月: 2023年1月

What Is a Lead Frame?

Lead frames are thin metal plates used within semiconductor device cases.

They are utilized in transistors, ICs, LSIs, photocouplers, LEDs, etc., with patterns designed to secure semiconductor devices, connect them to case terminals, and dissipate heat. Typically, copper or iron alloys are employed, with wiring patterns and external shapes created through press working and etching techniques.

Lead frames facilitate the high integration and functionality of semiconductor devices, utilizing metal materials renowned for their excellent electrical and thermal conductivity.

Applications of Lead Frames

1. Semiconductor Devices

Includes transistors, ICs, LSIs, photocouplers, LEDs, and diodes.

A photocoupler transmits electrical signals through light. A transistor, a semiconductor device, controls electrical signals, while a diode, also a semiconductor, allows current to flow in only one direction.

2. Electronic Components

Such as capacitors, resistors, and sensors.

3. Electrical Devices

Includes relays, motors, batteries, and switches.

4. Other

Pressure sensors, temperature sensors, actuators, and tact switches, the latter being a type of switch operated with a short stroke to produce instantaneous electrical signals.

Principle of Lead Frames

Lead frames ensure electrical and mechanical connections between semiconductor devices and the external environment. Comprised mainly of thin metal sheets with multiple electrodes, semiconductor elements are directly connected to these frames, facilitating the transmission of electrical connections to the outside.

They also play a vital role in dissipating the heat generated by semiconductor devices, thanks to their excellent thermal conductivity, ensuring the stable operation of these devices.

Properties of Lead Frames

1. Reliability

Lead frames significantly enhance the reliability of semiconductor devices. Precision in manufacturing is crucial for device reliability, necessitating stringent quality control to fulfill multiple functions. Their repeated use also underscores the importance of reliability.

2. Economical

Due to the ability to be mass-produced through stamping, lead frames are cost-effective. Technological advancements in surface treatment and processing have enabled high-precision manufacturing at reduced costs while maintaining reliability, making them prevalent in numerous electronic devices.

3. Conductivity

Primarily made from copper and iron alloys, lead frames boast exceptional electrical conductivity, crucial for the efficient transmission of electrical signals. Their conductive performance is further enhanced by plating.

4. Thermal Conductivity

Their material’s high thermal conductivity is vital for dissipating the heat from semiconductor devices efficiently. The large surface area of lead frames also facilitates heat dissipation through airflow.

5. Various Shapes

With the flexibility provided by stamping and etching techniques, lead frames can accommodate a wide range of shapes, allowing for diverse semiconductor device designs. This flexibility aids in enhancing device functionality and integration.

Etching, a technology for removing material surfaces chemically or physically, is essential for processing metal and semiconductor thin films.

What Is Martensitic Steel?

Martensitic steel refers to a group of stainless steel alloys characterized by a martensite crystal structure at room temperature.

Containing chromium as a primary element along with iron, it falls under chromium-based stainless steel, similar to ferritic stainless steel. Notable examples include SUS403 and SUS410, which comprise 13% chromium.

Applications of Martensitic Steel

Due to its relatively low chromium content, which is crucial for passivity formation, martensitic steel offers less corrosion resistance compared to other stainless steel types, limiting its use in corrosive environments. However, it finds extensive applications thanks to its affordability, strength, and heat resistance. Common uses include mechanical structural components like shafts and bolts, and molds for plastic injection molding. Furthermore, variants such as SUS440 and SUS420, recognized for their hardness post-quenching and tempering, are frequently chosen for cutlery, including knives, and medical instruments like scalpels.

Properties of Martensitic Steel

While properties can vary across different grades, a shared feature of martensitic steel is ferromagnetism, attributed to its body-centered cubic lattice structure. This is in contrast to austenitic stainless steel, which is non-magnetic due to its face-centered cubic lattice. The strength of martensitic steel is enhanced by quenching, and its wear resistance and toughness are further improved by tempering. The presence of a relatively high carbon content in austenitic stainless steel enables the formation of a hardened microstructure through high-temperature quenching.

Generally, martensitic steel undergoes quenching and tempering, with the resulting properties dependent on the tempering temperature. For instance, low-temperature tempering at 150 to 200°C enhances wear resistance, whereas high-temperature tempering at 600 to 750°C followed by rapid cooling boosts toughness. Conversely, tempering at around 475°C can lead to decreased ductility and toughness, a phenomenon known as 475°C embrittlement.

Structure of Martensitic Steel

Martensitic steel, containing approximately 11-18% chromium, exhibits a single-phase austenite structure or a dual-phase structure with minor ferrite at high temperatures. The carbon, soluble in austenite at elevated temperatures, transforms into a martensitic microstructure upon rapid cooling post-quenching. The fundamental composition includes 13% chromium and 0.2% carbon, with typical examples being SUS410 and SUS420J2, containing 11.50-13.00% chromium and up to 0.15% carbon, and SUS420J2, with 12.00-14.00% chromium and 0.26-0.40% carbon, respectively. These are also referred to as 13Cr steel or the 13Cr series.

