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The new die cast (HPDC) wheel alloy has been developed using recycled aluminum to attain considerable reduction of energy at the time of material production to make large contribution to the reduction of CO2 emissions. The material for motorcycle body parts, especially for wheels, requires a sufficient elongation property. However, when recycled aluminum, which contains large amount of impurities, is used as main raw material, the intermetallic compounds crystalize out and the elongation property is deteriorated. Accordingly, we firstly made the investigations on the elements contained in a recycled aluminum and it was clarified that the elongation property was correlated to the shape of crystallized iron-based intermetallic compounds.

Manganese oxides show high catalytic activity for CO and HC oxidation without including platinum group metals (PGM). However, there are issues with both thermal stability and resistance to sulfur poisoning. We have studied perovskite-type YMnO₃ (YMO) with the aim of simultaneously achieving both activity and durability. This paper describes the oxidation activity of PGM-free Ag/i-YMO, which is silver supported on improved-YMO (i-YMO). The Ag/i-YMO was obtained by the following two methods. First, Mn⁴+ ratio and specific surface area of YMO were increased by optimizing composition and preparation method. Second, the optimum amount of silver was supported on i-YMO. In model gas tests and engine bench tests, the Ag/i-YMO catalyst showed the same level of activity as that of the conventional Pt/γ-Al₂O₃ (Pt = 3.0 g/L). In addition, there was no degradation with respect to either heat treatment (700°C, 90 h, air) or sulfur treatment (600°C to 200°C, total 60 h, 30 ppm SO₂).

A hexavalent-chromium-free metal gasket for PWC engines was developed to correspond to the ELV (End of Life Vehicle) directive. In order to enhance the adhesive property, the ion capture to trap the chloride ion, an anti-rust pigment to reform the chemical coating, and an inorganic sealer to stop the passage of chloride ion were added to the adhesive and rubber raw material. A good adhesive property and rubber physical property was obtained through the addition of an anticorrosive pigment. The rubber vulcanization condition in the manufacturing process was reviewed. As a result, without modifying the current compound coating line for mass-production, a gasket with a blistering resistance more than hexavalent chromium conversion coating equivalence and coating adhesion was developed when using salt water for engine cooling.

In recent years, emission regulations have become more stringent as a result of increased environmental awareness in each region of the world. For diesel engines, reducing NOX emissions is a difficult technical challenge.[1],[2],[3],[4]. To respond to these strict regulations, an exhaust gas aftertreatment system was developed, featuring a lean NOX catalyst (LNC) that uses a new chemical reaction mechanism to reduce NOX. The feature of the new LNC is the way it reduces NOX through an NH3-selective catalytic reduction (SCR), in which NOX adsorbed in the lean mixture condition is converted to NH3 in the rich mixture condition and reduced in the following lean mixture condition. Thus, the new system allows the effective reduction of NOX. However, in order to realize cleaner emission gases, precise engine control in response to the state of the exhaust aftertreatment system is essential.

Owing to its combustion characteristics and chemical composition, natural gas features cleaner emissions and lower CO2 compared to gasoline under equal thermal efficiency. Natural gas can be a promising alternative energy source to respond to crude oil exhaustion and global warming issues. Focusing on the utility of natural gas, a feasibility study on CNG (Compressed Natural Gas) -fueled two-wheeled vehicles has been conducted. A proto-type two-wheeled vehicle was made based on a 125 cm3 class gasoline-fueled scooter. To adapt the engine to the use of CNG fuel, an electronically controlled gas injection system was applied to the fuel supply system. To provide abrasion resistance of engine valves and valve seats, the specific matter of gas-fuel was improved. Furthermore, a lubricant circulation passage was added to maintain the temperature of the pressure reducing valve.

Crankshafts of motorcycles require high strength, high reliability and low manufacturing cost. Recently, a reduction of Pb content in the free-cutting steel, which is harmful substance, is required. In order to satisfy such requirements, we started the development of Pb-free free-cutting steel which simultaneously enabled the omission of the normalizing process. For the omission of normalizing process, we adjusted the content of Carbon, Manganese and Nitrogen of the steel. This developed steel can obtain adequate hardness and fine microstructure by air-cooling after forging. Pb-free free-cutting steel was developed based on Calcium-sulfur free-cutting steel. Pb free-cutting steel is excellent in cutting chips frangibility in lathe process. We thought that it was necessary that cutting chips frangibility of developed steel was equal to Pb free-cutting steel. It was found that cutting chips frangibility depend on a non-metallic inclusion's composition, shape and dispersion.

The purpose of our research is to omit normalizing after hot forging in nitrocarburized crankshafts. Based on fundamental studies about the influence of chemical composition on as-forged and nitrocarburized properties, the authors have developed a new nitrocarburizing steel composed of 0.3% carbon, 0.8% manganese, and 0.02% nitrogen. The newly designed crankshafts for compact cars using the steel can be in use without the normalizing and have equivalent properties to conventional crankshafts, though the treatment is an indispensable process for conventional ones.