AU612609B2 - Creation of Inventions and Patents with Artificial Intelligence

AU612609B2 – Making composite metal deposit by spray casting
– Google Patents

AU612609B2 – Making composite metal deposit by spray casting
– Google Patents
Making composite metal deposit by spray casting

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Publication number
AU612609B2

AU612609B2
AU81191/87A
AU8119187A
AU612609B2
AU 612609 B2
AU612609 B2
AU 612609B2
AU 81191/87 A
AU81191/87 A
AU 81191/87A
AU 8119187 A
AU8119187 A
AU 8119187A
AU 612609 B2
AU612609 B2
AU 612609B2
Authority
AU
Australia
Prior art keywords
metal
sprays
streams
particles
substrate
Prior art date
1986-11-14
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)

Ceased

Application number
AU81191/87A
Other versions

AU8119187A
(en

Inventor
Richard Michael Jordan
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)

Rio Tinto Alcan International Ltd

Original Assignee
Alcan International Ltd Canada
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
1986-11-14
Filing date
1987-11-13
Publication date
1991-07-18
Family has litigation

First worldwide family litigation filed
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https://patents.darts-ip.com/?family=10607385&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=AU612609(B2)
“Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.

1987-11-13
Application filed by Alcan International Ltd Canada
filed
Critical
Alcan International Ltd Canada

