Patents by Inventor Eisuke Kurosawa

Eisuke Kurosawa 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).

  • Publication number: 20210379685
    Abstract: A method for manufacturing an additively-manufactured object, includes: an additively-manufacturing step of building a layered body by depositing a weld bead obtained by melting and solidifying a filler metal, the layered body having an opening along a forming direction of the weld bead and an internal space surrounded by the weld bead; and a closing step of forming a closing wall portion connecting an edge portion of the opening with the weld bead for closing. In the additively-manufacturing step, the opening is formed with a width dimension larger than a bead width of the weld bead, and in the closing step, the closing wall portion having a width dimension larger than the bead width is formed by the weld bead to close the opening.
    Type: Application
    Filed: October 21, 2019
    Publication date: December 9, 2021
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.)
    Inventors: Shinji SATO, Takeshi YAMADA, Tatsuya FUJII, Masatoshi HIDA, Shuo HUANG, Eisuke KUROSAWA
  • Publication number: 20210362236
    Abstract: A method for depositing a hardened layer includes sequentially depositing a hardened layer formed by supplying a powder material for forming a hardened layer, which is obtained by mixing a plurality of kinds of powders, to a substrate, and melting and solidifying the powder material on/above the substrate. The powder material contains a first powder containing an alloy to be serving as a matrix portion of the hardened layer and a second powder containing a ceramic. The method includes heating the powder material until at least a part of the second powder is melted, to allow at least a part of metal elements contained in the melted second powder to be dissolved in the matrix portion of the hardened layer.
    Type: Application
    Filed: September 26, 2019
    Publication date: November 25, 2021
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.)
    Inventor: Eisuke KUROSAWA
  • Publication number: 20210252600
    Abstract: A method for depositing a hardened layer includes sequentially depositing a hardened layer. The hardened layer is formed by spraying a powder material for forming a hardened layer, which is obtained by mixing a first powder containing a Stellite alloy with a second powder containing tungsten carbide, toward a substrate, and melting and solidifying the powder material on/above the substrate. As the hardened layer to be formed is away from the substrate in a deposition direction, at least one of a heat input adjustment step and a content adjustment step is performed. The heat input adjustment step is a step of reducing a heat input for the powder material during formation of the hardened layer. The content adjustment step is a step of increasing a content of the second powder in the powder material for the hardened layer.
    Type: Application
    Filed: October 16, 2019
    Publication date: August 19, 2021
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.)
    Inventor: Eisuke KUROSAWA
  • Patent number: 10766063
    Abstract: A mold wash is used in a casting method using a lost foam to make a casting having a hole with a diameter of 12 mm or less. The casting method includes determining a thermal decomposition amount ?C(?,t) [wt %] of a resin binder when the mold wash is exposed at a temperature ? [° C.] for a time t [sec], and determining a room temperature transverse rupture strength ?b(?,t) [MPa] of the mold wash after receiving thermal loads, and performing casting with the mold wash having the room temperature transverse rupture strength ?b(?,t) after receiving thermal loads being equal to or larger than a threshold value ?cr [MPa].
    Type: Grant
    Filed: January 26, 2017
    Date of Patent: September 8, 2020
    Assignee: KOBE STEEL, LTD.
    Inventors: Eisuke Kurosawa, Kazuyuki Tsutsumi
  • Publication number: 20190388962
    Abstract: A mold wash is used in a casting method using a lost foam to make a casting having a hole with a diameter of 12 mm or less. The casting method includes determining a thermal decomposition amount ?C(?,t) [wt %] of a resin binder when the mold wash is exposed at a temperature ? [° C.] for a time t [sec], and determining a room temperature transverse rupture strength ?b(?,t) [MPa] of the mold wash after receiving thermal loads, and performing casting with the mold wash having the room temperature transverse rupture strength ?b(?,t) after receiving thermal loads being equal to or larger than a threshold value ?cr [MPa].
    Type: Application
    Filed: January 26, 2017
    Publication date: December 26, 2019
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.)
    Inventors: Eisuke KUROSAWA, Kazuyuki TSUTSUMI
  • Patent number: 10022784
    Abstract: For continuously casting an ingot of titanium or titanium alloy, molten titanium or titanium alloy is poured into a top opening of a bottomless mold with a circular cross-sectional shape, the solidified molten metal in the mold is pulled downward from the mold, a plurality of plasma torches disposed on an upper side of molten metal in the mold such that their centers are located directly vertically above the molten metal in the mold, are operated to generate plasma arcs that heat the molten metal in the mold, and the plasma torches are moved in a horizontal direction above a melt surface of the molten metal in the mold, along a trajectory located directly vertically above the molten metal in the mold, while keeping a mutual distance between the respective plasma torches such that the plasma torches do not interfere with each other.
