Patents by Inventor Toshio Maetani

Toshio Maetani 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: 20210071286
    Abstract: The present disclosure relates to an iron-based prealloy powder having excellent strength and processability, and an iron-based alloy powder for powder metallurgy and a sinter-forged member using the same. The iron-based prealloy powder for powder metallurgy according to an embodiment of the present disclosure includes 0.5 to 5.0 wt % of Cu, 0.1 to 0.5 wt % of Mo, and a balance of Fe and other inevitable impurities. A Cu content (Cu %) and a Mo content (Mo %) satisfy the following Relational Equation (1): 0.3×Cu %+3×Mo %?2.7??(1).
    Type: Application
    Filed: March 26, 2020
    Publication date: March 11, 2021
    Inventors: Hak Soo KIM, Kohsuke Ashizuka, Akio Kobayashi, Naomichi Nakamura, Masashi Fujinaga, Toshio Maetani, Hirofumi Enokido, Hisashi Sudo
  • Patent number: 10265766
    Abstract: Provided is an alloy steel powder for powder metallurgy containing an iron-based powder as a main component that is capable of achieving both high strength and high toughness in a sintered body using the same. In the alloy steel powder, the iron-based powder contains a reduced powder, and Mo content with respect to a total amount of the alloy steel powder is 0.2 mass % to 1.5 mass %, Cu powder content with respect to a total amount of the alloy steel powder is 0.5 mass % to 4.0 mass % and graphite powder content with respect to a total amount of the alloy steel powder is 0.1 mass % to 1.0 mass %.
    Type: Grant
    Filed: April 25, 2014
    Date of Patent: April 23, 2019
    Assignee: JFE STEEL CORPORATION
    Inventors: Toshio Maetani, Shigeru Unami
  • Patent number: 10207328
    Abstract: An Fe—Mo—Cu—C-based alloy steel powder for powder metallurgy has a chemical composition containing Mo: 0.2 mass % to 1.5 mass %, Cu: 0.5 mass % to 4.0 mass %, and C: 0.1 mass % to 1.0 mass %, with a balance being Fe and incidental impurities, wherein an iron-based powder has a mean particle size of 30 ?m to 120 ?m, and a Cu powder has a mean particle size of 25 ?m or less. Despite the alloy steel powder for powder metallurgy having a chemical composition not containing Ni, a part produced by sintering a press formed part of the powder and further carburizing-quenching-tempering the sintered part has mechanical properties of at least as high tensile strength, toughness, and sintered density as a Ni-added part.
    Type: Grant
    Filed: November 24, 2015
    Date of Patent: February 19, 2019
    Assignee: JFE STEEL CORPORATION
    Inventors: Takuya Takashita, Akio Kobayashi, Naomichi Nakamura, Toshio Maetani, Akio Sonobe, Itsuya Sato
  • Publication number: 20190001409
    Abstract: A method for measuring an apparent density of a metal powder includes holding a metal powder in a vessel, applying an alternating magnetic flux to the metal powder using an exciting coil disposed outside the vessel, detecting the alternating magnetic flux passed through the metal powder using a-search coil disposed outside the vessel, and determining an apparent density of the metal powder from an amplitude of the detected alternating magnetic flux using a calibration curve representing a correlation between the apparent density of the metal powder and the amplitude of an alternating magnetic flux prepared in advance. The method enables to measure the apparent density of a metal powder with a high precision in an on-line and non-contact manner without stopping a process of producing a mixed powder or a process of producing a powder compact.
    Type: Application
    Filed: September 5, 2018
    Publication date: January 3, 2019
    Applicant: JFE STEEL CORPORATION
    Inventors: Toshio MAETANI, Hiroharu KATO
  • Patent number: 10092952
    Abstract: A method for measuring an apparent density of a metal powder includes holding a metal powder in a vessel, applying an alternating magnetic flux to the metal powder using an exciting coil disposed outside the vessel, detecting the alternating magnetic flux passed through the metal powder using a search coil disposed outside the vessel, and determining an apparent density of the metal powder from an amplitude of the detected alternating magnetic flux using a calibration curve representing a correlation between the apparent density of the metal powder and the amplitude of an alternating magnetic flux prepared in advance. The method enables to measure the apparent density of a metal powder with a high precision in an on-line and non-contact manner without stopping a process of producing a mixed powder or a process of producing a powder compact.