1988-05-19
Publication of AU8119187A
publication
Critical
patent/AU8119187A/en

1991-07-18
Application granted
granted
Critical

1991-07-18
Publication of AU612609B2
publication
Critical
patent/AU612609B2/en

2007-11-13
Anticipated expiration
legal-status
Critical

Status
Ceased
legal-status
Critical
Current

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Espacenet

Global Dossier

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Classifications

C—CHEMISTRY; METALLURGY

C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL

C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL

C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge

C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying

C—CHEMISTRY; METALLURGY

C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge

C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying

C23C4/123—Spraying molten metal

Description

S612609 COMMONWEALTH OF AUSTRALIA PATENTS ACT 1952-69 COMPLETE SPECIFICATION
(ORIGINAL)
Class Application Number: Lodged: Form Int. Class Complete Specification Lodged: Accepted: Published: Ptinrity: Related Art: 4 Name of Applicant: ess of Applicant 3 ddress of Applicant ALCAN INTERNATIONAL LIMITED 1188 Sherbrooke Street West, Montreal, Quebec, Canada I SActual Inventor: RICHARD MICHAEL JORDAN Address for Service: EDWD. WATERS SONS, 50 QUEEN STREET, MELBOURNE, AUSTRALIA, 3000.
Complete Specification for the invention entitled: MAKING COMPOSITE METAL DEPOSIT BY SPRAY CASTING The following statement is a full description of this invention, including the best method of performing it known to 1.
i; ll~-_L ‘i 1 0 C.
C
S.
S
C I* C C e g r* MAKING COMPOSITE METAL DEPOSIT BY SPRAY CASTING This invention is concerned with a method of making a composite metal deposit by spray casting.
The technique of spray casting is well known and comprises the steps of atomising a stream of molten metal to form a spray of hot metal particles by subjecting the stream to a relatively cold gas directed at the stream, and depositing the spray on a substrate.
The provision of rapid and controlled cooling permits the production of deposits having unusual microstructures, which can be rolled or formed into shaped articles. But with only one source of molten metal, there is a limit to the range of compositions and microstructures that can be obtained.
15 GB 8606733 describes a spray casting method which includes the step of applying to the stream or spray fine, solid particles of a material of different composition from the metal. The particles are incorporated in the deposit. The use of refractory particles e.g. of alumina or silicon carbide can result in metal matrix composites having enhanced properties.
US Patent 4522784 describes a casting method in which two streams of molten metal are mixed just prior to casting, the smaller stream having a higher temperature than the larger stream and being chosen so that a fine intermetallic precipitate is formed during and prior to casting. With the DC casting methods described, it is difficult to remove heat fast enough from the system to prevent to re-solution of the intermetallic precipitates.
GB 1359486 describes a spray casting technique for casting two immiscible metals of different density.
A single flow of molten metal consisting of concentric streams of the two metals is atomised and the drops collected on a substrate. The range of alloy -1 2 compositions that can be cast in this way is quite restricted.
This invention provides a convenient way of making composite metal deposits by spray casting, which is characterized over the above prior art by the fact that separate streams of molten metal are atomised separately. As a result, there is much less restriction on the compositions of the two metals.
GB 1083003 describes a method of making bearing materials by spraying Al and Pb simultaneously onto a backing strip. This results in a microstructure comprising alternating regions, of size corresponding (substantially) to the molten spray droplets, of Al and S• Pb. US 3826301 contain a similar disclosure.
The invention provides a method of making a S9’ composite metal deposit which method comprises providing a first metal stream, a second metal stream and a substrate, atomising the two streams to form first and second sprays of hot metal particles by 20 subjecting the streams to relatively cold gas directed at the streams, and depositing the sprays *oo999 consecutively on the substrate to form thereon a laminated deposit.
The first and second metal streams may be provided 25 by gravity flow from holding vessels containing supplies of the molten metals. The invention contemplates the use of two, three or more molten metal streams, each being atomised separately, and references to first and second metal streams should be construed accordingly.
Atomisation conditions may be chosen, as is known in the art, to control the size, velocity, direction and temperature of the sprays of hot metal particles.
On being atomised, the particles of molten metal spread out in a conical spray pattern, which may be of -3 circular cross-section or may be modified, as known in the art, to form a different cross-section or a more even spread of metal particles.
The substrate may be a metal surface, which may for example be flat or tubular with the metal spray to be deposited on the inner or the outer surface. It is generally preferred that the metal particles be still at least partially liquid on impact, otherwise the deposit may be too porous. By suitable control of the atomising conditions, the metal spray can be arranged to be partially or fully liquid but super- Se. cooled on impact, so that solidification takes place S immediately on impact and there is no need to extract S large amounts of heat through the substrate.
It is possible to provide fibres, whiskers or particles of refractory material, e.g. carbon or silicon carbide, on the substrate in such a way that they become embedded in the coherent composite metal S…deposit and provide reinforcement for it. Also if desired, particles of refractory material can be incorporated in the first and/or second spray by the Si technique described in GB 8606733 noted above.
Three (or more) sprays may be used. For example i the spray patterns of two may be superimposed and 1 25 operated simultaneously. This can result in a laminated structure in which alternate layers have a microstructure resulting from these two sprays. Or two superimposed sprays may be chosen to interact as described in the aforesaid US patent 4522784.
There is no critical range of ratios of the two metals constituting the first and second sprays.
Suitable proportions of the two (or more) metals are chosen for particular applications.. The spray patterns of the first and second sprays may, but need not, overlap; that is to say, the two sprays may be -4arranged to impact on the same or different areas of the substrate. The substrate may be translated, or reciprocated, or rotated in order to pick up the two metal sprays. These features can be used to exercise further control over the structure of the deposit. For example, if the spray patterns of the two sprays do not overlap and the substrate is reciprocated between them, the deposit may consist of alternating layers of first and second metal.
If the spray patterns of the two sprays do overlap, then it is necessary to operate the two sprays alternately in order to achieve the desired laminated structure. In order to operate both sprays •continuously, it is therefoe preferred that the two i 15 spray patterns can be arranged not to overlap, and to reciprocate or rotate the substrate so that alternating i layers of the two metals are deposited thereon.
Other variations in structure can be achieved by supplying one of the metal streams continuously and the ii 20 other only intermittently. Or a first metal stream Smay be supplied initially, followed by the second, so •that the deposit consists of the first metal with a surface coating of the second. The supply of molten metal in two or more streams gives the operator a great 25 deal of latitude in determining the structure of a deposit.