How to Select Martensitic Steel

Choosing the appropriate stainless steel—martensitic, ferritic, or austenitic—depends on the application, considering the variations in properties with different crystal structures.

1. Martensitic Stainless Steel

Primarily used for blades and cutting parts, martensitic steel is hardened through quenching.

2. Ferritic Stainless Steel

Optimal for building interiors, automotive components, and commercial kitchens. It resists stress corrosion cracking without hardening by quenching, offering great economic value.

3. Austenitic Stainless Steel

Known for its strength, ductility, toughness, and heat resistance, this alloy is non-magnetic and highly recyclable. Attention must be paid to stress corrosion cracking.

What Is a Preform?

Preforms are parts used as intermediate products in the manufacturing process.

Specifically, a preform is a part that is formed into a certain shape from pre-formed material and then heated in a molding machine to be formed into its final shape. Performs to improve the efficiency of the molding operation.

Preforms are widely used in the manufacture of plastic parts. PET resin preforms are used in the production of PET bottles, which are preformed into the shape of PET bottles in advance and then heated in a molding machine to be formed into the final shape during the final molding process.

Types of Preforms

Below are some of the types of preforms when classified by resin, glass, metal, and paper.

1. Resin Preforms

Resin preforms are classified into the following types

• PET resin preforms (PET=Polyethylene Terephthalate)
• PP resin preforms (PP=Polypropylene)
• PE resin preforms (PE=Polyethylene)
• PS preforms (PS=Polystyrene)
• ABS preforms (ABS=Acrylonitrile Butadiene Styrene)
• PVC preforms (PVC=Polyvinyl Chloride)
• Polycarbonate preforms
• Polyurethane preforms
• Polystyrene preforms
• Polypropylene preforms
• Polyethylene preforms

2. Glass Preform

Glass preforms are mainly two types as follows

• Glass Fiber Reinforced Plastics (GFRP) preforms
• Glass container preforms

3. Metal Preforms

Metal preforms are mainly two types as follows

• Sheet preforms for aluminum cans
• Sheet preforms for steel cans

4. Paper Preforms

Paper preforms are mainly the following two types

• Preforms for folding paper container
• Preforms for corrugated boxes

Uses of Preforms

1. Resin Preforms

• Pet Bottles, Beverage Containers, Cosmetic Containers, Pharmaceutical Containers
  PET resin preforms are used for
• Automobile Parts and Home Appliance Parts
  Preforms of ABS resin, polycarbonate resin, etc. are used.
• Building Materials
  Preforms made of PVC and polyurethane resins are used. For example, they are used for window frames and insulation materials.
• Packaging Materials
  Preforms such as polyethylene resin are used. Examples include cushioning materials and other packaging materials.
• Others
  Preforms such as polystyrene resin and polypropylene resin are used. For example, they are used for tableware and stationery.

2. Applications of Glass Preforms

• Manufacturing of Glass Fiber Reinforced Plastic (GFRP)
  ProductsGFRP (Glass Fiber Reinforced Plastic) preforms are made of glass fibers coated with resin and used in the manufacture of automotive parts, building materials, ship parts, etc. GFRP is made of glass fibers coated with resin.
• Glass Container Manufacturing
  Preforms of glass containers are molded into shapes such as bottles and flasks, which are used as intermediate products for molding into final container shapes.

3. Uses of Metal Preforms

• Aluminum Cans
  Aluminum sheet preforms are used. Sheet preforms are sheets of aluminum formed to a certain shape before forming, and are used as an intermediate product for forming into the final can shape.
• Steel Cans
  Steel sheet preforms are used. As with aluminum cans, sheet preforms are used as an intermediate product to be formed into the final can shape.

4. Uses of Paper Preforms

• Foldable Paper Containers
  Paper sheet preforms are used. Sheet preforms are sheets of preformed paper that are formed into some shape and are used as an intermediate product to be formed into the final container shape. Cups, take-out containers, and paper bags are examples of such uses.
• Corrugated Boxes
  Preforms for corrugated boxes are made by forming corrugated cardboard into a certain shape and are used as an intermediate product to be formed into the final box shape.

Properties of Preforms

1. Intermediate Product Before Molding

Preforms are intermediate products before molding and serve as the basis for molding into the final shape. Therefore, the shape and size of the product can be freely designed. Preforms also allow the selection of the most suitable material for the shape and size of the product.

2. Streamlining the Manufacturing Process

Preforms improve the efficiency of the manufacturing process compared to the use of preformed materials. Preforms can eliminate extra processing steps, resulting in shorter manufacturing times and lower costs.

3. High Hermeticity

Metal and glass preforms are suitable for beverage and pharmaceutical containers due to their ability to achieve a high degree of hermeticity. This helps maintain product freshness and quality. Hermetic containers are also important to prevent product leakage and contamination during transportation and storage.

