Patents by Inventor Kousuke Kuwabara
Kousuke Kuwabara 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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Publication number: 20240109123Abstract: The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.Type: ApplicationFiled: December 8, 2023Publication date: April 4, 2024Applicant: Proterial, Ltd.Inventors: Hiroshi Shiratori, Kazuya Shinagawa, Kousuke Kuwabara, Shuho Koseki
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Patent number: 11913097Abstract: Provided is a Fe—Al-based alloy vibration-damping component including 4.0 to 12.0% by mass of Al with the balance being Fe and inevitable impurities, having an average crystal grain size in the range of over 700 ?m to 2,000 ?m and a sectional defect rate of lower than 0.1%, and having an irregular sectional shape. Also provided is a method for manufacturing a Fe—Al-based alloy vibration-damping component. The method obtains a vibration-damping component having an irregular sectional shape, and includes a shaping step in which metal powder including 4.0 to 12.0% by mass of Al with the balance being Fe and inevitable impurities is melted and solidified using a heat source with a scanning rate set to 700 to 1700 mm/second to obtain a shaped product and an annealing step in which the shaped product is annealed at a temperature of 800 to 1200° C.Type: GrantFiled: May 22, 2020Date of Patent: February 27, 2024Assignee: Proterial, Ltd.Inventors: Junichi Nishida, Kousuke Kuwabara
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Patent number: 11883880Abstract: The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.Type: GrantFiled: March 31, 2021Date of Patent: January 30, 2024Assignee: PROTERIAL, LTD.Inventors: Hiroshi Shiratori, Kazuya Shinagawa, Kousuke Kuwabara, Shuho Koseki
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Publication number: 20240001445Abstract: Provided are a method for manufacturing an alloy member, and an alloy member, the alloy member having excellent mechanical properties and corrosion resistance, and further having abrasion resistance, and being manufactured by an additive manufacturing method using an alloy powder. The method for manufacturing an alloy member is characterized by having: an additive manufacturing step for forming an alloy substrate by means of a laminate shaping method using an alloy powder comprising, in an amount range of 5 atomic % to 35 atomic %, respectively, each element of Co, Cr, Fe, Ni, and Ti, and in an amount of 0 atomic % to 8 atomic % (exclusive of 0 atomic %) of Mo, with the balance being unavoidable impurities; and a surface treatment step for performing a surface treatment on the alloy substrate.Type: ApplicationFiled: November 2, 2021Publication date: January 4, 2024Applicant: Proterial, Ltd.Inventors: Shuho Koseki, Kousuke Kuwabara, Fumiaki HONDA
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Patent number: 11821059Abstract: Provided are a Ni-based alloy capable of being melted and solidified and excellent in corrosion resistance and abrasion resistance, a Ni-based alloy powder, a Ni-based alloy member, and a product including a Ni-based alloy member. The Ni-based alloy excellent in corrosion resistance and abrasion resistance includes, by mass %: Cr: 8.5% to 23.0%; Mo: 8.5% to 27.0%; Ta: 0.5% to 2.5%; W: 15.0 to 51.0%; and C: 1.0 to 3.5%, the balance being Ni and unavoidable impurities, in which the mass ratios Ni:Cr:Mo of Ni, Cr and Mo are 2.5 to 3.5:1:1.0 to 1.5.Type: GrantFiled: September 4, 2020Date of Patent: November 21, 2023Assignee: Proterial, Ltd.Inventors: Hiroshi Shiratori, Kazuya Shinagawa, Shuho Koseki, Yasuhiko Otsubo, Kousuke Kuwabara
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Publication number: 20230294201Abstract: Provided are a method for predicting a defect of an additive-manufactured product manufactured by melting and solidifying metal powder, and a method for manufacturing an additive-manufactured product. The method for predicting a defect of an additive-manufactured product has: a luminance data acquisition step for acquiring luminance data on light emitted from a melt pool formed when the metal power is melted and solidified; an evaluation data extraction step for extracting evaluation data from the luminance data; and an evaluation step for estimating the presence/absence of a defect of the additive-manufactured product by using the evaluation data, wherein the evaluation data includes a luminance average value and a luminance standard deviation.Type: ApplicationFiled: November 2, 2021Publication date: September 21, 2023Applicant: Proterial, Ltd.Inventors: Jing NIU, Kousuke KUWABARA
