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“Induction hardening” for single products, mass production, trial manufacturing, and large products with in-house coils

[Case 1] Large ring groove induction hardening

Due to the great degree of difficulty in manufacturing the necessary coils, only a limited number of companies are able to do partial induction hardening of the inner diameter of the large ring measuring φ1220×φ1037×238W.
We can manufacture with the optimum hardening method and coils using our more than 60 years of accumulated know-how of induction hardening.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/high-frequency/2021/11/15/2551.html

[Case 2] Large shaft induction hardening

A high-frequency oscillator with a large capacity output is necessary in order to move and harden the outer diameter of the φ940 shaft.
Using our 6 KHz × 600 KW large high frequency oscillator, we are able to do induction hardening even of large shafts with an outer diameter of φ940.
Deep hardened layers were required, so it was important that we ensure a high frequency of 6 KHz.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/high-frequency/2021/11/12/2546.html

[Case 3] Large lever induction hardening

In partial hardening of large specially shaped products, it is necessary to manufacture specially shaped coils in order to generate high frequencies, as shown in the drawing.
It is also necessary to have a large induction hardening machine that can handle that hardening.
Since we manufacture coils in-house, we can manufacture specially shaped coils with short turnaround time and at low cost. We also excel at large products, and for projects go into our factories, we can almost always do hardening.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/high-frequency/2021/09/02/2077.html

“Laser hardening” for various projects with the top-class equipment line in Japan

[Case 1] M 1.5 small gear tooth surface moving laser hardening

One of our clients told us that they wanted to do tooth surface hardening of catalog listed gears (finished products), but were worried that the products would get deformed. They were also concerned that induction hardening would cause the precision of gear teeth to deviate from JIS standards.
With laser hardening, only the tooth surface is hardened partially, making it possible to reduce deformation after heat treatment, and keeping the precision of the gear teeth after heat treatment within JIS standards.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/laser-hardening/2021/07/13/1222.html

[Case 2] 100 mm wide laser hardening

One disadvantage of laser hardening is that it cannot do hardening over a wide area, so several lines must be scanned in order to harden a wide area, which is a factor that causes higher cost of laser hardening. 
Using our 12 KW semiconductor laser and an optical system with a maximum width of 100 mm (which we introduced in March 2020), we are able to do laser hardening with a maximum width of 100 mm, helping to reduce the cost and turnaround time of laser hardening.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/laser-hardening/2021/07/13/1217.html

[Case 3] Fan-shaped plate laser hardening

When hardening fan-shaped plates by induction hardening as requested, there were two concerns.
・ There is a possibility that cracks will form in large holes near the outer diameter.
・ It is difficult to remove deformation

With laser hardening, there is no risk of cracks forming near holes around the outer diameter due to self-cooling. Also, deformation can be reduced to 0.1 mm or less by hardening both sides evenly.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/laser-hardening/2021/07/13/1211.html

“Laser cladding” to solve customers’ problems with latest technology

[Case 1] Drill hole laser cladding repair

One customer consulted with us saying that when they were drilling holes in plates they accidentally drilled holes in the wrong positions. They said that if they were to remanufacture the product, they would not meet the delivery deadline.
We do low heat input laser cladding work on parts with holes drilled.

Once machining was done, it was completely unrecognizable by sight alone.
This gave them a great advantage, as it both reduced remanufacturing costs and turnaround time.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/laser-cladding/2021/11/05/2520.html

[Case 2] Shaft laser cladding with a keyway

When making repairs with weld overlay or PTA overlay, it was necessary to add additional thickness of 1 mm or more to the finished size, which incurred extra cost in post-processing.
When we adopted overlay repair with laser cladding, post-processing after overlay was just 0.5 mm, that led to cost reduction.
We were also able to minimize collapse of the shape of the keyway.

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/laser-cladding/2021/07/14/1317.html

[Case 3] Wide laser cladding

We make full use of our 12 KW high-power semiconductor laser and wide-compatible clad nozzle (which we introduced in March 2020) to overlay large areas, which used to take time. By doing so, it has become possible to achieve a stable overlay speed of 3 times greater or more compared to conventional laser cladding (comparison made in-house).

■ Check details from the link below
https://www.fuji-koushuha.co.jp/technology/laser-cladding/2021/07/14/1309.html

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