ネツレン　高周波熱錬 List of Products and Services

The mild carburizing process was developed in 2006 by Aisin Corporation (formerly Aisin AW Co., Ltd.) and is a heat treatment technology that has already been mass-produced for gears, bearing races, shafts, and more. By combining vacuum carburizing and high-frequency quenching, it leverages the advantages of both methods and exhibits the following features: - Enables longer lifespan, smaller size, and lighter weight of components - Simplifies the finishing process - Reduces material costs and improves machinability - Contributes to carbon neutrality * Mild carburizing is a patented technology of Aisin Corporation. Our company conducts heat treatment contract processing under license.

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This is a subscription plan for the Netsuren equipment you are currently using. Please feel free to consult us regarding the details.

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This is a equipment sales plan available for a fixed fee (monthly or annually). Please consult with us.

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Butt-joined processing allows for flexible adjustment of the thickness of pipe materials through inner and outer diameter drawing. It enables inner diameter slimming without cutting! This contributes to weight reduction and material cost savings. Additionally, even in thin sections, performing IH heat treatment provides high strength and high toughness, achieving high bending fatigue strength. Example) "Before processing" Weight: 704g Total length: 300mm ↓ "After butt-joined processing" Weight: 576g Total length: 300mm - Reduction rate: 49% - Wall thickness (thinning): -31.9% - Weight reduction: 18.2%

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When using water-soluble quenching fluids, the cooling rate can change due to thermal degradation and contamination. If management is conducted solely with a concentration meter, it may not necessarily align with the quenching quality. Our cooling capability measurement service can assist in high-quality coolant management by measuring the "cooling rate" with our specially developed measurement equipment. This can be utilized as documentation for improving quality assurance levels and determining the timing for coolant replacement.

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The "Pre-Grout PC Steel Bar," developed to prevent insufficient grout filling at construction sites, is shipped from our controlled factory with the PC steel bar coated in grout and a sheath. This eliminates the need for sheath placement and grout work at the construction site, contributing to improved efficiency, shortened construction periods, and enhanced reliability of structures. We also provide coupler sheaths treated for rust prevention for use at the connection points. 【Features】 - The surface of the PC steel bar is coated with pre-grout resin and high-density polyethylene sheath, providing excellent corrosion resistance (tested for salt spray and alkali resistance). - Eliminating the need for sheath placement and grout work at the site contributes to reduced labor costs. - The use of PC steel bars as tensioning materials offers excellent self-support and connectivity, improving work efficiency. - It is possible to select pre-grout resins suitable for various environments (moisture-curing type, heat-curing type).

• Bridge Materials
• Secondary steel products

We can perform high-frequency heat treatment on large components as well. We offer various heat treatment solutions for oversized parts, including mobile quenching and single-shot quenching. (Large wheel component Φ1600mm) *We will accommodate your requested heat treatment specifications.

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We design, manufacture, and engineer equipment and systems to achieve inline induction heating, energy saving, and labor reduction in various industrial fields such as the automotive, construction machinery, machine tool, steel, chemical, and home appliance industries. As service bases, we have locations in Kanagawa and Nagoya, as well as overseas in the United States, China, Indonesia, Mexico, and South Korea, providing global support and services. We commercialize high-frequency power supply devices using SCR, IGBT, MOSFET, and SiC semiconductors, ranging from 0.5 to 400 kHz and 2.5 to 2,000 kW. Additionally, we have practical applications for CAE analysis up to metal transformation and "low (constant) deformation contour quenching technology" for gears and shafts, enabling us to provide equipment that ensures high quality stability in heat treatment. *Induction heating (IH) technology uses green electricity as a heat source and contributes to the reduction of CO2 emissions.

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We provide integrated manufacturing not only for conventional heat treatment processing but also for material procurement to finishing processes. We can accommodate your requests, including handling only specific processes if needed. Additionally, we can support integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, we can also expect a reduction in CO2 emissions in terms of transportation.