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Patent number: 11643711Abstract: Provided are a laminate shaped article made of a maraging steel and having excellent toughness, a method for manufacturing the same, and a metal powder for laminate shaping. The laminate shaped article is made of a maraging steel comprising 0.1-5.0 mass % of Ti. When sis is performed on concentration distribution of Ti in a cross section parallel to a lamination direction of the above laminate shaped article, a length of a linear Ti-rich portion having a Ti concentration B of (1.5×A) or more with respect to an average Ti concentration A in the cross section is 15 ?m or less. In addition, the method for manufacturing the laminate shaped article uses a metal powder made of a maraging steel comprising 0.1-5.0 mass % of Ti, and a heat source output is set to 50-330 W and a scanning speed is set to 480-3000 mm/sec during the laminate shaping.Type: GrantFiled: December 17, 2018Date of Patent: May 9, 2023Assignee: HITACHI METALS, LTD.Inventors: Norihide Fukuzawa, Koichi Sakamaki, Yousuke Nakano, Kousuke Kuwabara, Shiho Fukumoto, Kazuya Saito
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Publication number: 20230122004Abstract: A production method for an alloy member having mainly high hardness and high resistance to corrosion and produced by an additive manufacturing method, the alloy member, and a product using the alloy member are provided. The production method for an alloy member includes: an additive manufacturing step of forming a shaped member through an additive manufacturing method using an alloy powder containing elements Co, Cr, Fe, Ni, and Ti each in a range of 5 atom% to 35 atom% and containing Mo in a range exceeding 0 atom% and 8 atom% or less, the remainder being unavoidable impurities; and a heat treatment step of holding the shaped member in a temperature range higher than 500° C. and lower than 900° C. directly after the additive manufacturing step without undergoing a step of holding the shaped member in a temperature range of 1080° C. to 1180° C.Type: ApplicationFiled: January 29, 2021Publication date: April 20, 2023Applicant: HITACHI METALS, LTD.Inventors: Kousuke Kuwabara, Shuho Koseki
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Publication number: 20220364207Abstract: The present invention provides an alloy, an alloy powder, an alloy member, and a composite member which are excellent in corrosion resistance and wear resistance, have crack resistance, and are suitable for an additive manufacturing method and the like. An alloy and an alloy powder include, by mass %, Cr: 18 to 22%, Mo: 18 to 28%, Ta: 1.5 to 57%, C: 1.0 to 2.5%, Nb: 0 to 42%, Ti: 0 to 15%, V: 0 to 27%, Zr: 0 to 29%, and a remainder consisting of Ni and unavoidable impurities, where a molar ratio of (Ta+0.7Nb+Ti+0.6V+Zr)/C=0.5 to 1.5 is satisfied. An alloy member is an additively manufactured product or a cast having such a solidification structure, and the solidification structure is a dendrite-like crystal structure having a metal phase having a face-centered cubic structure and carbides.Type: ApplicationFiled: March 31, 2021Publication date: November 17, 2022Applicant: HITACHI METALS, LTD.Inventors: Hiroshi SHIRATORI, Kazuya SHINAGAWA, Kousuke KUWABARA, Shuho KOSEKI
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Patent number: 11492685Abstract: Provided are: an alloy member that is excellent in homogeneity of both the alloy composition and microstructure and excellent in shape controllability and includes a high entropy alloy having high mechanical properties and high corrosion resistance, a process for producing the same, and a product including the alloy member. In the present invention, the alloy member having a chemical composition comprising elements of Co, Cr, Fe, Ni, and Ti each in an amount within a range of 5 atomic % or more and 35 atomic % or less and Mo in an amount within a range of more than 0 atomic % and 8 atomic % or less, the reminder consisting of unavoidable impurities, wherein ultrafine grains having an average grain diameter of 100 nm or less are dispersed and precipitated in a parent phase crystal.Type: GrantFiled: August 9, 2018Date of Patent: November 8, 2022Assignee: HITACHI METALS, LTD.Inventors: Tadashi Fujieda, Hiroshi Shiratori, Kousuke Kuwabara, Atsuhiko Onuma