Other Information about Preforms

1. Adaptable to a Variety of Materials

Preforms can be made from a variety of materials. They can be molded from resin, glass, metal, paper, and other materials, taking advantage of the specialized characteristics of each material. This makes it possible to select the most suitable material for each application.

2. Recyclable

For example, resin preforms can be reprocessed to make new products. Glass and metal preforms can also be recycled.

3. High Degree of Design Freedom

Preforms can be made in a variety of shapes and sizes. Preforms can also be colored and printed, allowing for the creation of products with excellent design.

What Is a Bourdon Gauge Tube?

A Bourdon gauge tube is a pipe that is sealed at one end and designed with a flat cross-section. It was named after its inventor, E. Bourdon of France. This tube is commonly used in Bourdon gauge tube pressure gauges, and its principle is also applied in other measuring instruments such as barometers, differential pressure systems, and thermometers.

The shape of the Bourdon gauge tube changes in response to variations in pressure and temperature. The greater the movement, the higher the accuracy.

Bourdon gauge tubes are made from various materials, including brass, aluminum brass, stainless steel, phosphor bronze, and other highly elastic alloys. For high-precision pressure measurement, beryllium copper and nickel span are especially used.

Uses of Bourdon Gauge Tubes

The primary use of Bourdon gauge tubes is in pressure gauges. These gauges, known as Bourdon pressure gauges, are simple in construction, easy to use, and don’t require external energy such as electricity. They can measure a wide range of pressures, from vacuum to approximately 200 atmospheres.

Bourdon gauge tube thermometers, which operate on the same principle as the Bourdon gauge tube pressure gauges, are also widely used in industry. These thermometers measure temperature through the expansion and contraction of a liquid or gas sealed inside the Bourdon tube. Advantages of Bourdon tube thermometers include the ability to keep the indicating part distant from the temperature-sensitive part, suitability for high-temperature measurements, a simple and trouble-free structure, and no need for external energy.

Principle of Bourdon Gauge Tubes

When a Bourdon gauge tube is used in a pressure gauge, a curved Bourdon tube is connected to the measuring point. The tube extends with increased pressure and bends with decreased pressure. In a thermometer, a liquid such as alcohol is sealed inside the tube; the tube expands with rising temperatures, causing the liquid level to move. This movement indicates the temperature change. By varying the material and thickness of the Bourdon gauge tubes, a wide range of accuracy and measurement conditions can be accommodated.

However, the typical structure of a Bourdon gauge tube pressure gauge can be problematic when used with corrosive media, as the pressure-receiving medium is in direct contact with the Bourdon tube. In environments with vibration or fluctuating pressure, accuracy issues can arise. To address these issues, diaphragm pressure gauges that incorporate a diaphragm between the Bourdon tube and the pressure-sensing medium, and glycerin-filled gauges that contain glycerin inside to mitigate the effects of vibration and pulsation on the Bourdon tube are also used.

What Is a Blister?

Blisters are a type of packaging form for small items.

It consists of a concave section of clear plastic and a board covering the section. Generally, the plastic part is hard and transparent, and the board that covers the opening is made of thick paper or plastic and printed with information about the contents and instructions.

Blisters have the advantage of protecting the product from dirt and damage from the outside. The use of transparent plastic is also convenient because it makes it easy to check the product and see the color and shape of the product.

Uses of Blisters

1. Pharmaceutical Products

Tablets, capsules, ophthalmic solutions, and adhesives are examples.

2. Daily Necessities

Batteries, cosmetics, sponges, glue, adhesives, scissors, etc.

3. Food Products

Chocolate, gum, candy, seasonings, supplements, etc.

5. Electronic Devices

USB memory sticks, micro SD cards, mobile batteries, earphones, cords, etc.

6. Toys

Minicars, plastic models, figures, playing cards, etc.

7. Sports Equipment

Golf balls, table tennis rackets, etc.

8. Automotive

Valves, fuses, wiper rubbers, spark plugs, etc.

Spark plugs, also called spark plugs, are necessary for starting automobile engines.

9. Precision Instruments

These include semiconductors, liquid crystal displays, and sensors.

Types of Blisters

There are several different types of blisters. The following are some of them

1. One-Piece Molded Plastic Blisters

This product consists of an integrally molded plastic container and a backing paper placed and sealed in such a way that it fits into the top of the container. Blisters are available for various applications depending on the shape. For example, it is used for packaging dry cell batteries.

2. Card Blister

Blisters are made by punching a hole in a card (cardboard) and inserting the product into the hole, rather than placing the product in the blister. It is often used as packaging for toys, trading cards, etc.

3. Slide Blister

Blisters with a plastic lid that slides over the top of the plastic base paper, allowing the product inside the blister to be inserted and removed. When storing the product again, the lid can be easily sealed by simply closing it again. It is used in packaging such as headphones.

4. Sheet-Type Blisters

Sheet blisters are a type of blister that has a recessed area to allow the product to fit inside, and are also used for packaging medicines, etc.

