Toyota Jidosha Kabushiki Kaisha

Kabushiki Kaisha Toyota Chuo Kenkyusho

Tokyo Sintered Metals Corporation

Mikio Kondo

Hiroshi Okajima

Yoji Awano

Shigehide Takemoto

Takeshi Hattori

Yoshitaka Takahashi

Shin Tajima

Masatoshi Sawamura

Akira Sekiguchi

Naoki Miyagawa

A pressurizing forming process includes the steps of applying a higher fatty acid-based lubricant on a surface of a metallic workpiece and/or a forming surface of a forming tool, and forming, wherein a lubricating film including metallic soap is formed on a pressurized-and-contacted interface, at which the surface of the metallic workpiece and the surface of the forming tool are pressed against and are brought into contact with each other, in forming the metallic workpiece by pressurizing with the forming tool. The metallic workpiece and/or the forming tool can be heated prior to or in the forming step.

Pressurizing forming process and pressurized-and-formed member

The present invention is an apparatus for filling a multi-powder including a powder box () including a plurality of powder chambers storing a plurality of powders whose constituent compositions differ in a divided manner, and a gas feed pipe () disposed on the bottom side of the powder chamber and having an introducing hole for introducing a gas, wherein it can fill a plurality of the powders into a cavity () at once through the bottom openings of the powder box by introducing a gas through the introducing hole to substantially equalize the respective flow resistances of a plurality of the powders. Thus, it is possible to fill the powders whose constituent compositions differ at once without disposing them in a mixed manner.

Composite powder filling method and composite powder filling device, and composite powder molding method and composite powder molding device

This invention provides a method of forming a powder compact which can produce a high density compact under a high pressure and at the same time can reduce pressure for ejecting the compact from a die. This method comprises the application step of applying a higher fatty acid lubricant to an inner surface of a heated die, and the compaction step of filling metal powder into the die and compacting the metal powder under such a pressure as to force the higher fatty acid lubricant to be chemically bonded with the metal powder and form a metallic soap coating. Since the metallic soap coating is formed between the die and a compact, friction force between the die and the compact is decreased and ejecting pressure can be remarkably decreased despite of compaction with high pressure. Besides, a high density compact can be obtained owing to the compaction with high pressure.

Method of forming a powder compact

The present invention is characterized in that, in a powder magnetic core obtained by compaction of an iron-based magnetic powder covered with an insulation film, a saturation magnetization Ms is Ms&#x2267;1.9 T in a 1.6 MA/m magnetic field; a specific resistance &#x3c1; is &#x3c1;&#x2267;1.5 &#x3bc;&#x3a9;m; a magnetic flux density Bis B&#x2267;1.1 T in a 2 kA/m magnetic field; and a magnetic flux density Bis B&#x2267;1.6 T in a 10 kA/m magnetic field. In accordance with the present invention, it has been possible to industrially carry out compacting iron-based magnetic powders under remarkably high compacting pressures. As a result, high-performance powder magnetic cores are obtained which have a high density, and which are good in terms of the specific resistance and magnetic permeability.

Dust core and method for producing the same

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Aichi, Japan

Mikio Kondo