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Research paper : New material development by the integration of cast technology and powder metallurgy technology (K. Kobayashi et al.)−296−Synthesiology - English edition Vol.3 No.4 (2011) time. When the development of the hard material began, we aimed to replace some uses for cemented carbide, and it was clear that the outlet would be molds and cutting tools. Fortunately, the researcher who discovered this material had prior experience with cemented carbide in industry, and we were able to set the goal toward its realization relatively easily. It was difficult to achieve the targeted values using the conventional cemented carbide manufacturing process of the original hard material developed by AIST, but we were able to solve the issues steadily through the addition of new perspectives of researchers who were not directly involved in cemented carbides. However, the achievement of the target values did not lead to immediate practical utilization. By consistently transmitting the information at academic conferences for hard materials and by obtaining advice from the companies, we were able to find issues that brought us closer to realization. As a project for realizing this developed material, we obtained support from the Regional Consortium and the Strategic Core Industry Advancement Support Project (Support Industry) of the Ministry of Economy, Trade and Industry. Currently we are undertaking work towards realization through a collaboration of industry-academia-government, in addition to working towards establishment as a business. In the future, while the price increase of cobalt and its effects on the human body continue to cause concern for cemented carbides, further use can be expected due to the advancement of this development. The systems for supplying large and complex shaped members are being established, and we shall be able to provide samples to companies that are interested in this material. Our researchers are uniting to provide useful industrial material in the form of new hard materials featuring our WC-FeAl material.K. Kobayashi, K. Miwa and Y. Sakaguchi: Cemented carbide with high hardness and excellent oxidation resistance property (Kokodo de taisankasei ni sugureta chokogokin), Patent No. 2611177 (in Japanese).K. Kobayashi and K. Ozaki: Low-temperature formation method of aluminide intermetallic compound (Aruminaido kinzokukan kagobutsu no teiondo seikei gosei ho), Patent No. 2818860 (in Japanese).K. Kobayashi and K. Ozaki: Synthesis of aluminide intermetallics in low temperature using mechanical alloying process, Mater. Trans., JIM, 37, 738-742 (1996).K. Kobayashi and K. Sakazaki: Forming of FeAl intermetallic compound with Al liquid, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 42, 1247-1251 (1995) (in Japanese).K. Kobayashi, K. Miwa, M. Fukunaga and M. Machida: Preparation of cemented carbide with Fe-Al binder phase, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 41, 14-17 (1994) (in Japanese).M. Fukunaga, M. Machida, K. Kobayashi and K. Ozaki: Preparation of cemented carbide with FeAl binder phase by pulsed current sintering process, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder [1][2][3][4][5][6]ReferencesMetallurgy), 47, 510-514 (2000) (in Japanese).A. Matsumoto, K. Kobayashi, K. Ozaki and T. Nishio: Fabrication of FeAl-WC Composite Using Mechanical Alloying, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 48, 986-989 (2001) (in Japanese).A. Matsumoto, K. Kobayashi, T. Nishio, K. Ozaki and S. Tada: Fabrication of FeAl-WC by combustion synthesis and the mechanical properties, Euro PM2004 Conference Proceedings, 3, 641-645 (2004).K. Kobayashi, A. Matsumoto and K. Ozaki: Mechanical characteristic of WC-20 mass% Fe3Al mixture synthesized by short-term mechanical alloying, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 49, 284-289 (2002) (in Japanese).K. Kobayashi, A. Matsumoto, T. Nishio and S. Yasui: Change in binder phase of 75 vol% WC-FeAl mixture prepared by milling of elementary powders during pulsed current sintering, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 54, 269-273 (2007) (in Japanese).K. Kobayashi, K. Ozaki, S. Tada, T. Nishio and S. Yasui: Effects of WC particle size and the FeAl amount on mechanical property of WC-FeAl hard metal, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 55, 593-598 (2008) (in Japanese).K. Kobayashi, A. Matsumoto, K. Ozaki and K. Kikuchi: Fabrication of TiB2-20 mass% Fe3Al cermet using by mechanical alloying process, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 53, 58-61 (2006) (in Japanese).H. Nakayama, K. Kobayashi, K. Ozaki, S. Tada and H. Mikami: Characteristics of TiB2 added TiC-(Fe-Al) cermets fabricated by pulse current sintering, Funtai Oyobi Fummatsu Yakin (Journal of the Japan Society of Powder and Powder Metallurgy), 56, 775-779 (2009) (in Japanese).[7][8][9][10][11][12][13]AuthorsKeizo KobayashiObtained master’s degree at the Department of Metallurgy, Graduate School of Engineering, Osaka University in March 1986. Initially joined Kobe Steel, Ltd. and then moved to the Nagoya National Industrial Research Institute, Agency of Industrial Science and Technology in 1989. Research interests include levitation melting and casting for titanium alloys, semi-solid forming technology for magnesium alloys, and non-equilibrium powder synthesis technology by mechanical alloying. Doctorate (Engineering) obtained at Osaka University in July 1997. Leader of Phase Engineering for the Processing Group, Institute of Structural and Engineering Materials, AIST in April 2001. Leader of Phase Engineering for the Advanced Material Group, Material Research Institute for Sustainable Development from April 2004. In this disclosure, developed the WC-FeAl hard material using experience with cemented carbides, obtained the patent, proposed the overall plan, and managed the research.

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