Structure of Blisters

Blisters are used to protect products from external contamination and damage. It protects products from external dirt and damage, preventing them from being damaged or soiled.

The use of transparent plastic increases the appeal of the product itself, as the color and shape of the product can be seen. A sticker or mark can be added to indicate that the product has not been opened, making it easier to confirm that the product is unopened at the time of purchase.

Blisters are manufactured in a variety of forms, including forms with hooks or forms that can stand on stands, making them convenient for display in stores and for storage. Blisters also make it easy to identify which product is which when the same product is displayed together. Product content information and notes can be printed on the blister to confirm product characteristics, uses, and handling methods.

Other Information on Blisters

In addition to the above, there are other types of blisters, such as eco blisters and press blisters. Names may vary according to each manufacturer.

1. Eco-Blister

Eco blisters are environmentally friendly blisters. Compared to regular blisters, ecological materials, and designs are used, such as reducing the amount of plastic used.

Specifically, eco-blisters use recycled plastic, bio-plastic, and paper products. In addition, environmentally friendly efforts are made to reduce carbon dioxide emissions during the manufacturing process and to encourage waste reduction.

2. Aluminum Blister

Aluminum blisters are a type of blister manufactured using aluminum film. Unlike regular blisters, aluminum film is used to protect products from air and moisture, making them less susceptible to outside environmental influences. Aluminum blisters are used for packaging pharmaceuticals, cosmetics, food products, medical devices, etc., and are typically filled with liquids, powders, tablets, capsules, and other fillings. Aluminum films are also durable and suitable for storage after opening, helping to maintain product quality.

What Is Ferritic Stainless Steel?

Ferritic stainless steel is a general term for a type of stainless steel composed mainly of iron and chromium, an alloy that constitutes a ferrite phase at room temperature.

Ferritic stainless steel has excellent corrosion resistance and is more resistant to rust than ordinary steel. This makes it widely used in various fields.

Some grades contain elements such as molybdenum, niobium, and copper, but little or no nickel, which is frequently used in other stainless steels.

Applications of Ferritic Stainless Steel

Ferritic stainless steel has excellent formability, corrosion resistance, and weldability. The characteristics of ferritic stainless steel vary greatly depending on the ratio of the constituent element chromium and the additive elements, and its uses are also diverse.

1. Building and Construction Industry

Used in building components such as exterior walls, roofs, and pillars, it is suitable for buildings that require durability.

2. Food Processing Industry

Used in contact parts of food processing equipment, containers, etc., it is suitable for the food industry, where corrosion resistance is important.

3. Medical Equipment

Used in surgical instruments and medical equipment.

4. Automotive Industry

Used for automobile exhaust pipes, parts, body parts, etc., it is suitable for the automotive industry, which requires durability and heat resistance.

Properties of Ferritic Stainless Steel

Ferritic stainless steel has a variety of properties. In addition, it is less expensive than austenitic stainless steel due to the almost complete absence of nickel addition.

1. Magnetism

Ferritic stainless steel has a variety of characteristics, depending on the type of steel, but one common characteristic is its ferromagnetic properties. This is because the crystal structure of ferritic stainless steel is a body-centered cubic lattice. Martensitic stainless steels with a similar crystal structure are paramagnetic, while austenitic stainless steels with a face-centered cubic lattice are non-magnetic.

2. Strength

Ferritic stainless steel is known for its almost complete lack of hardening by heat treatment and is not suitable for applications requiring high strength because it does not show any strength increase by quenching and tempering.

3. Brittleness

Ferritic stainless steel is known to be brittle depending on the temperature conditions. High-temperature embrittlement occurs in the 400~540°C range, and storage in the 550~800°C temperature range causes embrittlement.

There is also a ductile-to-brittle transition temperature in the low-temperature range, where the impact resistance decreases rapidly. The low-temperature brittleness can be improved by using high-purity ferritic stainless steel with low carbon and nitrogen content.

4. Other Features

Other characteristics of ferrite stainless steel include corrosion resistance, workability, and strength, which are generally inferior to those of austenitic stainless steel, such as Type 304, but superior to those of martensitic stainless steel, such as Type 403.

Types of Ferritic Stainless Steel

Ferritic stainless steel is the type of stainless steel with the number in the 400 series in the name of SUS. The most common type of ferritic stainless steel is SUS430, and other types of ferritic stainless steel are made by adding various elements to SUS430 or changing the ratio of elements.

The physical properties that can be improved from SUS 430 and the types of SUS are as follows.

1. Oxidation Resistance (SUS405)

Oxidation resistance is improved by reducing chromium content from 18% to 13% and adding aluminum.

2. Workability (SUS410L, SUS429)

Chromium content is reduced.

3. Machinability (SUS430F)

Machinability is improved by adding sulfur.

4. Workability, Weldability (SUS430LX, SUS430J1L)

Machinability and weldability are improved by adding titanium and niobium and reducing carbon content.

