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Ever since the creation of the spark plug, improvements have continually been made to achieve high ignitability and long life. To fulfill these requirements, “Iridium Spark Plug” was introduced in 1997 with fine-wire center electrode technology to promote ignitability and long life. Then in 2003 “Super Ignition Spark Plug” was developed which uses fine-wire precious metal alloys on both the center and ground electrodes to achieve supreme ignitability and long life. Currently, the global technology trend is focusing more and more on the regulation of emissions and fuel consumption. This is driven by increased awareness for environmental conservation. These regulations are becoming stricter, which leads to a higher demand for spark plug ignitability from all kinds of vehicles ranging from luxury cars through compact sized cars. Particularly in the small vehicle category, both ignitability and low cost are a requirement.

In a common rail type fuel injection system installed in recent diesel engines, a supply pump is needed to accumulate high pressure fuel. In this supply pump, a bushing is used for the outer cam system. The bushing is lubricated by diesel fuel with relatively low viscosity and unit load of the bushing is higher. Therefore, lubricating film thickness of the bushing is extremely thin. In order to ensure the bushing function under such severe sliding conditions, the bushing is required higher seizure resistance and higher fatigue resistance. Conventionally, lead bronze alloys are applied for the bushing material. We developed a new high performance copper alloy material without lead, which is one of substances of environmental concern. The newly developed bushing contains bismuth instead of lead for tribological component.

NOx reduction activity in an oxidizing exhaust gas was significantly improved by discharging non-thermal plasma and catalysts (plasma assisted catalysis). We investigated effective catalyst for plasma assisted catalysis in view of hydrocarbon-selective catalytic reduction(HC-SCR). Plasma assist was effective for γ-alumina and alkali or alkaline earth metals loaded zeolite and γ-alumina showed the highest NOx conversion among these catalysts. On the other hand, Plasma assist was not effective for Cu-ZSM-5 and Pt loaded catalyst. The NOx conversion for the plasma assisted γ-alumina decreased by formation of a deposit on the catalyst below 400°C. It is shown that indium loading on γ-alumina improved the NOx reduction activity and suppressed the degradation of the NOx reduction activity at 300°C with plasma assist.

To meet diesel emission regulations, high injection pressure is demanded for the supply pump of electronically controlled common-rail type injection system. DENSO has produced common-rail type injection system in 1999. Cam and roller to generate high pressure in the supply pump at the system are composed of steel and silicon nitride ceramics, and are rolling contact under light oil lubrication. Therefore, rolling contact fatigue failure had been concerned. In order to assure the components, we estimated the influence on the materials and the lubrication on the rolling fatigue strength of silicon nitride ceramics, the contact fatigue life was tested under oil lubrication.

Phosphating is a surface treatment process widely used for preparing metal surfaces before painting. The phosphate coating plays a very important role in enhancing after-painting corrosion resistance, which is one of the essential quality requirements of painted surfaces. Continued research and development is therefore under way in various parts of the world to increase the corrosion resistance enhancement effect of phosphating. Moreover, because the demand for environmental protection has been increasing in recent years, reducing the amount of waste (sludge) generated during the phosphating process is also strongly required. To meet these requirements, we have developed a novel phosphating technology called the “electrolytic phosphating process,” which drastically enhances corrosion resistance after painting and reduces sludge generation. The developed process has already been put to practical use for surface preparation before cation electrodeposition painting of automotive parts.

Among aluminum heat exchangers used for automotive air conditioning, the evaporator is located in the instrument panel. We have developed a new evaporator by: 1) improving the heat transfer performance through use of thinner tubes and fins; 2) establishing technologies for improving corrosion resistance and enabling reduction in wall thickness (development of highly corrosion-resistant material and control of Zn diffusion by shortening brazing time); and 3) improving refrigerant distribution in the tanks. The new evaporator is equivalent to our conventional MS Evaporator (of Multi-Tank Super-Slim Structure)(1) in cooling performance and corrosion resistance, while being significantly thinner (35% reduction) and lighter in weight (40% reduction).

Evaporator surface treatment technology is important for air conditioners in that it provides resistance to rust, odor and bacteria, while imparting hydrophilicity. However, since the first-layer chromate coating contains hexavalent chromium, an environmental loading substance whose stricter regulation is under consideration, development of an alternative technology is needed. We selected titanium coating for the first-layer non-chromate coating, and added an inhibitor to the second-layer multifunctional resin coating to impart a self-healing effect without undermining the other functions. As a result, we succeeded in developing a non-chromate surface technology that ensures the same level of rust resistance and other qualities as with conventional technology.