    Type: Grant
    Filed: October 18, 2016
    Date of Patent: July 17, 2018
    Assignee: KOBE STEEL, LTD.
    Inventors: Eisuke Kurosawa, Takehiro Nakaoka, Kazuyuki Tsutsumi, Hideto Oyama, Hidetaka Kanahashi
  • Patent number: 9925582
    Abstract: The present invention provides a method for casting a slab having a good cast surface. The method includes heating the surface of molten metal on a metal inlet side of a mold by a first heat source so that the following formulas: q?0.87 and c?11.762q+0.3095 are satisfied where c is a cycle time [sec] of turning movement of the first heat source, and q is an average amount of heat input [MW/m2] determined by accumulating an amount of heat input applied by at least the first heat source to the contact region between the upper surface of the slab on the metal inlet side and the mold, along the path of turning movement of the first heat source, and dividing the resultant accumulated value by the cycle time c.
    Type: Grant
    Filed: March 6, 2017
    Date of Patent: March 27, 2018
    Assignee: Kobe Steel, Ltd.
    Inventors: Kazuyuki Yanagiya, Eisuke Kurosawa, Takehiro Nakaoka, Hidetaka Kanahashi
  • Patent number: 9908174
    Abstract: In the present invention the torch movement period is 20-40 seconds, with the torch movement period being the time required to move plasma torches (which heat the surface of molten metal in the casting mold) one time. The average heat input amount at multiple sites, which are obtained by dividing the initial solidification portion (which is where the molten metal makes contact with the casting mold and first solidifies) into multiple sites in the circumferential direction of the casting mold, is 1.0-2.0 MW/m2. The molten metal advection time, which is the time required for electromagnetically stirred molten metal to travel the length of the torch heating region of the surface of the molten metal in the lengthwise direction of the casting mold, is 3.5 seconds or less.
    Type: Grant
    Filed: September 28, 2017
    Date of Patent: March 6, 2018
    Assignee: Kobe Steel, Ltd.
    Inventors: Eisuke Kurosawa, Takehiro Nakaoka, Hideto Oyama, Hidetaka Kanahashi
  • Publication number: 20180015534
    Abstract: In the present invention the torch movement period is 20-40 seconds, with the torch movement period being the time required to move plasma torches (which heat the surface of molten metal in the casting mold) one time. The average heat input amount at multiple sites, which are obtained by dividing the initial solidification portion (which is where the molten metal makes contact with the casting mold and first solidifies) into multiple sites in the circumferential direction of the casting mold, is 1.0-2.0 MW/m2. The molten metal advection time, which is the time required for electromagnetically stirred molten metal to travel the length of the torch heating region of the surface of the molten metal in the lengthwise direction of the casting mold, is 3.5 seconds or less.
    Type: Application
    Filed: September 28, 2017
    Publication date: January 18, 2018
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Eisuke KUROSAWA, Takehiro NAKAOKA, Hideto OYAMA, Hidetaka KANAHASHI
  • Patent number: 9796016
    Abstract: The present invention provides a method for casting a slab with good cast surface quality. The method includes pouring molten metal 8 into a mold 2 from one of the paired shorter sides of the mold 2 while allowing superheat ?T [° C.], which is a temperature difference obtained by subtracting the melting point Tm [° C.] of the raw material from the temperature Tin [° C.] of the molten material on the surface of the molten metal in the mold and at the pouring point of the molten metal, to satisfy the following Formula (1) and Formula (2): 0.0014?T2 +0.0144?T+699.45>800 ??Formula (1) 0.0008?T2 +0.2472?T+853.
    Type: Grant
    Filed: December 12, 2016
    Date of Patent: October 24, 2017
    Assignee: Kobe Steel, Ltd.
    Inventors: Eisuke Kurosawa, Kazuyuki Yanagiya, Takehiro Nakaoka, Hidetaka Kanahashi
  • Publication number: 20170282240
    Abstract: The present invention provides a method for casting a slab having a good cast surface. The method includes heating the surface of molten metal on a metal inlet side of a mold by a first heat source so that the following formulas: q?0.87 and c?11.762q+0.3095 are satisfied where c is a cycle time [sec] of turning movement of the first heat source, and q is an average amount of heat input [MW/m2] determined by accumulating an amount of heat input applied by at least the first heat source to the contact region between the upper surface of the slab on the metal inlet side and the mold, along the path of turning movement of the first heat source, and dividing the resultant accumulated value by the cycle time c.