5. Corrosion Resistance (SUS443J1, SUS434, SUS436J1L, SUS436L, SUS444)

Corrosion resistance is improved by adding molybdenum, titanium, and niobium. It has the same corrosion resistance as austenitic SUS304 and is used not only in outdoor panels and chemical plants but also in corrosive environments such as in seawater.

What Is a Fin Tube?

Fin tubes are tubes with fins attached to the outer circumference of a metal tube.

A fin is a metal wing-shaped component inside a heat exchanger that is attached to the surface of a tubular heat exchanger to increase its surface area, thereby improving the heat transfer performance of the heat exchanger. Fins are usually made of metals with high thermal conductivity, such as aluminum or copper.

Fins allow efficient heat exchange to improve equipment performance and enable compact designs. Fin tubes are widely used in various fields, such as air conditioning equipment, automobile radiators, and power plant coolers.

Applications of Fin Tubes

1. Automotive Industry

Fin tubes are used in engine coolers and air conditioning system coolers. In large vehicles such as buses and trucks, they are also used in engine oil coolers and transmission oil coolers.

2. Refrigeration and Air Conditioning Industry

Used in cooling towers, air conditioners, freezers, refrigerators, frozen vehicles, etc.

3. Electric Power Industry

Used in cooling towers, heat exchangers, and other coolers in power plants. It is also used in reactor coolers in nuclear power plants.

4. Chemical and Petrochemical Industries

Used in heat exchangers for petroleum refining equipment, petrochemical plants, chemical plants, etc.

5. Food and Beverage Industry

Used in heaters, coolers, distillers, drying equipment, etc. Examples include beer and beverage coolers and coffee machine heaters.

6. Medical Industry

Used in medical heaters and coolers, such as MRI (magnetic resonance imaging) machines.

7. Oil and Gas Industry

Used in heat exchangers and heaters for oil drilling. Also used as a heat insulator for pipelines.

8. Construction Industry

Used in air conditioning equipment such as heaters, heat pumps, and air conditioners. It is also used in renewable energy sources such as geothermal and solar thermal applications.

Properties of Fin Tubes

1. Heat Conductivity

Fin tubes improve the heat exchange rate by increasing the surface area of the fins. Fins are usually made of aluminum alloy and have high thermal conductivity.

The fins of fin tubes are characterized by their fine shape. The reason is to transfer more heat by increasing the surface area of the fins. Thus, fins with high thermal conductivity and large surface area allow fin tubes to efficiently exchange heat.

2. Compact Design

Fin tubes can exchange the same amount of heat in a more compact design than a standard heat exchanger. This is because the use of fins reduces the length of the tube required to achieve the same heat transfer area. The fins increase the surface area, which improves the heat transfer coefficient, resulting in more efficient heat exchange.

For example, in aircraft heat exchangers, a large amount of heat exchange area must be placed in a limited space. Fin tubes have a compact design and high heat exchange performance, enabling efficient heat exchange even in a small space such as an aircraft.

In some cases, space is also limited in factories. Fin tubes can be installed in smaller spaces with the same heat exchange capacity, thus improving space efficiency in factories.

3. Flexibility

Fin tubes are flexible because they can be manufactured in a variety of shapes and sizes depending on the requirements of the heat exchanger. For example, small fin tubes can be used when the heat exchanger needs to be installed in a small space, while large fin tubes can be used when a large amount of heat needs to be transferred.

4. Corrosion Resistance

Aluminum fins are made of an aluminum alloy and are suitable for many chemical environments because of their corrosion resistance. This is one reason why fin tubes are widely used. Aluminum alloys are lightweight and durable. They also have high thermal conductivity and transfer heat efficiently due to their high thermal conductivity.

5. Vibration Resistance

Fin tubes have a strong structure against mechanical vibration because the fins and tubes are integrated into one piece. Therefore, it can be used in mobile equipment such as vehicles, ships, and construction machinery, as well as in buildings where vibration is high. For example, in the engine room of a ship, vibrations caused by the engine and the sea can cause vibration.

6. Long Life

Fin tubes are usually made of aluminum alloys, which are highly corrosion-resistant and have excellent thermal conductivity. In addition, the joints between fin tubes and fins are welded or soldered together to ensure that the joints are firmly fixed, making them highly reliable for long-term use. Fin tubes are therefore widely used in buildings, machinery, and other facilities and equipment that must operate stably over long periods.

Other Information on Fin Tubes

Maintenance of Fin Tubes

Fin tubes are easy to maintain because they are installed inside heat exchangers. Fin tubes themselves may need to be replaced, but it is easy to do so without having to disassemble the entire heat exchanger. Also, since fin tubes are made of metal, periodic cleaning can remove deterioration and dirt, thus maintaining the performance of the heat exchanger.

What Is Piano Wire?

Piano Wire is a type of high-tensile steel wire.

It is used in a wide range of applications, including wire and various spring materials in the automotive and electronics fields, cables used in suspension bridges, bed springs, and prestressed concrete.

Uses of Piano Wire

1. Wire in the Automotive and Electronics Fields

Wires for opening and closing rear hatch of automobiles, voice coils of speakers, etc.

