Papers by Author: Hirotaka Tanabe

Abstract: This paper proposes a novel process strategy for micro-cutting edge fabrication. Micro-cutting edges need a hardening process for the ridgeline parts that requires abrasive resistance, as well as edge sharpness and shape accuracy, based on their applications. Micro-cutting edge shapes also vary greatly in ridgeline profile and section. The proposed method is shape fabrication after laser hardening, which easily addresses these issues. In the present paper, effects of the proposed method are discussed and the results of a demonstration test are introduced.

Abstract: In our previous studies, a new surface modification method by combination of ceramic coating and heat treatment, named “substrate quenching after coating” was developed. The thrust type rolling contact fatigue tests were carried out for TiN coated steels and CrAlN coated steels processed by substrate quenching after coating, and the effects of the type of ceramic coating (TiN or CrAlN) and the quenching methods (by furnace quenching or by laser quenching) on the flaking initiation life were investigated. For the specimens quenched by furnace, the flaking life of CrAlN coated specimen was longer than that of TiN coated specimen. This reason could be explained by the difference of the oxidization of CrAlN and TiN in their furnace quenching process. For CrAlN coated specimens, the flaking life of the specimens quenched by laser was longer than that of the specimens quenched by furnace. This reason could be explained by the difference of the process time of the furnace quenching and the laser quenching. It is considered that laser quenching after coating could be an effective way to improve the flaking initiation life under rolling contact fatigue.

Abstract: In order to identify the mechanisms of changes in the magnetic flux density distribution around fatigue cracks that occur during crack propagation, JIS SCM440 specimens were fatigue tested, and the relation between crack morphology and magnetic flux density distribution was investigated. Two features were observed: a high intensity area around the crack tip, and a low intensity area around the crack root. The low intensity area grew larger for wide open cracks and disappeared when the crack was closed by external force. It was hence found that the magnetic flux density distribution is strongly affected by the crack opening.

Abstract: In our previous study, it has been shown that improvement of the adhesive strength and substrate hardness of ceramic coated steels without compromising the film hardness can be achieved by applying laser quenching. In the present research, in order to quench a larger area of ceramic coated steel uniformly and efficiently, a high power diode laser equipped with a galvano-scanner unit was used in the laser heat treatment process. The scanning laser irradiation conditions to achieve uniformly quenched substrates without any surface damage were investigated for 3 kinds of ceramic-coated steels: CrAlN, TiAlN and CrN. The film hardness and adhesive strength of the laser irradiated regions were evaluated. It is shown that scanning laser quenching after coating effectively improved the mechanical properties for larger area of ceramic-coated steels.

Abstract: In our previous study, it has been shown that improvement of the adhesive strength and substrate hardness of ceramic coated steels without compromising the film hardness can be achieved by applying laser quenching. In the present research, in order to demonstrate further development of this method, the fracture strength of laser-irradiated ceramic thin films (CrAlN, TiAlN and CrN) was investigated by sphere indentation testing. To prevent heat-induced changes in the substrate hardness, a cemented carbide WC-Co rather than steel was used as substrate material. While the fracture strength of each film decreased significantly through furnace heat treatment, it remained almost unchanged in case of the laser irradiated films. Laser quenching has been shown to effectively reduce the fracture strength loss of the ceramic thin films in coated steels.

Abstract: In order to investigate the effectiveness of laser quenching for ceramic coated steels, 2 kinds of ceramic coated specimens of CrAlN and TiAlN were prepared, and the laser quenching experiments under various irradiation conditions were carried out. The influence of laser irradiation on the substrate hardness, film hardness and adhesive strength were investigated. Because of the high heat absorption of CrAlN and TiAlN films when compared to TiN, it was possible to quench the substrate effectively without any absorbent material for these specimens, although an absorbent was required for TiN coated specimen. The quenched area on the cross section of the substrate of CrAlN coated specimen was larger than that of TiAlN coated specimen. The difference of the quenched area could be explained by the difference of the heat absorption of these films. It was also possible to improve the adhesive strength of these films by laser irradiation. Although the film hardness decreased considerably by furnace quenching for ceramic coated steels, film hardness did not decrease by laser irradiation. It was concluded that the improvement of the adhesive strength and substrate hardness without the decrease of film hardness was achieved by laser quenching for CrAlN and TiAlN coated specimens.

Abstract: Fatigue failure of steel occurs when cracks form in a component and continue to grow to a size large enough to cause rupture. In order to understand the crack initiation and propagation phenomena, non-destructive evaluation methods that can be correlated to in-situ measurements around the crack tips are necessary. In the present work, we developed a scanning Hall probe microscope (SHPM) equipped in a GaAs film sensor to observe fatigue cracks at room temperature in air while they were growing. Medium carbon low alloy steels specimens (JIS S45C) were used in the experiments. Only the area around the crack tip was magnetized and the changes at the crack tips were observed.

Abstract: Fatigue failure of steel occurs when cracks form in a component and continue to grow to a size large enough to cause fracture. In order to understand the strength of a steel component, it is important to locate these cracks. We developed a scanning Hall probe microscope (SHPM), equipped with GaAs film sensors to observe fatigue cracks at room temperature in air while they were growing. In our previous works [1,2], the correlation between crack growth and magnetic field in high carbon tool steels (JIS SKS93 and JIS SUJ2) were determined. We also reported the sensitivity of the SHPM equipped with a three-dimensional line-probe that was developed to decrease the sensor gaps. By using the line-probe sensor we succeeded to measure the magnetic flux density distributions in very close proximity to the specimen’s surface. However, in order to further understand the relation between magnetic flux density and crack growth, other materials, microstructures and fatigue test conditions should be evaluated. In the present work, we focus on the effect of stress ratios on the changes of the magnetic flux density in annealed carbon tool steel.