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Latest update: 26/02/2020 10:25:13

Tobata seisakusho co.,Ltd.

We supply commercialized copper-cast tuyeres mainly made of high-strength aluminum bronze for high quality.

We manufacture nonferrous metal products for the iron and steel, shipbuilding, and industrial machinery industries. Our products are mainly made of pure copper or copper alloy. We have also expanded our manufacturing to a magnesium alloy featuring excellent heat resistance and non-flammability. In addition, we are developing a copper alloy casting made of high-strength aluminum bronze and copper-cast tuyeres. These are used in an environment where the ambient temperature is 1,800°C or more.

Main image

Sales Pitch

Pure copper cast products and welded can products
We manufacture and sell flame-resistant magnesium alloy products
Our flame-retardant magnesium alloy is a revolutionary lightweight metal with an ignition temperature over 900 °C. Our company has been manufacturing and selling ingots, billets, and other materials and cast products since 2003. This alloy requires no flux or inert gas (SF6) with a high temperature coefficient, and it is friendly to the environment. Special equipment is unnecessary and existing aluminum solving equipment can be used as-is. Dry processing and shaving recycling are possible. Shavings are easy to handle. We flexibly support small-volume production and prototyping.
Machining cases and uses
Flame-retardant magnesium alloy is a revolutionary light metal material with an ignition temperature not less than 900 °C. Our company has been manufacturing and selling materials such as ingots and billets since 2003, as well as cast products. These articles are popular among customers and friendly to the environment because flux or inert gas (SF6) with high global warming potential is unnecessary. Aluminum dissolving equipment can also be used as-is without any alteration. Dry processing and shaving recycling are possible and it is easy to handle  shavings. We are flexible about small-lot production and test production.
Technical information
Casting technology
Now, as in the past, metal casting dies are basically made of sand. The sand is removed and products are taken out after cooling. Complicated cast products with inner cavities are manufactured by combining casting and welding.

Our hot air inlet (tuyere) for a blast furnace at an ironworks is a kind of copper pipe about 80 cm long with a deformed conical shape of about 50 to 60 cm in diameter. Air as hot as about 1,200 °C is blown into the furnace from the bottom through the tuyere. The temperature inside the furnace is about 2,000 °C or more. The tuyere functions even in a severe environment sometimes subject to molten metal splashing because the tuyere is always cold due to cooling water flowing into it.

The tuyere uses a spiral water channel where water is circulated at high speed to cool the tip of the tuyere.
Diffusion joining
Our company used to manufacture copper and copper alloy cast products by welding. However, in 1985 we developed a diffusion bonding machine jointly with Kyushu Institute of Technology and Kitakyushu Industrial Experiment Station (now the Fukuoka Industrial Technology Center).

We can manufacture (1) hollow parts, (2) precision parts with minimal deformation, and (3) parts manufactured by laminating many kinds of metals. A feature of our company’s work is that comparatively small force is necessary in the manufacturing processes.

We now have a total of four diffusion bonding machines. The largest is 1.3 m long, 2.3 m wide, and 80 cm high. We are trying to join various metals and alloys. We have succeeded in joining 25 combinations of eight kinds of metals (copper, titanium, copper, stainless steel, tool steel, nickel, cobalt, and aluminum), excluding three combinations (copper and cobalt, titanium and cobalt, and aluminum and cobalt).

Other presentation

[Company strength]
We supply pure copper cast products, which are manufactured by only a few companies in Japan. We deliver products to iron works as tuyeres for blast furnaces, lance nozzles for converters, and wall coolers for electronic furnaces. They are highly appreciated for their high quality. We can handle small-quantity production for prototyping and mass production, and can propose materials and manufacturing methods suitable for customer needs. Quality assurance begins from the design meeting, and we conduct inquiries after use and solicit improvement proposals to supply products that satisfy customers.

[Business description]
We manufacture and sell nonferrous metal products. In particular, we provide net copper products and copper alloy products for the iron and steel, shipbuilding, and industrial machinery industries. We have also been tackling magnesium manufacturing in recent years. Our heat-resistant nonflammable magnesium alloy has been attracting attention from various industries.

Nonferrous metal manufacturing

[Strength of products/technologies]
Our copper alloy casting is appreciated in various industries as worm wheels and so on, with the high-strength aluminum we developed being first on the list. Our copper-cast tuyeres for blast furnaces in the iron and steel industry are used under severe environments where the ambient temperature is 1,800°C or more and high quality is expected. We believe that we are leading other manufacturers in Japan in copper welding, which is said to be a difficult technology. We are sure that we can make satisfactory proposals for magnesium alloys because we handle various kinds of materials.

[Representative's message]
We have been engaged in pure copper casting and nonferrous special welding for many years. We are always committed to enhancing casting and welding technologies and to developing new products without losing our ambition. Exports were not active for several years but the recent trend of a weak yen is establishing a competitive environment. We will take this opportunity to expand our overseas sales. We aim to make our heat-resistant nonflammable magnesium alloy one of our key businesses. To accomplish this we will conduct broad-based public relations activities in the automotive field and so on, as well as the rolling stock field.

[Company structure for market development/overseas expansion]
The iron and steel industry accounts for the greatest percentage of our transactions. We sell our products mainly to major iron and steel manufacturers represented by Nippon Steel & Sumitomo Metal Corporation and JFE Steel Corporation. Our sales system is organized based on sales staff in respective areas. They are carrying out sales and follow-up activities in their assigned areas, with a commitment to quickly supporting clients, including local trading firms. We make use of trading firms in various regions for overseas activities. Our standard practice is for staff in charge of overseas activities to accompany staff from a trading firm in customer visits and to conduct public relations activities. We are hoping to increase our exports by further strengthening our systems.

[Market share/Ranking]
Copper-cast tuyeres for blast furnaces: 60% share of the domestic market in Japan.
Copper-cast lances for converters: 60% share of the domestic market in Japan.

Strategic Core Technology Advancement Program approval

[Joint research and development]
NEDO “Development of Evaluation Technology for the Manufacturing Process and Quality of Heat-Resistant Nonflammable Magnesium Alloy” (Kyushu University, AIST, etc., in 2013); Strategic Core Technology Advancement Program Project “Development of Innovative Electrode Material Using Thin Plates Cast from Nonflammable Magnesium Alloy to Implement Magnesium Air Batteries as an Emergency Power Supply” (AIST, etc., in 2013 to 2015); and many others.

[Main Clients / Business History (domestic)]
Nippon Steel & Sumitomo Metal Corporation, JFE Steel Corporation, Mitsubishi Heavy Industries Co., Ltd., IHI Corporation, and many other major iron and steel manufacturers.

[Main Clients / Business History (overseas)]
China Steel, Danieli Corus, BSL, AHMSA, and other major iron and steel companies.

[Exhibition History/Information]
Kumamoto Industrial Business Fair 2013, International Magnesium Fair 2013, IFEX 2013 India, Automotive World 2014 (scheduled), the 4th Automotive Weight Reduction Expo (scheduled).

This company is recommended by the following support organizations.

Kyushu Head Office, SMRJ

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