2. Various Spring Materials

Springs for automobile suspensions and seats, springs for industrial machinery, etc.

Piano wire is sometimes used as springs for industrial machinery in the following places:

Arm springs of hydraulic excavators
Arm springs of hydraulic excavators are used to support the arms of hydraulic excavators. Piano wire is used to produce arm springs that have high strength and durability and are not easily deformed even after long use.

Tension Adjustment Springs for Rolling Mills
Tension adjustment springs are required in rolling mills when processing thin metal sheets. By using piano wire, we can manufacture springs with high strength and accurate tension adjustment.

Heddle springs for looms
In a loom, heddle springs are essential parts for loom operation. By using piano wire, springs can be manufactured that have high strength and durability, and that do not deform even after long periods of use.

The heddle spring of a loom is the part that opens and closes the threads of the yarn. In a loom, warp and weft yarns cross each other to make fabric, which requires the warp yarns to move up and down at regular intervals. The heddle spring controls this movement and is essential for the accurate operation of the loom.

Printer pick-up roller spring
The pick-up roller spring of a printer is a part for capturing paper. Piano wire is used to produce springs that have high strength and can withstand the load of the rollers rotating at high speed.

3. Structural Components

Examples include cables used in suspension bridges, highway safety fences, and prestressed concrete.

Prestressed concrete is a type of reinforced concrete in which high-tensile steel wires and cables pre-tensioned to the structure and precompressed to minimize deformation due to subsequent loading and stress. By applying compressive forces in advance, the concrete exhibits higher strength, making structures such as large-span bridges and skyscrapers safer and lighter.

4. Everyday Items

Examples include bed springs and bicycle brake wires.

5. Other

Reinforcing material for power line wires, etc.

Properties of Piano Wire

1. High Tensile Strength

The reason for the high tensile strength of piano wire lies in the manufacturing process. Piano wire is made from high-quality steel material and manufactured through the drawing and quenching processes.

Drawing is a process by which metal wire is stretched to produce a thin, uniform wire rod. By drawing metal wire through a metal mold, the wire can be made uniformly thin. It is the process of drawing steel wire out of a die to produce uniformly thin wire with a fine diameter. Wires produced by drawing have a uniform structure and are characterized by high strength.

Quenching heats iron wire in a high-temperature environment and then quenches it, giving the wire elasticity and strength. The heat expands the iron wire, and the rapid cooling causes it to contract, resulting in a stronger wire.

2. High Durability

Piano wire is highly durable, and quenching at high temperatures further improves its durability.

Piano wire is made of high quality steel material, and drawing and quenching during the manufacturing process allows piano wire to withstand very high tensile forces. They have excellent corrosion resistance and are resistant to rust, so they do not deteriorate easily even after long-term use.

Quenching is the process of heating piano wire in a high-temperature environment and then cooling it rapidly to give the wire elasticity and strength. Quenching at high temperatures improves the crystal structure of piano wire and forms a stronger structure. This improves the durability of piano wire and allows it to withstand use for a longer period of time. Quenching also hardens the surface of the piano wire and makes it more resistant to wear and tear, so it is less likely to deteriorate even if worn during use.

What Is a Billet?

Billets are a type of raw material used in metalworking.

Billets are generally cylindrical or rectangular, have a fixed length, and are mainly manufactured from metallic materials such as steel or aluminum. They are transformed into products of various shapes and sizes through casting and forging processes and are processed into bar, plate, or pipe materials.

Billets are usually mass-produced using equipment such as molten steel furnaces and continuous casting machines. Proper quality control is important because material uniformity, strength, and workability affect the quality of billets.

Uses of Billets

Billets are processed in a variety of ways, including extrusion, forging, cutting, welding, and cold forging.

• Extrusion
  Construction materials, automotive parts, railroad parts, electric power equipment, etc.
• Forging
  Drill bits, milling blades, hammers, etc.
• Cutting
  Gears, bearings, pistons, valves, bolts, etc.
• Welding
  Manufacturing of structures, ships, bridges, pipes, tanks, plants, etc.
• Cold Forging
  Hammerheads, automobile crankshafts, valves, etc.

Properties of Billets

1. Strength

Billets are usually manufactured from high-strength metal materials. Therefore, they are resistant to physical loads and stresses and are not easily deformed or destroyed.

2. Durability

Billets have excellent durability and have the advantage that their performance is not easily degraded by repeated loading or prolonged use. The durability of billets is a factor in the crystalline structure and uniformity of the material.

Strength and durability are critical to the continued stable functioning of a product or structure. For example, parts and structures made from billets play an important role in the construction and automotive industries.

These products and structures must withstand external loads and environmental conditions and provide safe and reliable performance over the long term.

3. Uniformity

Billets are machined to a consistent shape during the manufacturing process, and their internal crystalline structure is uniformly aligned to ensure consistent material properties and performance. Uniformity is important for product quality control and reliability.