    Type: Application
    Filed: March 6, 2017
    Publication date: October 5, 2017
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Kazuyuki YANAGIYA, Eisuke KUROSAWA, Takehiro NAKAOKA, Hidetaka KANAHASHI
  • Publication number: 20170197243
    Abstract: The present invention provides a method for casting a slab with good cast surface quality. The method includes pouring molten metal 8 into a mold 2 from one of the paired shorter sides of the mold 2 while allowing superheat ?T [° C.], which is a temperature difference obtained by subtracting the melting point Tm [° C.] of the raw material from the temperature Tin [° C.] of the molten material on the surface of the molten metal in the mold and at the pouring point of the molten metal, to satisfy the following Formula (1) and Formula (2): 0.0014?T2 +0.0144?T+699.45>800 ??Formula (1) 0.0008?T2 +0.2472?T+853.
    Type: Application
    Filed: December 12, 2016
    Publication date: July 13, 2017
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Eisuke KUROSAWA, Kazuyuki YANAGIYA, Takehiro NAKAOKA, Hidetaka KANAHASHI
  • Patent number: 9682421
    Abstract: Provided is a device for titanium continuous casting (1) capable, even when continuously casting large diameter titanium ingots or titanium alloy ingots, of suppressing component segregation thereof. The device for titanium continuous casting (1) comprises: a mold (3) having an upper section having a circular upper opening (3a) for pouring in molten metal (6), and a bottom section having a lower opening for continuously drawing ingots (11); and a plurality of plasma torches (4, 5) to heat the molten metal in the mold (3) from the upper opening (3a) side. The plurality of plasma torches (4, 5) are disposed so that the amount of heat input to the molten metal (6) present in the outer circumference enclosing the center of the upper opening (3a) is greater than the amount of heat input to the molten metal (6) present in the center of the upper opening (3a).
    Type: Grant
    Filed: December 17, 2013
    Date of Patent: June 20, 2017
    Assignee: Kobe Steel, Ltd.
    Inventors: Hidetaka Kanahashi, Hideto Oyama, Takehiro Nakaoka, Eisuke Kurosawa, Kazuyuki Tsutsumi
  • Publication number: 20170087625
    Abstract: In the present invention the torch movement period is 20-40 seconds, with the torch movement period being the time required to move plasma torches (which heat the surface of molten metal in the casting mold) one time. The average heat input amount at multiple sites, which are obtained by dividing the initial solidification portion (which is where the molten metal makes contact with the casting mold and first solidifies) into multiple sites in the circumferential direction of the casting mold, is 1.0-2.0 MW/m2. The molten metal advection time, which is the time required for electromagnetically stirred molten metal to travel the length of the torch heating region of the surface of the molten metal in the lengthwise direction of the casting mold, is 3.5 seconds or less.
    Type: Application
    Filed: March 20, 2015
    Publication date: March 30, 2017
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Eisuke KUROSAWA, Takehiro NAKAOKA, Hideto OYAMA, Hidetaka KANAHASHI
  • Publication number: 20170036265
    Abstract: For continuously casting an ingot of titanium or titanium alloy, molten titanium or titanium alloy is poured into a top opening of a bottomless mold with a circular cross-sectional shape, the solidified molten metal in the mold is pulled downward from the mold, a plurality of plasma torches disposed on an upper side of molten metal in the mold such that their centers are located directly vertically above the molten metal in the mold, are operated to generate plasma arcs that heat the molten metal in the mold, and the plasma torches are moved in a horizontal direction above a melt surface of the molten metal in the mold, along a trajectory located directly vertically above the molten metal in the mold, while keeping a mutual distance between the respective plasma torches such that the plasma torches do not interfere with each other.
    Type: Application
    Filed: October 18, 2016
    Publication date: February 9, 2017
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.)
    Inventors: Eisuke KUROSAWA, Takehiro NAKAOKA, Kazuyuki TSUTSUMI, Hideto OYAMA, Hidetaka KANAHASHI
  • Patent number: 9475114
    Abstract: By controlling the temperature (TS) of a surface portion (11a) of an ingot (11) in a contact region (16) between a mold (2) and the ingot (11) and/or a passing heat flux (q) from the surface portion (11a) of the ingot (11) to the mold (2) in the contact region (16), the thickness (D) in the contact region (16) of a solidified shell (13) obtained by the solidification of molten metal (12) is brought into a predetermined range. Consequently, an ingot having a good casting surface state can be cast.
