Overview
JFE Steel had been using Sinter bar manufactured by Fujiko for over 20 years, but had begun to question their cost and wear resistance and was seeking a solution.
Industry
Steel
Location
Fukuyama city, Hhiroshima prefecture, JP
Component/Workpiece
Sinter Bar
Business Type
Integra - Workshop
Job Type
New
OEM
Fujico Co.,Ltd
Type of Wear
Base Metal
SS400 ≠ ASTM A36 , Q235B
General Dimensions (mm)
3571mm x 509mm x 170mm
The challenge the customer was facing
Equipment that previously had a service life of one and a half years saw its lifespan reduced to less than a year following an increase in productivity; holes began to appear in the water-cooling system, and the sintered material was no longer being sufficiently crushed.
Previous Service Life
8mo
How WA solved the challenge
It consists of two main structural components, and the wear-resistant units feature a 3D-Carb coating using CV-O and CNV-O to compete with rival castings.
Product Category
Integra Services
Product Description
3D-Crab CV-O 2.8mm , CNV-O 2.4mm
Job Duration
3mo
Technical Advantages
Competitor hardfacing products failed to extend service life due to their large grid patterns; the material was prone to both abrasive wear and macroscopic chipping (spalling). Conversely, WA's 3D-Carb utilizes a dense honeycomb structure that eliminates such detachment issues. Following a successful trial period, its durability was verified to exceed one year, leading to its formal implementation.
Service Life
1y
Photos and visuals for this case study
Annual Cost Before
¥2,600,000.00
Annual Cost After
¥1,766,666.67
Annual Savings
¥833,333.33
32.0% reduction
Annual Cost = (A × E) + (E − 1) × (F + G + H)
Where: A = Cost of Part, E = Parts/Year, F = Maintenance, G = Disassembly, H = Downtime
The customer typically replaces the sinter bar (anvil) during an annual major overhaul. Previously, if significant wear was detected during mid-term inspections, urgent emergency welding was required. Since adopting WA's sinter bar, they have achieved stable operations. This has not only reduced maintenance costs but also allowed the team to allocate their time to other maintenance tasks.
No WPS data available for this case study
Contributor
Takanori Sasaki
takanori.sasaki@waj.co.jp
Created
April 16, 2026
Submitted
April 16, 2026
Approved By
Laslo Ekres
April 16, 2026