For example, in parts and structures made from billets, uniform material structure increases the dimensional accuracy of the product. Material uniformity also reduces variations in product strength and hardness, resulting in consistent quality.

4. Processability

Billets have uniform dimensions and crystalline structure, making them suitable for shape change, machining, drilling, and cutting. For example, they can be machined to the required shape and dimensions using a CNC machine or CNC lathe.

Having a certain shape and dimensions, it is relatively easy to control dimensional accuracy during processing. This ensures consistency and accuracy of product dimensions.

5. Heat Treatability

The heat treatability of billets allows the following processing

Adjustment of Strength
Heat treatment can change the crystal arrangement and grain size, increasing or decreasing the strength of the material.

Hardness Control
By controlling the appropriate temperature and cooling rate, the surface and internal hardness of billets can be altered.

Improvement of Durability
Heat treatment can improve material durability and creep performance by changing the crystal arrangement and grain growth.

Stress Relief
Billets can be relieved of internal stress by heat treatment. In particular, when billets accumulate stress during processing and cooling, heat treatment can release the stress and improve the stability of the material.

Types of Billets

There are many different types of billets. The following are some of them

1. Steel Billets

Steel billets are alloys consisting primarily of iron and carbon and are used as raw materials for steel products. Steel billets are melted at high temperatures and used for casting and manufacturing steel products. They are usually square or rectangular and are heated before being used in processing steps such as forging and rolling.

2. Aluminum Billets

Aluminum billets are materials consisting of pure aluminum or aluminum alloys. Aluminum is lightweight, corrosion-resistant, and a good conductor of heat and electricity. Aluminum billets are used in processing methods such as rolling and extrusion and are useful in a wide range of industries including automotive parts, aircraft parts, and construction materials.

3. Copper Billets

Copper billets are made of pure copper or copper alloys, which conduct heat and electricity well and are corrosion-resistant. Copper billets are used in the production of wires, tubes, and fabricated parts, and are formed by forging, rolling, extruding, and casting.

4. Magnesium Billets

Magnesium billets are made of a lightweight, high-strength magnesium alloy. Magnesium billets are used in processing methods such as extrusion and forging and are useful in the manufacture of engine parts, frames, wheels, etc.

5. Zinc Billets

Zinc billets are materials consisting of pure zinc and are used as raw material for galvanizing and zinc alloys. Zinc is widely used to protect iron and steel from corrosion and is a material used in the manufacture of building materials, automotive parts, electronics, etc.

Zinc billets are easily melted, and after melting, they are processed into the desired shape through casting or extrusion processes. In galvanizing, zinc billets are used as raw material for electrolytic plating to form a uniform zinc coating on metal surfaces.

Billets typically have a cylindrical or rectangular shape, but not all billets are necessarily the same. Depending on the material and industry, there may be additional specific types of billets, and they may have different names.

Other Information on Billets

How Steel Billets are Produced

1. Raw Material Preparation
Iron ore or scrap is fed into a molten steel furnace and melted to produce liquid steel called molten steel.

2. Casting
Molten steel is taken out of the furnace and poured into molds. The mold is shaped like a billet, and the molten steel cools and solidifies to form a billet. In casting, the quality and crystal structure of billets can be adjusted by vibrating the molds and cooling them with cooling water.

3. Scouring
To improve the quality of steel billets, scouring is sometimes performed. In scouring, impurities and unwanted gases in the steel are removed, for example, by desulfurization or deoxidization to improve the purity and composition of the steel.

4. Cooling
After casting, the billets are cooled. Cooling methods include natural cooling and water cooling. By selecting the appropriate cooling method, the crystal structure and physical properties of the billets can be adjusted.

5. Inspection and Finishing
The produced steel billets are inspected. The dimensions, appearance, and microstructure of the billets are checked to determine if they meet quality standards. Final finishing operations are carried out, and the surfaces are pickled if necessary.

What Is a Heat Spreader?

Heat spreaders are components used to remove heat from computers and other electronic devices.

Components under high loads generate a large amount of heat during operation. If this heat is not dissipated, the internal temperature of the equipment can rise and cause malfunction.

Heat Spreaders are flat, metallic (e.g., aluminum) components that are attached to these heavily loaded components. Heat spreaders absorb the heat generated by the heavily loaded components and conduct and distribute the heat over a large area. As a result, the heat is distributed evenly, preventing the internal temperature of the equipment from rising.

Applications of Heat Spreaders

1. Telecommunications and IT Fields

Applications include computer CPUs and GPUs, memory (storage devices), hard disk drives, and printers.

CPU stands for Central Processing Unit, a component in a computer system that is mainly responsible for arithmetic and control processing. GPU stands for Graphics Processing Unit, a component in a computer system that is responsible for image processing and 3D graphics arithmetic processing.

2. Automotive Electronics

Automotive electronic devices include engine control units (ECUs) and brake system controllers.