    Type: Grant
    Filed: January 10, 2014
    Date of Patent: October 25, 2016
    Assignee: Kobe Steel, Ltd.
    Inventors: Eisuke Kurosawa, Takehiro Nakaoka, Kazuyuki Tsutsumi, Hideto Oyama, Hidetaka Kanahashi, Hitoshi Ishida, Daiki Takahashi, Daisuke Matsuwaka
  • Patent number: 9427796
    Abstract: Disclosed is a continuous casting method in which a melt obtained by melting titanium or a titanium alloy is poured into a bottomless mold and is drawn downward while being solidified, wherein: the surface of the melt in the mold is heated by horizontally moving a plasma torch over the surface of the melt; thermocouples are provided at a plurality of locations along the circumferential direction of the mold; if the temperature of the mold measured by one of the thermocouples is lower than a target temperature, then the output of the plasma torch is increased when the plasma torch comes close to the location where that thermocouple is installed; and if said temperature is higher than the target temperature, then the output of the plasma torch is decreased when the plasma torch comes close to the location where that thermocouple is installed.
    Type: Grant
    Filed: January 23, 2014
    Date of Patent: August 30, 2016
    Assignee: Kobe Steel, Ltd.
    Inventors: Takehiro Nakaoka, Eisuke Kurosawa, Kazuyuki Tsutsumi, Hideto Oyama, Hidetaka Kanahashi, Hitoshi Ishida, Daiki Takahashi, Daisuke Matsuwaka
  • Patent number: 9333556
    Abstract: A continuous casting method in which a molten metal obtained by melting titanium or a titanium alloy is injected into a bottomless mold having a rectangular cross-section and withdrawn downward while being caused to solidify, wherein a plasma torch (7) is caused to rotate in the horizontal direction above the surface of the molten metal (12) in the mold (2), and a horizontally rotating flow is generated by electromagnetic stirring on at least the surface of the molten metal (12) in the mold (2). It is thereby possible to cast a slab in which the casting surface condition is excellent.
    Type: Grant
    Filed: January 23, 2014
    Date of Patent: May 10, 2016
    Assignee: Kobe Steel, Ltd.
    Inventors: Eisuke Kurosawa, Takehiro Nakaoka, Kazuyuki Tsutsumi, Hideto Oyama, Hidetaka Kanahashi, Hitoshi Ishida, Daiki Takahashi, Daisuke Matsuwaka
  • Publication number: 20160114385
    Abstract: A continuous casting apparatus continuously casts an ingot formed of titanium or a titanium alloy. The apparatus includes a bottomless mold with a circular cross-sectional shape and a plasma torch. In the bottomless mold, a molten metal is poured from a top opening and the molten metal is solidified and the molten metal solidified is pulled out downward. The plasma torch is disposed on an upper side of the molten metal in the mold and generates a plasma arc that heats the molten metal. A plurality of plasma torches are disposed on the upper side of the molten metal in the mold. The plurality of plasma torches are moved in a horizontal direction above a melt surface of the molten metal along a trajectory keeping a distance not to allow for interference with each other.
    Type: Application
    Filed: June 11, 2014
    Publication date: April 28, 2016
    Applicant: KABUSHIKI KAISHA KOBE SEIKO SHO (KOBE STEEL, LTD.)
    Inventors: Eisuke KUROSAWA, Takehiro NAKAOKA, Kazuyuki TSUTSUMI, Hideto OYAMA, Hidetaka KANAHASHI
  • Publication number: 20150343521
    Abstract: Provided is a device for titanium continuous casting (1) capable, even when continuously casting large diameter titanium ingots or titanium alloy ingots, of suppressing component segregation thereof. The device for titanium continuous casting (1) comprises: a mold (3) having an upper section having a circular upper opening (3a) for pouring in molten metal (6), and a bottom section having a lower opening for continuously drawing ingots (11); and a plurality of plasma torches (4, 5) to heat the molten metal in the mold (3) from the upper opening (3a) side. The plurality of plasma torches (4, 5) are disposed so that the amount of heat input to the molten metal (6) present in the outer circumference enclosing the center of the upper opening (3a) is greater than the amount of heat input to the molten metal (6) present in the center of the upper opening (3a).
    Type: Application
    Filed: December 17, 2013
    Publication date: December 3, 2015
    Applicant: Kabushiki Kaisha Kobe Seiko Sho (Kobe Steel, Ltd.)
    Inventors: Hidetaka KANAHASHI, Hideto OYAMA, Takehiro NAKAOKA, Eisuke KUROSAWA, Kazuyuki TSUTSUMI