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By incorporating the preceding and subsequent processes into conventional heat treatment contract processing, we handle everything from material procurement to processing, various heat treatments, finishing, and assembly, delivering it as "completed parts." Since everything is completed solely by Netsuren, we provide a consistent quality assurance system and reduce our customers' "multi-process management." We primarily operate from two domestic factories (Ibaraki Prefecture and Hyogo Prefecture). For any inquiries regarding various projects, please feel free to consult your nearest sales office.

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Since its establishment in 1946, Netsuren has been a pioneer in induction heating, receiving requests for "surface heat treatment processing" that contributes to the improvement of the mechanical properties of steel components from various industries such as automotive, construction machinery, machine tools, and steelmaking, based on advanced heat treatment technology and extensive track record. We have four domestic factories (in Ibaraki, Aichi, Hyogo, and Okayama) and bases in three overseas countries (China, Indonesia, and Mexico), enabling us to support our customers' global expansion. We also accommodate various prototype requests, so please feel free to consult with your nearest sales office.

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We provide integrated manufacturing not only for conventional heat treatment processing but also for material procurement to finishing processes. We can accommodate your requests, including handling only specific processes if needed. Additionally, we can support integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, we can also expect a reduction in CO2 emissions in terms of transportation.

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We provide integrated manufacturing not only for conventional heat treatment processing but also from material procurement to finishing. We can accommodate your requests, including handling only specific processes. Additionally, we can support integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, CO2 reduction in transportation can also be expected.

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We provide integrated manufacturing not only for conventional heat treatment processing but also for material procurement to finishing processes. We can accommodate your requests, including handling only specific processes if needed. Additionally, we can support integrated manufacturing for both small and large items. Please feel free to consult with us. *Since it is integrated manufacturing, we can also expect a reduction in CO2 emissions in terms of transportation.

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We can perform high-frequency heat treatment on oversized components as well. We offer various heat treatment solutions for oversized parts, including mobile quenching and single-shot quenching. (Large wheel component Φ1600mm) *We will accommodate your requested heat treatment specifications.

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We accommodate a variety of vehicles, from light cars to large trucks. We have established a mass production system and are producing with a consistent quality assurance system. *Prototype production is also available, so please feel free to inquire.

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We can also perform high-frequency heat treatment on large components. We cater to a wide range of heavy and large industrial machinery, from construction machinery to others. (Large double helical gear Φ1180mm, approximately 26t) *We will accommodate your requested heat treatment specifications.

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We handle a variety of parts from light vehicles to large trucks. We have established a mass production system and are producing with a consistent quality assurance system. We also accommodate heat treatment and painting processes. *Prototyping is also available, so please feel free to contact us.

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We provide a reliable quality assurance system for various parts, such as engines and chassis components, where "safety" is prioritized. Our contract processing has bases in four domestic factories (Ibaraki, Aichi, Hyogo, Okayama) and three overseas countries (China, Indonesia, Mexico), enabling us to support our customers' global expansion.

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We contribute to the stable operation of our customers with a comprehensive after-sales service menu even after the equipment is delivered. We also offer preventive maintenance options such as regular inspections of high-frequency power supplies. We provide global support, including two locations in Japan, as well as sites in the United States, China, Indonesia, Mexico, and South Korea.

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This is a device for measuring the cooling capacity of the quenching liquid that is used regularly. The cooling capacity of the quenching liquid changes with daily use. By using Netsuren's "Cooling Capacity Measurement Device," you can manage daily cooling capacity as well as determine the timing for replacing the quenching liquid.

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This is a general-purpose vertical single-axis machine. Custom-made design and manufacturing tailored to customer needs, including compatible models, is also possible. If production as a standard Netsuren machine is feasible, we will also propose cost advantages. It can be combined with various output high-frequency power supplies, allowing for heat treatment and heating equipment that meets customer specifications.