    Type: Grant
    Filed: May 16, 2012
    Date of Patent: October 9, 2018
    Assignee: JFE STEEL CORPORATION
    Inventors: Toshio Maetani, Hiroharu Kato
  • Publication number: 20180193911
    Abstract: A method of producing a mixed powder for powder metallurgy comprises: mixing an iron-based powder with a Mo-containing powder and a Cu-containing powder, to obtain a raw material mixed powder; heat-treating the raw material mixed powder to cause Mo and Cu to diffusionally adhere to a surface of the iron-based powder, to obtain a partially diffusion-alloyed steel powder; and mixing the partially diffusion-alloyed steel powder with a graphite powder, to obtain a mixed powder for powder metallurgy, wherein the iron-based powder has an average particle size of 30 ?m to 120 ?m, a cuprous oxide powder is used as the Cu-containing powder, and the mixed powder for powder metallurgy has a chemical composition containing Mo: 0.2 mass % to 1.5 mass %, Cu: 0.5 mass % to 4.0 mass %, and C: 0.1 mass % to 1.0 mass %, with a balance being Fe and incidental impurities.
    Type: Application
    Filed: September 12, 2016
    Publication date: July 12, 2018
    Applicant: JFE STEEL CORPORATION
    Inventors: Akio KOBAYASHI, Naomichi NAKAMURA, Toshio MAETANI, Akio SONOBE, Itsuya SATO
  • Patent number: 9815115
    Abstract: A finish heat treatment apparatus for an iron powder. Raw iron powder is placed on a continuous moving hearth and continuously charged into the apparatus. In a pretreatment zone, the raw iron powder is subjected to a pretreatment of heating the raw iron powder in an atmosphere of hydrogen gas and/or inert gas at 450 to 1100° C. In decarburization, deoxidation, and denitrification zones, the pretreated iron powder is subsequently subjected to at least two treatments of decarburization, deoxidation, and denitrification. In the pretreatment zone, a hydrogen gas and/or an inert gas serving as a pretreatment ambient gas is introduced separately from an ambient gas used in the at least two treatments is introduced from the upstream side of the pretreatment zone and released from the downstream side so as to flow in the same direction as a moving direction of the moving hearth.
    Type: Grant
    Filed: January 4, 2016
    Date of Patent: November 14, 2017
    Assignee: JFE STEEL CORPORATION
    Inventors: Yasuhiko Sakaguchi, Toshio Maetani
  • Publication number: 20170259340
    Abstract: An Fe—Mo—Cu—C-based alloy steel powder for powder metallurgy has a chemical composition containing Mo: 0.2 mass % to 1.5 mass %, Cu: 0.5 mass % to 4.0 mass %, and C: 0.1 mass % to 1.0 mass %, with a balance being Fe and incidental impurities, wherein an iron-based powder has a mean particle size of 30 ?m to 120 ?m, and a Cu powder has a mean particle size of 25 ?m or less. Despite the alloy steel powder for powder metallurgy having a chemical composition not containing Ni, a part produced by sintering a press formed part of the powder and further carburizing-quenching-tempering the sintered part has mechanical properties of at least as high tensile strength, toughness, and sintered density as a Ni-added part.
    Type: Application
    Filed: November 24, 2015
    Publication date: September 14, 2017
    Applicant: JFE STEEL CORPORATION
    Inventors: Takuya TAKASHITA, Akio KOBAYASHI, Naomichi NAKAMURA, Toshio MAETANI, Akio SONOBE, Itsuya SATO
  • Publication number: 20160214171
    Abstract: Provided is an alloy steel powder for powder metallurgy that is capable of achieving both high strength and high toughness in a sintered body using the same. An alloy steel powder for powder metallurgy of this disclosure comprises a composite alloy steel powder and graphite powder. The composite alloy steel powder has a specific surface area of 0.100 m2/g or more and Mo content in a range of 0.2 mass % to 1.5 mass %, and the graphite powder content with respect to 100 mass % of the alloy steel powder for powder metallurgy is in a range of 0.1 mass % to 1.0 mass %.
    Type: Application
    Filed: August 26, 2014
    Publication date: July 28, 2016
    Applicant: JFE STEEL CORPORATION
    Inventors: Toshio Maetani, Shigeru Unami, Tomoshige Ono, Yukiko Ozaki
  • Publication number: 20160151837
    Abstract: A mixed powder for powder metallurgy includes a machinability improvement powder that is crystalline layered alkaline silicate heat-treated at 400° C. to 1100° C. and whose mix proportion is in an amount of 0.01% to 1.0% by mass in terms of total content of an iron-based powder, an alloying powder, and the machinability improvement powder. Such a mixed powder not only enables a compact to be sintered without adversely affecting the environment in a sintering furnace, but also enables a sintered body having excellent lathe machinability and excellent drill machinability to be obtained.
