.01 to 0.5 ?m including Co, Al and W are dispersively precipitated, and wherein on boundary regions of the segregation cells and grain boundaries of the ? phase crystal grains, ? phase grains within a size of 0.005 to 2 ?m including Co and W are dispersively precipitated.Type: GrantFiled: August 30, 2022Date of Patent: January 30, 2024Assignee: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Atsuo Ota, Shinya Imano
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Publication number: 20230094413Abstract: The present invention relates to a Co-based alloy product including a polycrystal of a Co-based alloy, the Co-based alloy including: 0.001 mass %?C<0.100 mass %; 9.0 mass %?Cr<20.0 mass %; 2.0 mass %?Al<5.0 mass %; 13.0 mass %?W<20.0 mass %; and 39.0 mass %?Ni<55.0 mass %, with the balance being Co and unavoidable impurities, in which the Co-based alloy product comprises segregated cells formed inside a crystal grain of the polycrystal, the segregated cells have an average size of 1 ?m or larger and 100 ?m or smaller, and the segregated cells contain Al and Cr, and a method for producing the Co-based alloy product.Type: ApplicationFiled: September 27, 2022Publication date: March 30, 2023Inventors: Shigenobu EGUCHI, Shinya Imano, Atsuo Ota, Kenji Sugiyama, Yoshiki Kumagai
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Publication number: 20230070692Abstract: There is provided a Co-based alloy material, having a chemical composition including: Al of 0.1 to 10 mass %; W of 3 to 45 mass %, the total content of Al and W being 50 mass % or less; O of 0.007 to 0.05 mass %; and the balance being Co and impurities, wherein in ? phase crystal grains as a matrix phase of the Co-based alloy material, segregation cells within an average size of 0.15 to 1.5 ?m are formed, wherein in the segregation cells, ?? phase grains within a size of 0.01 to 0.5 ?m including Co, Al and W are dispersively precipitated, and wherein on boundary regions of the segregation cells and grain boundaries of the ? phase crystal grains, ? phase grains within a size of 0.005 to 2 ?m including Co and W are dispersively precipitated.Type: ApplicationFiled: August 30, 2022Publication date: March 9, 2023Applicant: MITSUBISHI HEAVY INDUSTRIES, LTD.Inventors: Atsuo Ota, Shinya Imano
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Patent number: 11566313Abstract: Provided is a method for manufacturing an Ni-based alloy member in which the equilibrium amount of ?? phase precipitation at 700° C. is from 30 to 70 volume %. The method includes the steps of preparing an Ni-based alloy powder having a predetermined chemical composition; forming a precursor body wherein an average grain diameter of the ? phase grains is 50 ?m or less, by using the Ni-based alloy powder; and heating the precursor body to a temperature at least the ?? phase solvus temperature and subsequently slow-cooling the heated precursor body from the temperature to a temperature at least 100° C. lower than the ?? phase solvus temperature at a cooling rate of 100° C./h or lower. There is obtained a softened body in that the ?? phase particles of at least 20 volume % precipitate between/among the ? phase grains having an average grain diameter of 50 ?m or less.Type: GrantFiled: August 8, 2018Date of Patent: January 31, 2023Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Atsuo Ota, Shinya Imano
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Patent number: 11401597Abstract: This method for manufacturing a high-temperature component formed of a Ni-based alloy includes a step of subjecting a workpiece of the Ni-based alloy to hot die forging using predetermined dies to form a forge-molded article, the step including: a die/workpiece co-heating substep of heating the workpiece interposed between the dies to a forging temperature; and a hot forging substep of taking out the workpiece and the dies into a room temperature environment and immediately performing hot forging on the workpiece using a press machine. The predetermined dies are formed of another Ni-based superalloy comprising ? and ?? phases, and have features in that: a solvus temperature of the ?? phase is 1050-1250° C.; and the ?? phase precipitates at least 10 vol. % at 1050° C. and has two kinds of forms of intra-grain ?? phase precipitations within the ? phase grains and inter-grain ?? phase precipitations between/among the ? phase grains.Type: GrantFiled: April 25, 2021Date of Patent: August 2, 2022Assignee: Mitsubishi Heavy Industries, Ltd.Inventors: Atsuo Ota, Shinya Imano