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This is an advanced version of the high-frequency power supply device "MK16A type." By digitizing the control mechanism (FPGA: field-programmable gate array), it enables support for a wider variety of production compared to existing models. It is also possible to record operational data independently from the power supply unit, thus addressing customers' requests for "preventive maintenance." It can be manufactured in a wide output range (50 to 1200 kW) for small to large components.

• Power generation equipment

The irregular PC steel bar "Ulbon(R)" is a high-strength PC steel bar that excels in adhesion performance with concrete and spot weldability. Due to its excellent performance and ease of use, it has received high praise in the pile and pole industry and is widely used as a tensioning material. 【Features】 - Under appropriate working conditions, using a spot welding automatic assembly machine for rebar cage assembly does not significantly reduce mechanical properties. - It has very little relaxation and remains stable even over long periods. - The surface of the steel bar is formed with spiral grooves along its entire length, providing excellent adhesion to concrete. - When unwound, the coil material becomes straight, eliminating the need for correction work. - The cross-sectional shape is uniform along its entire length, allowing for direct rolling screw processing. - Our warm forging system enables head processing without reducing mechanical properties, allowing for economical fixation.

• Bridge Materials
• Secondary steel products

This is a steel rod that has been softened to below 1200 MPa in the surface layer, which is the starting point for delayed fracture, in relation to high-strength steel materials (tensile strength reference: 1200-2200 MPa), thereby reducing the risk of delayed fracture (patent obtained). By applying this technology, the delayed fracture resistance (hydrogen embrittlement resistance) of high-strength steel materials and high-stress components can be significantly improved, and the softening of the surface layer enhances workability, making machining easier. It has been mass-produced for use in high-stress spring steel wire, high-strength deformed PC steel rods, etc.

• Steel

Netsuren "ITW(R)" imparts the necessary mechanical properties to carefully selected materials through high-frequency quenching and high-frequency tempering, and conducts flaw inspection using eddy current testing along the entire length, as well as quality assurance through monitoring of heat treatment temperatures. It is manufactured on a per-coil basis, ensuring uniform wire diameter and strength throughout the entire length. Additionally, the variation between product coils is kept to a minimum.

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As a pioneer in high-strength spring steel wire for cold forming, we supply it worldwide (Production bases: Japan, China, the United States, Europe). Netsuren "ITW(R)" imparts the necessary mechanical properties to carefully selected materials through high-frequency quenching and high-frequency tempering, and conducts quality assurance over the entire length through eddy current testing for defects and monitoring of heat treatment temperatures. We manufacture in units of one coil, ensuring uniform wire diameter and strength throughout the entire length. Additionally, the variation between product coils is kept to a minimum. 【Features when formed into springs】 - Variation in shape is minimized. - While being high-strength, it allows for the formation of springs with a small D/d ratio. - Both durability and resistance to deformation are at the highest level. - High operating stress can be achieved, enabling weight reduction. - Spring manufacturing through cold forming can significantly reduce CO2 emissions compared to hot forming.

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The NAPP method involves placing pre-tensioned hollow PC steel rods, called "NAPP units (R)," within a formwork, and after pouring and curing the concrete, releasing the tension to introduce prestress into the concrete. The tension is introduced at our factory, which is strictly managed, and delivered to the site. At the construction site, prestress can be introduced without using reaction abutments or hydraulic jacks, eliminating the need for complex tension management, sheath placement, and grouting. This method is particularly efficient in challenging work environments, such as high altitudes, where introducing prestress is difficult. ■ Examples of NAPP method implementation Reinforcement of external cable anchorage, reinforcement of misalignment sections, reinforcement of PC steel anchorage, shear reinforcement, and lateral tightening. ■ Examples of NAPP anchor method implementation Widening of existing bridge abutment edges, reinforcement of external cable anchorage, and reinforcement of bridge substructures (widening of low slabs).

• Renovation and repair methods

Neji-Bon(R) is a fully threaded PC steel bar that has a thread shape similar to mechanical joints used in reinforced concrete structures and provides mechanical properties equivalent to PC steel bars. 【Features】 - Since the thread rolling process is unnecessary, it can be cut to any desired length on the construction site and fixed in place. - It can be supplied as a set with fixation accessories. - Upon request, we also offer epoxy resin coating with excellent rust prevention properties.