An ECU (Engine Control Unit) is a control device that controls the engine of an automobile or aircraft. ECUs optimize engine efficiency by controlling engine speed, fuel injection volume, ignition timing, etc., to reduce fuel consumption and emissions.

3. Aircraft Electronics

Avionics equipment and communication devices are examples.

Avionics equipment is a general term for electronic equipment required for aircraft operation and navigation. Heat spreaders also play an important role in aircraft avionics equipment. For example, heat spreaders are used for CPUs and GPUs, which are high-load parts of electronic equipment such as the displays used in aircraft instrument panels.

Heat spreaders are also used in aircraft communication devices. For example, Heat Spreaders are used on the chips in the high-load parts of interface cards used in aircraft navigation and communication equipment to distribute heat evenly and maintain normal operation.

An interface card is a type of computer expansion card that provides an interface (a means or method for different systems or components to communicate or operate with each other) between a computer and peripheral devices. It mainly includes network cards, sound cards, graphics cards, and so on.

4. Home Appliance Field

Compressors are used in refrigerators, air conditioners, freezers, and other cooling devices; CPUs, GPUs, memory, and power supplies for smartphones, tablets, and other devices.

5. Electronic Components Field

Semiconductor devices, LEDs, electrolytic capacitors, etc

Semiconductor device is a general term for electronic devices manufactured from semiconductor materials used to control electrical signals. There are many types of semiconductor devices, including transistors, diodes, integrated circuits (ICs), and optical devices. LED stands for Light Emitting Diode, a type of semiconductor device that emits light when electricity is passed through it. An electrolytic capacitor is an electrical component that stores electricity and consists of an electrolyte between two metal plates (electrodes).

6. Medical Field

Examples include laser devices (laser surgery devices, laser treatment devices, laser diagnostic devices) and ultrasound generators (ultrasound diagnostic imaging devices, ultrasound treatment devices).

Types of Heat Spreaders

There are several types of heat spreaders as follows

1. Metal Heat Spreaders

Metal heat spreaders are made of metals such as aluminum and copper and have high thermal conductivity and durability. Metal heat spreaders are generally used in small electronic devices such as computers.

2. Ceramic Heat Spreaders

Ceramic heat spreaders are made of ceramics and can withstand high temperatures. They are mainly used in industrial equipment, automobiles, aircraft, and power plants that are used in high-temperature environments.

3. Polymer Heat Spreaders

Polymer heat spreaders are made of thermoplastic resin and can be manufactured at low cost. Polymer heat spreaders are mainly used in small electronic devices, but due to their low thermal conductivity, they are used for relatively low-load components.

4. Silicon Carbide Heat Spreaders

Silicon carbide heat spreaders are made of silicon carbide, which has high thermal conductivity and is used in industrial equipment and aircraft used in high-temperature and high-pressure environments.

Silicon carbide is a compound composed of carbon and silicon, represented by the chemical formula SiC. The compound is characterized by high heat resistance, corrosion resistance, hardness, chemical stability, and semiconductor performance.

5. Graphite Heat Spreader

Graphite heat spreaders are heat-conductive materials made of graphite, which has high thermal conductivity and are mainly used for cooling electronic and semiconductor devices.

Graphite has a higher thermal conductivity than aluminum and is lighter, making it ideal for cooling electronic devices. Graphite also has a low coefficient of thermal expansion, which enables stable performance in high-temperature environments.

Graphite heat spreaders have a dense, uniform microstructure and excellent thermal conductivity. This allows heat to be dispersed evenly even in high-temperature environments, preventing heat transfer to surrounding equipment and components. Graphite heat spreaders are also very thin, allowing for flexibility in component design and layout.

Graphite is an allotrope of carbon with a crystalline structure consisting of very thin, planar layers of carbon. Graphite, like diamond, is an allotrope of carbon, but unlike diamond, graphite is very soft.

Properties of Heat Spreaders

1. Heat Dispersion

Heat spreaders are installed around high-temperature components to prevent overheating of the components by dispersing heat over a wide area and thereby preventing heat concentration. They are available in various shapes and sizes.

2. Durability

Heat spreaders are highly durable and can be used for a long period. Especially high-quality ones are less prone to thermal deformation and deterioration, thus maintaining stable performance. Not only metallic materials such as aluminum and copper but also non-metallic materials such as ceramics are used, designed to match the characteristics and performance of the equipment and environmental conditions.

Heat spreaders are used in small electronic devices as well as in large industrial equipment, automobiles, aircraft, power plants, and other equipment. These devices are exposed to higher temperatures and pressures and require greater durability.

Other Information on Heat Spreaders

Proper Design of Heat Spreaders

Heat spreaders are becoming increasingly important due to the evolution of heat treatment technology as semiconductor devices become more densely integrated. The heat generated by semiconductor devices operating at high speeds is extremely localized and can reach temperatures high enough to destroy the devices themselves. Therefore, the proper design and placement of heat spreaders can prevent semiconductor devices from overheating and achieve high-speed, high-performance operation. Heat spreaders also improve the reliability and extend the life of semiconductor devices.