Preferably, the laminated deposit comprises at least two layers of each metal in alternating L superimposed relationship. The thickness of the alternating layers has a significant effect on the properties of the laminate. In the as-sprayed deposit, each layer preferably has a thickness in the range 0.01 100 mm, particularly 1 10mm. The as-sprayed deposit may be subjected to rolling. For many purposes -uq i 55
S
S
ij
S
hi 5 it is preferred that each layer in the rolled product have a thickness of from 10 to 500 microns, particularly to 200 microns.
Since the two metals do not contact one another prior to deposition on the substrate, which may be followed by immediate solidification, there is very little restriction on the nature of the metals that may be used. It would be disadvantageous if the temperature of one metal on deposition were so high that substantial melting of the other took place on the deposit. It is often convenient to use two different alloys of the same base metal. The method is of particular interest for spray casting aluminium alloys, for which purpose an inert gas such as argon or nitrogen is generally desirable though not essential.
Reference is directed to Figures 1 to 3, each of which is a schematic diagram of a system for making a composite metal deposit according to the invention.
Referring to Figure 1, the system comprises first and 20 second furnaces 10 and 12 for supplying first and second streams of molten metal, which are atomised (by means not shown) to form first and second sprays, 14 and 16, of hot metal particles. The spray patterns overlap, and each spray is operated in turn while the 25 other is shut off. The sprays are deposited in turn on a substrate 18, whose position and orientation are controlled by means 20. The metal sprays and the substrate are contained within a spray chamber 22, which is closed except for an exit vent for gas and any overspray powder.
A refractory material contained in a stream of carrier gas is supplied via a pipe 26 to the region where the first metal is atomised, and becomes incorporated in the first metal spray 14.
6 In the system shown in Figure 1, the substrate 18 might be maintained stationary, so as to build up a composite metal body thereon; or it might be translated, rotated or reciprocated in order to build up a uniform composite metal layer. The substrate 18 might have taken the shape of a mould, with the intention of working the deposit while on the substrate to form a shaped article. In the system shown, provided that the metal drops are still liquid on impact, the deposit will be substantially non-porous and will comprise alternating layers of the first and second metals.
Figure 2 corresponds to Figure 1, except that the S0 spray patterns of the two metal sprays 14 and 16 are 15 shown as being non-overlapping. In this case, the sprays are operated continuously and the substrate 18 i is reciprocated in order to obtain a deposit consisting i of alternating layers of first and second metal.
i In Figure 3, the spray patterns of the two metal t6 o” 20 sprays 14 and 16 are shown as partly overlapping when i they impact on cylindrical substrate 18 which is caused to rotate round a horizontal axis 28. A fibre 30 is supplied from a spool 32 and becomes incorporated in *the deposit.
25 There follow examples of combinations of metals and alloys that can be used to make composite metal Sdeposits according to this invention. In each case, the first metal or alloy mentioned will generally be present in the deposit in a volume concentration as great or greater than the second metal or alloy.
A. The first metal is the alloy designated 7010 in the Aluminum Association Register, and the second metal is a softer Al alloy such as 6061 or pure Al metal. 7010 is typically used for aircraft
-I
S7 structures, and the second metal improves fracture toughness by a micro-laminated structure to reduce fatigue and blunt cracks.
B. The first metal is 7010 alloy and the second metal is 6010 alloy to confer ductility, toughness and fatigue resistance.
C. The first metal is 7010 alloy and the second metal is an Al/Zn alloy to improve stress corrosion resistance.
D. The first metal is 7075 alloy, used for armour plating, and the second metal is an Al/Si alloy “u to increase resistance to spalling.
E. The first metal is 7075 alloy, and the second metal is Pb to increase density, improve ballistic 15 properties, and provide a microstructure to break up shock waves.
F. The first metal is any Al alloy and the second metal is Zn, applied on the surface as a layer i amounting to 1 to 5% of the total thickness of the 20 deposit, to aid diffusion bonding.
G. The first metal is 6061 alloy and the second metal is 7475 alloy +’SiC to provide a product having l improved ductility and toughness.
EXAMPLE
25 Laminated material was sprayed using a combination :of 6061 Al alloy from one atomizer and 7475 Al alloy SiC from the other atomizer.
1. Spraying conditions.
Both crucibles used were alumina with zirconia nozzles. The atomizing gas was nitrogen. The collector was an aluminium plate 300 mm long by 150 mm wide. The plate was reciprocated beneath the sprays at a frequency of 1 Hz.
8 The following are the spraying conditions for the 6061 alloy Temperature of melt 730 C Primary gas Pressure 1.8 bar Flow rate 0.6 m /min Velocity 240 m/sec Secondary gas Pressure 5.5 bar Flow rate 8.0 m /min Velocity 300 m/sec w** The conditions for the 7475 alloy were the same 15 apart from the melt temperature which was 710°C. SiC S. particulate (F600) was fed to the 7475 spray only, SiC was fed at a rate of 1.72 kg/min to the atomizing nozzle.
Several batches of material were made using 20 similar conditions.
2. Microstructure of product Measurements of the elemental distribution across the bands indicate that there has been a degree of interdiffusion between adjacent layers indicating that an I 25 effective metallurgical bond has been made between them.
The SiC content of the 7475 layers was 10-12% by volume.
i 3. Mechanical properties ;i The as sprayed material was consolidated by hot rolling at 430°C to approximately 2 mm in thickness and then further cold rolling to 1 mm. Any as sprayed porosity was found to close up during this process to form a fully consolidated product. The sheet was solution heat treated by holding for at least 30 min at 500 0 C and cold water quenching. The material was artificially aged for 20 hr at 120 0
C.
9 Tensile properities were determined on several batches of sheet containing different thicknesses of laminate. The following table contains a summary of the results.
Material 0.2% PS (MPa) TS (MPa) Ef .44, Sn a .a p, a layer laminate 270 369 4.4 (=200 micron layers) 17 layer laminate 273 406 9.9 (=70 micron layers) 7475 alloy with SiC 525 581 1.7 6061 alloy 240 260 6061 alloy with SiC 322 340 0.9 Crack initiation and propagation were also determined with the following results.
Material Initiation Propagation energy energy (J/m 2 (J/m 2 layer laminate (=200 micron layers) 13433 40597 17 layer laminate micron layers) 17623 55788 7475 alloy with SiC 3189 8182 10 These results illustrate that the combination of the two materials in the laminate can result in improvements in mechanical properties over the individual constituents. In this instance the results indicate an improvement in strength and ductility over 6061 and an improvement in ductility and crack initiation and propagation energy (indicating improved toughness) over the 7475 alloy with SiC. The results also indicate a significant improvement in the properties (notably ductility) over that of the 6061 alloy with SiC. It is also notable that the thickness .of the laminated regions is highly important in ^controlling the final properties of the material specifically in this instance the ductility and toughness of the laminate.
a a S