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PC steel bars are high-strength steel bars used in prestressed concrete, which improves the properties of concrete that is weak in tension by applying compressive forces in advance, thereby significantly enhancing the strength of concrete structures. They are used to continuously apply high stress, around 80% of the yield point, to compress the concrete. Netsuren PC steel bars have been widely used for over half a century in various applications, including foundation concrete piles, concrete poles for power transmission and communication, concrete sleepers for railways, sewers, box culverts for utility trenches, as well as in bridges and buildings. 【Features】 - Manufactured under one of the best quality control systems in the country, they possess stable mechanical properties and relaxation characteristics. - The ends are processed with rolled threads, allowing for anchoring. - Unbonded PC steel bars are also available, coated with a special asphalt-based polymer on the surface.

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Cold Sequential Forming Technology (Case Study of Tooth Forming for Hollow Steering Rack Bars) ◉ Technology Introduction By combining the new plastic processing technology "Cold Sequential Forming" with our expertise in "High-Frequency Heat Treatment," we manufacture hollow rack bars for steering, significantly contributing to the lightweighting of automobiles. - Features ◆ Optimal lightweight structuring through "Cold Sequential Forming" from pipe materials ◆ Achieving machining accuracy equal to or greater than that of cutting processes (tooth section) ◆ The smoothness of the tooth surface unique to cold plastic processed products enables low friction (low μ) performance

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- DH (Direct Resistance Heating) is a method of directly heating a conductive object by passing current through it, utilizing the Joule heat generated by the object's internal resistance. It enables rapid heating of both "rectangular" and "non-rectangular" thin plates. - Features ◉ Reduction of CO2 emissions ◉ High energy conversion efficiency from electricity to heat ◉ Increased speed and space-saving through rapid heating ◉ Shortened startup time due to rapid heating ◉ Improved process flexibility through high controllability ◉ Control of heating speed and capability for rapid heating

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- DH (Direct Resistance Heating) is a method of directly heating a conductive object by passing current through it, utilizing the Joule heat generated by the object's internal resistance, and it allows for the heating of continuous wire materials. - Features ★ Low CO2 emissions ★ Control of heating speed, rapid heating ★ Partial heating is also possible ★ Safe for products and people as no voltage is generated between the electrodes ★ Space-saving due to compact structure ★ The device is compact and space-saving

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The "Pre-Grout PC Steel Bar," developed to prevent insufficient grout filling at construction sites, is shipped from our controlled factory with the PC steel bar coated with grout and a sheath. This eliminates the need for sheath placement and grout work at the construction site, contributing to improved efficiency, shortened construction periods, and enhanced reliability of structures. We also provide coupler sheaths treated for rust prevention for use at the joints. 【Features】 - The surface of the PC steel bar is coated with pre-grout resin and high-density polyethylene sheath, providing excellent corrosion resistance (salt spray test and alkali resistance test conducted). - Eliminates the need for sheath placement and grout work at the site, contributing to labor reduction. - The use of PC steel bars as tensioning materials offers excellent self-supporting and connectivity properties, improving work efficiency. - It is possible to select pre-grout resins suitable for various environments (moisture-curing type, heat-curing type).

• Bridge Materials

Since its establishment in 1946, Netsuren has commercialized high-efficiency and highly reliable high-frequency power supply devices as a pioneer in induction heating, leveraging advanced technology and extensive achievements for various applications. The Netsuren MK series high-frequency power supply devices offer a wide range of outputs (2.5 to 2,000 kW) and frequencies (0.3 to 400 kHz) using SCR, IGBT, MOSFET, and SiC semiconductors. 【Features】 - Industry-leading stability and high reliability - High efficiency, compact design, and reduced cooling water requirements - Easy maintenance and inspection, comprehensive after-sales service - Excellent safety design (reliable protection circuits)