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Publication number: 20220220585Abstract: There is provided a cobalt-based alloy material comprising: in mass %, 0.08-0.25% C; 0.003-0.2% N, the total amount of C and N being 0.083-0.28%; 0.1% or less B; 10-30% Cr; 5% or less Fe and 30% or less Ni, the total amount of Fe and Ni being 30% or less; W and/or Mo, the total amount of W and Mo being 5-12%; Al and/or Si, at least one of Al and Si being more than 0.5% and 3% or less, and the total amount of Al and Si being more than 0.5% and 4% or less; 0.5% or less Mn; 0.5-4% of an M component being a transition metal other than W and Mo and having an atomic radius of more than 130 pm; and the balance being Co and impurities. There is also provided a product formed from the cobalt-based alloy material.Type: ApplicationFiled: September 4, 2020Publication date: July 14, 2022Applicant: Mitsubishi Heavy Industries, Ltd.Inventors: Yuting WANG, Shinya IMANO, Atsuo OTA
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Publication number: 20220220583Abstract: A Co-based alloy structure includes: a matrix phase (? phase) having an fcc structure and containing mainly Co; and a precipitated phase (?? phase) that contains an intermetallic compound having an L12 fcc structure, such as Co3(Al,W) in terms of an atomic ratio, and that is dispersively precipitated in the matrix phase. The Co-based alloy structure is configured to include the ?? phase having a grain size of 10 nm to 1 ?m, and grains of the ?? phase uniformly disposed and precipitated, and to have a precipitation amount of 40 vol % to 85 vol %.Type: ApplicationFiled: December 2, 2020Publication date: July 14, 2022Applicant: Mitsubishi Heavy Industries, Ltd.Inventors: Atsuo OTA, Shinya IMANO
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Publication number: 20210381084Abstract: There is provided a cobalt-based alloy product comprising: in mass %, 0.08-0.25% C; more than 0.04% and 0.2% or less N, the total amount of C and N being more than 0.12% and 0.28% or less; 0.1% or less B; 10-30% Cr; 5% or less Fe and 30% or less Ni, the total amount of Fe and Ni being 30% or less; W and/or Mo, the total amount of W and Mo being 5-12%; 0.5% or less Si; 0.5% or less Mn; 0.5 to 2 mass % of an M component being a transition metal other than W and Mo and having an atomic radius of more than 130 pm; and the balance being Co and impurities. The product comprises matrix phase crystal grains, in which particles of MC carbides, M(C,N) carbonitrides and/or MN nitrides including the M component are precipitated at an average interparticle distance of 0.13-2 ?m.Type: ApplicationFiled: September 4, 2020Publication date: December 9, 2021Applicant: MITSUBISHI POWER, LTD.Inventors: Atsuo OTA, Shinya IMANO, Yuting WANG, Yasuhiro AKIYAMA
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Publication number: 20210340644Abstract: An objective of the invention is to provide an Ni-based alloy softened powder that is formed of a high precipitation-strengthened Ni-based alloy material, has better forming/molding processability than ever before, and is suitable for powder metallurgy. The Ni-based alloy softened powder has a chemical composition allowing ?? phase precipitated in ? phase as a matrix to have an equilibrium precipitation amount of 30-80 volume % at 700° C., has an average particle size of 5-500 ?m, and includes particles comprising a polycrystalline body of fine crystals of the ? phase. The ?? phase is precipitated on grain boundaries of the ? phase fine crystals in an amount of 20 volume % or more. And, the particles have a Vickers hardness of 370 Hv or less at room temperature.Type: ApplicationFiled: February 4, 2019Publication date: November 4, 2021Inventors: Atsuo OTA, Shinya IMANO
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Publication number: 20210331239Abstract: There is provided a manufacturing method of a Ni-based alloy repaired member having a repair piece formed at a damaged portion of a base material. The base material and the repair piece are made of a high precipitation-strengthened Ni-based alloy material. The manufacturing method includes the steps of: preprocessing a surface of the damaged portion; preparing a Ni-based alloy powder having a predetermined chemical composition; depositing a sprayed piece on the damaged portion by a high-speed collision spraying process using the Ni-based alloy powder; subjecting the sprayed piece to a predetermined heat treatment so that the sprayed piece is thermally refined to a softened sprayed piece; processing the softened sprayed piece into a shaped sprayed piece with a desired shape; and subjecting whole of the shaped sprayed piece and the base material to a predetermined heat treatment so that the shaped sprayed piece is thermally refined to the repair piece.Type: ApplicationFiled: January 26, 2021Publication date: October 28, 2021Inventors: Takeshi IZUMI, Atsuo OTA
