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240 Landmarks TopProduction > FCD axle housing
 FCD axle housing
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Changing the axle housing material from cast steel to highly productive FCD enables substantial improvements in manufacturing environment and productivity. To achieve this change, a new technology was established that allowed diffusion bonding of steel at the end of FCD at the same time as forging, which was previously impossible due to chills and cracks. This made welding with the axle tube possible. This was the first application in the world of the cast-in diffusion bonding process technology to strength members. This technology enabled FCD axle housings for heavy-duty trucks, and substantial improvements in production and productivity.
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Storage location:HINO MOTORS LTD.
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Year manufactured:2004
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Manufacturer:Hino Motors Ltd.
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Classification:Mass-production part
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Current status:In use: open to the public
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Model:Heavy-duty truck, the Hino Profia FR1EXYJ, etc.
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Company name:Hino Motors Ltd.
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Familiar name:-
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Installation vehicle:Heavy-duty truck, the Hino Profia FR1EXYJ, etc.
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Year of manufacture:2004
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Designed by:Hino Motors Ltd.
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Collaboration:Hokkaido University, Aisin Takaoka Co., Ltd., etc.
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Structure, type, measure, means, etc.:See the figure on the right.
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Points of interest, topicality:Using a half-size mold of the axle housing and a S35 ring, BNi-3 powders were applied to the binder and the surface of the mixing ring. Ring volume was reduced by 50% for better heat supply from the periphery of the ring. After processes of trial and error that modified the so-called "Dakase" method for the runner in the ring periphery, continuous heat supply to the bonded surface was achieved by the this method and the newly invented "Hakase method".
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Features:The cast-in diffusion bonding process technology was established with the objective to give a weldability function to FCD materials. The key technology to obtain uniform joints in this diffusion bonding is a new casting method that optimally controls Ni thin film coating on the steel material side and molten metal flow. With this technology, a continuous slope structure from FCD to the steel material is realized, allowing an innovative bonded interface to be obtained when bonding FCD materials to different materials with 10% or more elongation. The fatigue strength of the material is equivalent to that of conventional cast steel without weakening the diffusion bonding interface, and highly reliable composite members could be obtained. As a result, the FCD cast-in diffusion bonding technology could be first applied to the strength members.
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Reference materials:Kuroki et al., Cast-in Diffusion bonding Process for Ductile-iron Axle Housing, Hino Technical Review, No. 55 (2004), etc.
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