• Secondary steel products

This is a spiral shear reinforcement bar used as shear reinforcement for cast-in-place piles. The only high-strength shear reinforcement bar that has received certification and general evaluation from the Minister of Land, Infrastructure, Transport and Tourism is "Ulvon 1275(R)." 【Features】 - Cost reduction and shortened construction time are possible due to the reduction in pile cross-section. - The use of high-strength shear reinforcement bars significantly improves deformation capacity. - The diameter of the shear reinforcement bars can be reduced compared to using ordinary rebar, resulting in a decrease in the amount of rebar used. Additionally, the workability of the concrete is improved. - On-site welding is not required, allowing work to be carried out even in rainy conditions, ensuring consistent quality. - The strength of the pile is increased, and performance is enhanced.

• Steel

The 'High-Strength Shear Reinforcement Bar Urubon 1275' is a deformed PC steel bar certified by the Minister of Land, Infrastructure, Transport and Tourism, with a yield point of 1275 N/mm² and a tensile strength of 1275 N/mm². Compared to conventional ordinary rebar (SD bars), it can achieve a maximum design stress up to four times higher, significantly reducing the amount of rebar used and contributing to cost and schedule reductions for customers (resource conservation, CO2 reduction). This time, we obtained performance evaluation from the Better Living Foundation for the calculation formula of the required bond length for the cutoff of the second main reinforcement bar using 'Urubon 1275'. By using this new calculation formula, it has become possible to reduce costs (shortening the length of the second main reinforcement bar and reducing the number of joints) and shorten construction time (reducing installation and inspection work hours). - It is possible to reduce the number of joints by 30-50% compared to conventional methods. - The reduction in joint locations leads to decreased installation and inspection work hours. - We provide a calculation tool (utilizing CSV data) for determining cutoff lengths. *Cost comparisons with other products can be calculated. Please feel free to contact us.

• Secondary steel products

The 'High-Strength Shear Reinforcement Bar Ulbon 1275' is a deformed PC steel bar certified by the Minister of Land, Infrastructure, Transport and Tourism, with a yield point of 1275 N/mm² and a tensile strength of 1275 N/mm². Compared to conventional ordinary rebar (SD bars), it allows for a maximum design stress up to four times greater, significantly reducing the amount of rebar used and contributing to improved work efficiency, cost reduction, and shortened construction periods at job sites (resource conservation, CO2 reduction). With the addition of the new bar diameter U11.8 to the lineup, further design options tailored to various member cross-sectional widths have become possible. The new bar diameter U11.8 demonstrates effectiveness with column cross-sections of 1,100 mm square for heights of 30 to 60 meters (levels 10 to 20), enabling approximately a 10% reduction in rebar quantity compared to conventional diameters. * The new bar diameter U11.8 has already obtained certification from the Minister of Land, Infrastructure, Transport and Tourism and evaluation from the Japan Building Center (general construction method and welded joint method).

• Secondary steel products

The "High-Strength Shear Reinforcement Bar Ulbon 1275" is a deformed PC steel bar certified by the Minister of Land, Infrastructure, Transport and Tourism, with a yield point of 1275 N/mm² and a tensile strength of 1275 N/mm². Compared to conventional ordinary rebar (SD bars), it can increase the design stress by up to four times, significantly reducing the amount of rebar used and contributing to improved work efficiency, cost reduction, and shortened construction periods at construction sites (resource conservation, CO2 reduction). Additionally, by accommodating the high-strength requirements of columns and beams in reinforced concrete (RC) structures, it enables the construction of super-tall buildings over 60 meters high. * A design method using bonded split reinforcement bars (based on plastic theory shear resistance formulas and patented methods by Netsuren) has been established, allowing for reinforcement of up to 1.5% as P_w + P_b (bonded split reinforcement ratio).