    Type: Application
    Filed: January 23, 2014
    Publication date: June 2, 2016
    Inventors: Kouichi Nushiro, Toshio Maetani, Tomoshige Ono, Yukiko Ozaki
  • Publication number: 20160136727
    Abstract: Provided is an alloy steel powder for powder metallurgy containing an iron-based powder as a main component that is capable of achieving both high strength and high toughness in a sintered body using the same. In the alloy steel powder, the iron-based powder contains a reduced powder, and Mo content with respect to a total amount of the alloy steel powder is 0.2 mass % to 1.5 mass %, Cu powder content with respect to a total amount of the alloy steel powder is 0.5 mass % to 4.0 mass % and graphite powder content with respect to a total amount of the alloy steel powder is 0.1 mass % to 1.0 mass %.
    Type: Application
    Filed: April 25, 2014
    Publication date: May 19, 2016
    Applicant: JFE STEEL CORPORATION
    Inventors: Toshio MAETANI, Shigeru UNAMI
  • Publication number: 20160114391
    Abstract: In a finish heat treatment method and finish heat treatment apparatus for an iron powder, a raw iron powder is placed on a continuous moving hearth and continuously charged into the apparatus. In the pretreatment zone, the raw iron powder is subjected to a pretreatment of heating the raw iron powder in an atmosphere of hydrogen gas and/or inert gas at 450 to 1100° C. In decarburization, deoxidation, and denitrification zones, the pretreated iron powder is subsequently subjected to at least two treatments of decarburization, deoxidation, and denitrification. In the pretreatment zone, a hydrogen gas and/or an inert gas serving as a pretreatment ambient gas is introduced separately from an ambient gas used in the at least two treatments is introduced from the upstream side of the pretreatment zone and released from the downstream side so as to flow in the same direction as a moving direction of the moving hearth.
    Type: Application
    Filed: January 4, 2016
    Publication date: April 28, 2016
    Applicant: JFE STEEL CORPORATION
    Inventors: Yasuhiko SAKAGUCHI, Toshio MAETANI
  • Patent number: 9321103
    Abstract: In a finish heat treatment method and finish heat treatment apparatus for an iron powder, a raw iron powder is placed on a continuous moving hearth and continuously charged into the apparatus. In the pretreatment zone, the raw iron powder is subjected to a pretreatment of heating the raw iron powder in an atmosphere of hydrogen gas and/or inert gas at 450 to 1100° C. In decarburization, deoxidation, and denitrification zones, the pretreated iron powder is subsequently subjected to at least two treatments of decarburization, deoxidation, and denitrification. In the pretreatment zone, a hydrogen gas and/or an inert gas serving as a pretreatment ambient gas is introduced separately from an ambient gas used in the at least two treatments is introduced from the upstream side of the pretreatment zone and released from the downstream side so as to flow in the same direction as a moving direction of the moving hearth.
    Type: Grant
    Filed: December 15, 2011
    Date of Patent: April 26, 2016
    Assignee: JFE STEEL CORPORATION
    Inventors: Yasuhiko Sakaguchi, Toshio Maetani
  • Publication number: 20140314615
    Abstract: A method for measuring an apparent density of a metal powder includes holding a metal powder in a vessel, applying an alternating magnetic flux to the metal powder using an exciting coil disposed outside the vessel, detecting the alternating magnetic flux passed through the metal powder using a search coil disposed outside the vessel, and determining an apparent density of the metal powder from an amplitude of the detected alternating magnetic flux using a calibration curve representing a correlation between the apparent density of the metal powder and the amplitude of an alternating magnetic flux prepared in advance. The method enables to measure the apparent density of a metal powder with a high precision in an on-line and non-contact manner without stopping a process of producing a mixed powder or a process of producing a powder compact.