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Publication number: 20220341008Abstract: Provided are a Ni—Cr—Mo-based alloy, a Ni—Cr—Mo-based alloy powder, a Ni—Cr—Mo-based alloy member, and a member that can be melted and solidified and have excellent corrosion resistance, wear resistance, and crack resistance. A Ni—Cr—Mo-based alloy member according to the present invention includes, by mass %, Cr: 18% to 22%, Mo: 18% to 39%, Ta: 1.5% to 2.5%, B: 1.0% to 2.5%, and a remainder consisting of Ni and unavoidable impurities, where 25 Cr+(Mo/2B)<38 is satisfied, in which boride particles with a maximum particle size of 70 ?m or less are dispersed and precipitated in a parent phase.Type: ApplicationFiled: March 31, 2021Publication date: October 27, 2022Inventors: Hiroshi SHIRATORI, Kazuya SHINAGAWA, Shuho KOSEKI, Kousuke KUWABARA, Yasuhiko OTSUBO
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Publication number: 20220331870Abstract: Provided are: a method for producing an alloy member that is fabricated by additive manufacturing and has increased mechanical strength and ductility as well as higher corrosion resistance; and the alloy member produced from this method. The alloy member production method comprises: an additive manufacturing step for forming products by additive manufacturing using an alloy powder including each of Co, Cr, Fe, Ni, and Ti in the range of 5-35 atom % and Mo in the range of greater than 0 atom % and 8 atom % or less, the balance comprising unavoidable impurities; a heat treatment step for raising a temperature of the products through heating, and holding the products in the temperature range of 1080-1180° C.; and a forced cooling step for cooling the products after the heat treatment in the temperature range from the holding temperature to 800° C. at a cooling rate of 110-2400° C./min.Type: ApplicationFiled: September 2, 2020Publication date: October 20, 2022Inventor: Kousuke Kuwabara
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Publication number: 20220290276Abstract: Provided are a WC-based cemented carbide powder from which a WC-based cemented carbide member excellent in high thermal conductivity and high abrasion resistance can be manufactured, a WC-based cemented carbide member, and a manufacturing method for a WC-based cemented carbide member. The WC-based cemented carbide powder of the present invention includes WC, Cu, and at least one of Co, Fe, and Cr. The content of WC is equal to or more than 40 mass %, the content of at least one of Co, Fe, and Cr is equal to or more than 25 mass % and less than 60 mass %, and the ratio a/b of the content ‘a’ of Cu and the content ‘b’ of at least one of Co, Fe, and Cr satisfies 0.070?a/b?1.000.Type: ApplicationFiled: August 27, 2020Publication date: September 15, 2022Inventors: Hiroshi SHIRATORI, Kazuya SHINAGAWA, Shuho KOSEKI, Kousuke KUWABARA, Yasuhiko OTSUBO, Shinya OKAMOTO
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Publication number: 20220220594Abstract: Provided is a Fe-Al-based alloy vibration-damping component including 4.0 to 12.0% by mass of Al with the balance being Fe and inevitable impurities, having an average crystal grain size in the range of over 700 ?m to 2,000 ?m and a sectional defect rate of lower than 0.1%, and having an irregular sectional shape. Also provided is a method for manufacturing a Fe-Al-based alloy vibration-damping component. The method obtains having an irregular sectional shape, and includes a shaping step in which metal powder including 4.0 to 12.0% by mass of Al with the balance being Fe and inevitable impurities is melted and solidified using a heat source with a scanning rate set to 700 to 1700 mm/second to obtain a shaped product and an annealing step in which the shaped product is annealed at a temperature of 800 to 1200° C.Type: ApplicationFiled: May 22, 2020Publication date: July 14, 2022Applicant: HITACHI METALS, LTD.Inventors: Junichi NISHIDA, Kousuke KUWABARA
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Publication number: 20220213577Abstract: Provided are a Ni-based alloy capable of being melted and solidified and excellent in corrosion resistance and abrasion resistance, a Ni-based alloy powder, a Ni-based alloy member, and a product including a Ni-based alloy member. The Ni-based alloy excellent in corrosion resistance and abrasion resistance includes, by mass %: Cr: 8.5% to 23.0%; Mo: 8.5% to 27.0%; Ta: 0.5% to 2.5%; W: 15.0 to 51.0%; and C: 1.0 to 3.5%, the balance being Ni and unavoidable impurities, in which the mass ratios Ni:Cr:Mo of Ni, Cr and Mo are 2.5 to 3.5:1:1.0 to 1.5.Type: ApplicationFiled: September 4, 2020Publication date: July 7, 2022Applicant: HITACHI METALS, LTD.Inventors: Hiroshi SHIRATORI, Kazuya SHINAGAWA, Shuho KOSEKI, Yasuhiko OTSUBO, Kousuke KUWABARA