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Publication number: 20210301723Abstract: There is provided a gas turbine combustor which includes a fuel nozzle which is high in damping performance against vibration stress caused by unstable combustion, in the gas turbine combustor which includes the fuel nozzle which is molded by 3D additive manufacturing. In the gas turbine combustor which includes the fuel nozzle which is molded by the 3D additive manufacturing, the fuel nozzle has a first region on which metal powders are sintered and a second region which is surrounded by the first region and on which the metal powders are not sintered.Type: ApplicationFiled: January 12, 2021Publication date: September 30, 2021Inventors: Satoshi KUMAGAI, Kota NAGANO, Atsuo OTA
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Publication number: 20210246538Abstract: This method for manufacturing a high-temperature component formed of a Ni-based alloy includes a step of subjecting a workpiece of the Ni-based alloy to hot die forging using predetermined dies to form a forge-molded article, the step including: a die/workpiece co-heating substep of heating the workpiece interposed between the dies to a forging temperature; and a hot forging substep of taking out the workpiece and the dies into a room temperature environment and immediately performing hot forging on the workpiece using a press machine. The predetermined dies are formed of another Ni-based superalloy comprising ? and ?? phases, and have features in that: a solvus temperature of the ?? phase is 1050-1250° C.; and the ?? phase precipitates at least 10 vol. % at 1050° C. and has two kinds of forms of intra-grain ?? phase precipitations within the ? phase grains and inter-grain ?? phase precipitations between/among the ? phase grains.Type: ApplicationFiled: April 25, 2021Publication date: August 12, 2021Inventors: Atsuo OTA, Shinya IMANO
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Patent number: 11021780Abstract: This method for manufacturing a high-temperature component formed of a Ni-based alloy includes a step of subjecting a workpiece of the Ni-based alloy to hot die forging using predetermined dies to form a forge-molded article, the step including: a die/workpiece co-heating substep of heating the workpiece interposed between the dies to a forging temperature; and a hot forging substep of taking out the workpiece and the dies into a room temperature environment and immediately performing hot forging on the workpiece using a press machine. The predetermined dies are formed of another Ni-based superalloy comprising ? and ?? phases, and have features in that: a solvus temperature of the ?? phase is 1050-1250° C.; and the ?? phase precipitates at least 10 vol. % at 1050° C. and has two kinds of forms of intra-grain ?? phase precipitations within the ? phase grains and inter-grain ?? phase precipitations between/among the ? phase grains.Type: GrantFiled: November 16, 2016Date of Patent: June 1, 2021Assignee: Mitsubishi Power, Ltd.Inventors: Atsuo Ota, Shinya Imano
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Publication number: 20200306674Abstract: To provide a metal filter having a small number of production steps and having high filtration performance, and a production method therefor. A mesh filter portion having a filtration function and a support portion that includes plural beam members supporting the mesh filter portion are seamlessly continuous to each other.Type: ApplicationFiled: December 18, 2019Publication date: October 1, 2020Applicant: MITSUBISHI HITACHI POWER SYSTEMS, LTD.Inventors: Atsuo OTA, Shinya IMANO
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Publication number: 20200277692Abstract: In a manufacturing method of a turbine rotor blade using an Ni-based forged alloy, provided is a turbine rotor blade and a member of a turbine rotor blade having an excellent workability and a high degree of freedom in the design of a cooling structure. The turbine rotor blade includes at least two members, including a first member and a second member, and each member is provided with cooling structural parts acting as cooling flow passages. The turbine rotor blade has a joint that integrates the first member and the second member, wherein the joint has a forged structure and the whole turbine rotor blade including the joint has a uniform forged structure.Type: ApplicationFiled: May 14, 2020Publication date: September 3, 2020Inventors: Atsuo OTA, Shinya IMANO
