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Brazing using arc-sprayed coatings was investigated for application to non-oxidation copper brazing. It was found that the more porous sprayed coatings have an excellent brazeability. This newly developed joining method is more suitable than conventional methods for brazing complicated parts. We have applied this method to fabricate a torque converter for practical use.

We have developed a Hall effect device based height sensor of a smaller size, and with higher temperature operation durability, as compared to conventional devices. Downsizing of the sensor is realized by decreasing a number of parts, and by employing a short bearing. Improvement in heat resistance is achieved by adopting an IC with sufficient heat resistance and a SmCo magnet with high coercive force. In addition, a sensor of a high degree of accuracy is accomplished by improvements in linearity and robustness of magnetic characteristics. Development of a small, heat-resistant and accurate height sensor will promote the spread of systems using a height sensor, such as a High Intensity Discharge (HID) headlamp.

As a process that enables the high-speed and continuous forming of lengthy materials with a constant cross-sectional configuration, roll forming offers much higher productivity than the stamping process. However, in case a change must be made to the shape of the cross section, the material must normally be stamped or joined with a part containing a separate shape. This affects productivity, increases the number of pieces, and degrades the material's appearance. This report describes the roll-forming technology that we developed, in which the cross section of the material can be changed gradually. This method adopts a system which uses a movable and rotatable roll-stand that enables high-speed, continuous roll-forming processes.

As automotive electronic systems advance, the wire harness is the mainstream for necessary wiring in resin-made motor-driven actuators with wire connection labor and purchased-parts accounting for the majority of costs. As a means to eliminating the harness, there is a method of forming the conductive material on the inside, but this method leads to cost increases when there is a comparatively large number of wires because the required die insertion time becomes longer and automatic insertion equipment becomes necessary. The following paper reports on an integrated high-speed process that combines stamping and injection molding into a single process.