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Honda has developed, in collaboration with Hitachi Metals and Daido Steel, two types of low-nickel heat-resistant alloys for exhaust valves which are more cost effective than the conventional nickel alloys. They are NCF4015 that contains approximately 40% nickel and NCF3015 with approximately 30% nickel content. The two types of new alloys were developed based on our unique alloy design concept. Both alloys feature superb high-temperature strength and are capable of maintaining favorable material properties, even after an high-temperature exposure. The NCF4015 is compatible with the conventional Inconel 751 and 60Ni alloys in terms of high-temperature strength. The NCF3015 falls slightly behind the two metals, but overwhelms the 21-4N (SUH35) in high-temperature strength. The exhaust valves made of the two alloys developed have been used for mass production engines.

Two or more aftertreatment systems will be required for diesel vehicles to reduce PM and NOx, simultaneously and achieve the same levels of exhaust emissions as gasoline vehicles. Thus, aftertreatment devices such as the DPF and DeNOx catalyst need to be compact and less restrictive to exhaust gas flow. An IP Filter for removing particulate in exhaust gas has been developed to reduce both unit size and pressure drop and structured to integrate the DOC and DPF functions into one unit. A conventional wall-flow DPF has a cellular structure with either individual open-end or closed-end channels on both the inlet and outlet sides. The IP Filter has no plugs on the front end but has plugs at the interface of the DOC and DPF parts (internal plugs) in addition to the plugs at the rear end. Several test IP Filters that were made of highly porous cordierite material were prepared for testing to evaluate their performance characteristics.

Conventionally, the Ni-based superalloys NCF3015 (30Ni-15Cr) and the high nickel content NCF440 (70Ni-19Cr) (with its outstanding wear resistance and corrosion resistance), have been used as engine exhaust valve materials. In recent years, automobile exhaust gases have become hotter because of exhaust gas regulations and enhanced fuel consumption efficiency. Resource conservation and cost reductions also factor into global environmental challenges. To meet these requirements, NCF5015 (50Ni-15Cr), a new resource-conserving, low-cost Ni-based heat-resistant alloy with similar high-temperature strength and wear resistance as NCF440, has been developed. NCF5015's ability to simultaneously provide wear resistance, corrosion resistance and strength when NCF5015 is used with diesel engines was verified and the material was then used in exhaust valves.

The recent progress of electronic control systems in vehicles is remarkable as evidenced by the development of electronic fuel injection systems,(EFI), automatic transmission control systems, and anti-lock brake systems,(ABS). The number of actuators for the systems has been increasing. Consequently, a need has been identified for a reduction in volume and number of the system actuators for control purposes. A composite magnetic material has been developed with the aim of miniaturizing magnetic solenoid valves for actuator applications. A composite magnetic material is such that both ferromagnetic and paramagnetic sections coexist within a single material, and can contribute to optimization of the magnetic circuit of a solenoid valve. This paper describes the development of a composite magnetic material, and its resultant characteristics.