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Publication number: 20200131614Abstract: To provide a manufacturing process of a Ni based superalloy and a member of the Ni based superalloy which achieves both of excellent workability in a manufacturing step of the Ni based superalloy of the precipitation strengthening type which contains much amount of the gamma prime phase and excellent high temperature strength of the Ni based superalloy. The manufacturing process of a Ni based superalloy includes a step for working the Ni based superalloy softening material into a desired shape and a solution-aging step for obtaining a Ni based superalloy member. The composition of the Ni based superalloy contains, in mass %, 10% or more and 25% or less of Cr, 30% or less of Co, 3% or more and 9% or less of the total of Ti, Nb and Ta, 1% or more and 6% or less of Al, 10% or less of Fe, 10% or less of Mo, 8% or less of W, 0.03% or less of B, 0.1% or less of C, 0.08% or less of Zr, 2.0% or less of Hf, and 5.Type: ApplicationFiled: December 23, 2019Publication date: April 30, 2020Inventors: Atsuo Ota, Shinya Imano, Hironori Kamoshida
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Publication number: 20200056275Abstract: This method for manufacturing a high-temperature component formed of a Ni-based alloy includes a step of subjecting a workpiece of the Ni-based alloy to hot die forging using predetermined dies to form a forge-molded article, the step including: a die/workpiece co-heating substep of heating the workpiece interposed between the dies to a forging temperature; and a hot forging substep of taking out the workpiece and the dies into a room temperature environment and immediately performing hot forging on the workpiece using a press machine. The predetermined dies are formed of another Ni-based superalloy comprising ? and ?? phases, and have features in that: a solvus temperature of the ?? phase is 1050-1250° C.; and the ?? phase precipitates at least 10 vol. % at 1050° C. and has two kinds of forms of intra-grain ?? phase precipitations within the ? phase grains and inter-grain ?? phase precipitations between/among the ? phase grains.Type: ApplicationFiled: November 16, 2016Publication date: February 20, 2020Inventors: Atsuo OTA, Shinya IMANO
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Patent number: 10557189Abstract: To provide a manufacturing process of a Ni based superalloy and a member of the Ni based superalloy which achieves both of excellent workability in a manufacturing step of the Ni based superalloy of the precipitation strengthening type which contains much amount of the gamma prime phase and excellent high temperature strength of the Ni based superalloy. The manufacturing process of a Ni based superalloy includes a step for softening the Ni based superalloy and improving the workability, in which the step for softening the Ni based superalloy and improving the workability is a step for precipitating the gamma prime phase that is incoherent with a gamma phase that is a matrix by 20 vol % or more.Type: GrantFiled: June 17, 2015Date of Patent: February 11, 2020Assignee: Mitsubishi Hitachi Power Systems, Ltd.Inventors: Atsuo Ota, Shinya Imano, Hironori Kamoshida
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Publication number: 20190048451Abstract: Provided is a method for manufacturing an Ni-based alloy member in which the equilibrium amount of ?? phase precipitation at 700° C. is from 30 to 70 volume %. The method includes the steps of preparing an Ni-based alloy powder having a predetermined chemical composition; forming a precursor body wherein an average grain diameter of the ? phase grains is 50 ?m or less, by using the Ni-based alloy powder; and heating the precursor body to a temperature at least the ?? phase solvus temperature and subsequently slow-cooling the heated precursor body from the temperature to a temperature at least 100° C. lower than the ?? phase solvus temperature at a cooling rate of 100° C./h or lower. There is obtained a softened body in that the ?? phase particles of at least 20 volume % precipitate between/among the ? phase grains having an average grain diameter of 50 ?m or less.Type: ApplicationFiled: August 8, 2018Publication date: February 14, 2019Inventors: Atsuo OTA, Shinya IMANO
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Publication number: 20180209026Abstract: In a manufacturing method of a turbine rotor blade using an Ni-based forged alloy, provided is a manufacturing method of a turbine rotor blade having an excellent workability and a high degree of freedom in the design of a cooling structure. A manufacturing method of a turbine rotor blade according to the present invention is, in a manufacturing method of a turbine rotor blade, using an Ni-based forged alloy, characterized by including: a softening process of increasing a ?? phase incoherent with a ? phase that is a matrix phase in the Ni-based forged alloy; a first working process of forming at least two members constituting a rotor blade by using the Ni-based forged alloy after subjected to the softening process; a second working process of forming cooling structural parts in the respective members; and a third working process of joining the members.Type: ApplicationFiled: September 14, 2015Publication date: July 26, 2018Inventors: Atsuo OTA, Shinya IMANO