    Type: Application
    Filed: May 16, 2012
    Publication date: October 23, 2014
    Applicant: JFE STEEL CORPORATION
    Inventors: Toshio Maetani, Hiroharu Kato
  • Publication number: 20140048184
    Abstract: In a finish heat treatment method and finish heat treatment apparatus for an iron powder, a raw iron powder is placed on a continuous moving hearth and continuously charged into the apparatus. In the pretreatment zone, the raw iron powder is subjected to a pretreatment of heating the raw iron powder in an atmosphere of hydrogen gas and/or inert gas at 450 to 1100° C. In decarburization, deoxidation, and denitrification zones, the pretreated iron powder is subsequently subjected to at least two treatments of decarburization, deoxidation, and denitrification. In the pretreatment zone, a hydrogen gas and/or an inert gas serving as a pretreatment ambient gas is introduced separately from an ambient gas used in the at least two treatments is introduced from the upstream side of the pretreatment zone and released from the downstream side so as to flow in the same direction as a moving direction of the moving hearth.
    Type: Application
    Filed: December 15, 2011
    Publication date: February 20, 2014
    Applicant: JFE STEEL CORPORATION
    Inventors: Yasuhiko Sakaguchi, Toshio Maetani
  • Publication number: 20120048063
    Abstract: High compressibility iron powder that is suitably used for parts with excellent magnetic characteristics or high density sintered parts and that has good productivity is provided from pure iron powder which includes, as impurities in percent by mass, C: 0.005% or less, Si: more than 0.01% and 0.03% or less, Mn: 0.03% or more and 0.07% or less, P: 0.01% or less, S: 0.01% or less, O: 0.10% or less, and N: 0.001% or less, and whose particle includes four or less crystal grains on average and has a micro Vickers hardness (Hv) of 80 or less on average. The circularity of the iron powder is preferably 0.7 or more.
    Type: Application
    Filed: January 30, 2007
    Publication date: March 1, 2012
    Applicant: JFE STEEL CORPORATION a corporation of Japan
    Inventors: Toshio Maetani, Satoshi Uenosono, Aya Uenosono, Masateru Ueta
  • Publication number: 20100150768
    Abstract: A pure iron powder of a diameter of 10 to 500 ?m and a purity of 99% by mass or more is heated to a temperature in the range of 600 to 1400° C., and a Si-concentrated layer is formed in regions within a depth of 5 ?m from the surfaces of the powder particles by gas-phase reaction at a temperature of that range. The average Si concentration in the regions within this depth is controlled in the range of 0.05% to 2% by mass. Thus, a dust core metal powder enhancing the adhesion of insulating material to the particle without degrading compressibility is produced. The resulting dust core maintains a high saturation magnetic flux density and exhibits a low iron loss.
    Type: Application
    Filed: May 26, 2008
    Publication date: June 17, 2010
    Applicant: JFE STEEL CORPORATION
    Inventors: Akira Fujita, Tatsuhiko Hiratani, Toshio Maetani
  • Publication number: 20040126609
    Abstract: This invention provides a metal powder for powder magnetic cores, which have good insulation performance and high magnetic flux density, and which is favorable for motor cores. Ferromagnetic metal powder may be coated with a coating material and a phosphate or phosphoric acid compound containing aluminum is used for the coating material. Coating the surface of iron powder with aluminum phosphate realizes to produce high-quality powder magnetic cores that have good insulation performance and high magnetic flux density and are favorable for motor cores. Further coating the aluminum phosphate-coated metal powder with silane compound or surfactant realizes more stable compressed shaped articles of the powder. And the properties of the articles do not fluctuate while stored for, so long as they are resistant to moisture. This invention contributes to producing powder magnetic cores for motors, and to the process for powder magnetic cores, furthermore, to the related art field.
    Type: Application
    Filed: December 9, 2003
    Publication date: July 1, 2004
    Applicant: JFE STEEL CORPORATION
    Inventors: Masateru Ueta, Naomichi Nakamura, Toshio Maetani, Satoshi Uenosono
  • Publication number: 20030180455
    Abstract: The invention provides a coating method for forming a uniform coating layer on the entirety of powder by using simple means. The method has the steps of supplying the powder into a container; rotating a stirring blade so that a rotation speed of an end portion thereof is about 1.5 m/sec or more while blowing a fluidizing gas into the powder at a velocity of about 3.0 m/sec or more from a position above the powder for stirring and fluidizing, the stirring blade being disposed at a bottom portion of the container; spraying a coating fluid onto the powder from a position thereabove; and drying the coating fluid to form a coating layer.
    Type: Application
    Filed: March 18, 2003
    Publication date: September 25, 2003
    Applicant: KAWASAKI STEEL CORPORATION
    Inventors: Toshio Maetani, Naomichi Nakamura, Masaki Ueta, Shingo Saito