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Patent number: 11359638Abstract: An object of the invention is to provide an alloy article that exhibits even better mechanical properties than conventional high entropy alloy articles without sacrificing high corrosion resistance thereof. An alloy article according to the invention comprises matrix phase crystal grains being equiaxed crystals with an average crystal grain size of 150 ?m or less, the alloy article having a metallic composition including: Co, Cr, Fe, Ni and Ti, each within a range of 5 atomic % or more and 35 atomic % or less; Mo within a range of more than 0 atomic % and less than 8 atomic %; and a balance comprising inevitable impurities, wherein in the matrix phase crystal grains, ultrafine particles with an average particle size of 100 nm or less and oxide particles with an average particle size of 100 nm or less are dispersedly precipitated.Type: GrantFiled: October 31, 2018Date of Patent: June 14, 2022Assignee: HITACHI METALS, LTD.Inventors: Meichuan Chen, Tadashi Fujieda, Kousuke Kuwabara
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Publication number: 20210040591Abstract: An additive layer manufactured hot work tool according to the present disclosure includes a component composition of by mass %, C: 0.3-0.5% to Si: 2.0% or less, Mn: 1.5% or less, P: 0.05% or less, S: 0.05% or less, Cr: 3.0 to 6.0%, 1 or 2 kinds of compounds of Mo and W, a relation between Mo and W being represented by a relational expression of (Mo+1/2W): 0.5 to 3.5%, V: 0.1 to 1.5%, Ni: 0 to 1.0%, Co: 0 to 1.0%, and Nb: 0 to 0.3%, and with Fe and an unavoidable impurity as a remainder, and an area ratio of defects having an area of 1 ?m2 or more is 0.6% or less in a cross section parallel to the amination direction.Type: ApplicationFiled: April 25, 2019Publication date: February 11, 2021Inventors: Norihide FUKUZAWA, Kouichi SAKAMAKI, Yousuke NAKANO, Shiho FUKUMOTO, Kazuya SAITO, Kousuke KUWABARA
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Publication number: 20200399747Abstract: Provided are a laminate shaped article made of a maraging steel and having excellent toughness, a method for manufacturing the same, and a metal powder for laminate shaping. The laminate shaped article is made of a maraging steel comprising 0.1-5.0 mass % of Ti. When sis is performed on concentration distribution of Ti in a cross section parallel to a lamination direction of the above laminate shaped article, a length of a linear Ti-rich portion having a Ti concentration B of (1.5×A) or more with respect to an average Ti concentration A in the cross section is 15 ?m or less. In addition, the method for manufacturing the laminate shaped article uses a metal powder made of a maraging steel comprising 0.1-5.0 mass % of Ti, and a heat source output is set to 50-330 W and a scanning speed is set to 480-3000 mm/sec during the laminate shaping.Type: ApplicationFiled: December 17, 2018Publication date: December 24, 2020Applicant: HITACHI METALS, LTD.Inventors: Norihide FUKUZAWA, Koichi Sakamaki, Yousuke NAKANO, Kousuke KUWABARA, Shiho FUKUMOTO, Kazuya SAITO
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Patent number: 10787725Abstract: An object of the invention is to provide: an HEA article that has excellent homogeneity in the alloy composition and microstructure as well as significant shape controllability, using an HEA with significant mechanical strength and high corrosion resistance; a method for manufacturing the HEA article; and a product using the HEA article. There is provided an HEA article comprising: Co, Cr, Fe, Ni, and Ti elements, each element in content of 5 to 35 atomic %; more than 0 atomic % to 8 atomic % of Mo %; and remainder substances of unavoidable impurities.Type: GrantFiled: November 8, 2016Date of Patent: September 29, 2020Assignee: Hitachi Metals, Ltd.Inventors: Tadashi Fujieda, Kousuke Kuwabara, Mamoru Hirota, Kinya Aota, Takahiko Kato, Akihiko Chiba, Yuichiro Koizumi, Kenta Yamanaka
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Publication number: 20200290118Abstract: An objective of the invention to provide an alloy article that exhibits even better mechanical properties and/or even higher corrosion resistance than conventional high entropy articles without sacrificing the attractive properties thereof, a product formed of the alloy article, and a fluid machine having the product. An alloy article according to the invention has a predetermined chemical composition comprising: Co, Cr, Fe, Ni and Ti, each within a range of 5 atomic % or more and 35 atomic % or less; Mo within a range of more than 0 atomic % and less than 8 atomic %; an element with a larger atomic radius than the atomic radiuses of Co, Cr, Fe and Ni within a range of more than 0 atomic % and 4 atomic % or less; and a balance of inevitable impurities.Type: ApplicationFiled: October 31, 2018Publication date: September 17, 2020Applicant: HITACHI METALS, LTD.Inventors: Meichuan CHEN, Tadashi FUJIEDA, Kousuke KUWABARA