• Steel

We design, manufacture, and engineer equipment and systems to achieve inline induction heating, energy saving, and labor saving in various industrial fields such as automotive, construction machinery, machine tools, steel, chemicals, and home appliances. As service bases, we have locations in Kanagawa and Nagoya, as well as overseas in the United States, China, Indonesia, Mexico, and South Korea, providing global support and services. We commercialize high-frequency power supply devices using SCR, IGBT, MOSFET, and SiC semiconductors, ranging from 0.5 to 400 kHz and 2.5 to 2,000 kW. Additionally, we have practical applications for CAE analysis up to metal transformation and "low (constant) deformation contour quenching technology" for gears and shafts, enabling us to provide equipment with high quality stability in heat treatment. *Induction heating (IH) technology uses green electricity as a heat source and contributes to the reduction of CO2 emissions.

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This is a technology that allows for the formation of a flange (creating a bulge on the shaft) through plastic processing without cutting or forging the shaft material. It has been successfully applied in gear pump shafts, intermediate shafts, ball screws, etc. 【Features】 - There is no material loss. (It can also handle difficult-to-machine materials such as titanium.) - Processing time can be significantly reduced compared to cutting processes. - Flanging can be performed on large diameter and long products (up to φ70mm, up to L600mm). - Since it is not a hot processing method, CO2 emissions can be significantly reduced.

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In conventional heat treatment using furnaces, it was difficult to apply heat to the entire steel material while only treating the necessary parts. However, by utilizing high-frequency induction heating (IH) to selectively harden only a portion of the steel (enhancing strength and durability), we have achieved multiple strength levels with a single steel rod. By placing high-strength sections in areas that require structural integrity and low-strength sections in other areas, it is possible to control damage and reduce material usage. Using this technology and product, we have started selling high-strength rebar placed in column-beam joints, named "Double Stark®," which contributes to damage control in structures, reduction of rebar quantity, improved workability, and comfortable living spaces. *In 2018, we received the "Super" Monozukuri Parts Award and the Lifestyle-Related Parts Award.

• Steel

"IH + Axial Expansion" is an innovative flange-forming process that takes the environment into consideration. It is a sequential process that shapes a flange approximately three times the diameter of the material. This reduces material costs and energy consumption. It can be used for processing bar materials and pipe materials. We also accommodate prototype requests, so please feel free to consult with us. 【Features】 ■ Suppression of grain coarsening ■ Improved dimensional accuracy ■ Reduction of scale adhesion ■ Reduction of material costs ■ Reduction of energy consumption *For more details, please refer to the PDF document or feel free to contact us.

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We manufacture and sell pre-hardened materials with excellent straightness by performing high-frequency heat treatment on various special steel materials, including structural steel, die steel SKD61, high-speed tool steel SKH51, and stainless steel. According to customer requirements, we deliver products in a nearly complete form, including centerless grinding, cutting to product length, center hole processing, and chamfering. 【Features of Netsuren Pre-Hardened Materials】 - We deliver steel types with significant heat treatment warping and thin materials in a straight condition, eliminating (or greatly reducing) the need for straightening processes. (Example: SUS440C φ2.0x2200L with warping of less than 30μm) - Due to short-time quenching with high-frequency heating, almost no decarburization layer occurs on the surface, allowing for reduced grinding allowance in subsequent processes. (Process shortening, resource saving) - We also provide centerless grinding, delivering materials with industry-leading roundness and cylindricity. (Example: AISI4150 with roundness of less than 2μm and cylindricity of less than 3μm) - Not only surface hardening but also through hardening is possible. - We can also accommodate hollow materials.

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Through Neturen's unique cold sequential forming technology, we can shape the rack teeth from pipes, enabling a weight reduction of up to 50% compared to solid materials. Additionally, by performing full circumferential quenching, we process products that maintain precision while achieving high strength. The rack teeth can be formed into a V.G.R. (Variable Gear Ratio) shape, allowing us to meet the needs for quick stroke end and increased manual assist force at the stroke end. Since 2016, we have started mass production of hybrid rack bar blanks that combine hollow rack bars with solid materials through friction welding to support double pinion EPS.

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