Claims (4)

1. A method of making a laminated metal article having consecutive layers of deposited metal compositions wherein the compositions of any two consecutive layers in the laminated article are different which method comprises providing a first metal stream, a second metal stream and a substrate, the first and second metal streams being of different composition, atomising each of the metal streams to form first and second sprays of hot metal particles by subjecting each of the metal streams to relatively cold gas directed at said metal streams, applying particles of a refractory material to one of the metal streams or sprays, depositing metal particles from each of the sprays consecutively on the substrate to form thereon a laminated deposit such that any two consecutive layers in the laminate have different compositions, and wherein the atomisation conditions are controlled such that the metal particles of the sprays when the said particles impact on the substrate are partially or fully liquid but are sufficiently cooled to the extent that solidification takes place on impact; and subsequently rolling the laminated article such that after rolling each deposited layer has a thickness of from 10 to 500 microns.

2. A method as claimed in claim 1, wherein the first and second metals are different alloys of the same base metal. .age

3. A method as claimed in claim 2, wherein the base metal is aluminium.

4. A method as claimed in any one of claims 1 to 3, wherein the laminated article comprises at least two layers of each metal in alternating superimposed relationship. Dated this 24th day of April, 1991. ALCAN INTERNATIONAL LIMITED WATERMARK PATENT TRADEMARK ATTORNEYS FLOOR 2, 290 BURWOOD ROAD, HAWTHORN VICTORIA 3122 AUSTRALIA 4. ;PJ W 7

AU81191/87A
1986-11-14
1987-11-13
Making composite metal deposit by spray casting

Ceased

AU612609B2
(en)

Applications Claiming Priority (2)

Application Number
Priority Date
Filing Date
Title

GB868627308A

GB8627308D0
(en)

1986-11-14
1986-11-14
Composite metal deposit

GB8627308

1986-11-14

Publications (2)

Publication Number
Publication Date

AU8119187A

AU8119187A
(en)

1988-05-19

AU612609B2
true

AU612609B2
(en)

1991-07-18

Family
ID=10607385
Family Applications (1)

Application Number
Title
Priority Date
Filing Date

AU81191/87A
Ceased

AU612609B2
(en)

1986-11-14
1987-11-13
Making composite metal deposit by spray casting

Country Status (10)

Country
Link

EP
(1)

EP0270265B1
(en)

JP
(1)

JPS63145762A
(en)

KR
(1)

KR880006378A
(en)

CN
(1)

CN1011389B
(en)

AU
(1)

AU612609B2
(en)

BR
(1)

BR8706130A
(en)

CA
(1)

CA1269284A
(en)

DE
(1)

DE3780131T2
(en)

GB
(1)

GB8627308D0
(en)

ZA
(1)

ZA878404B
(en)

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1989-12-19
1991-04-11
Mtu Muenchen Gmbh

CA2025302A1
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1989-12-26
1991-06-27
John R. Rairden, Iii
Reinforced microlaminted metal-matrix-composite structure

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1992-05-20
1992-07-08
Lucas Ind Plc
Improvements in and relating to thixoformable layered materials and articles made from them

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1994-04-21
Wieland Werke Ag

Rotationally symmetrical semi-finished product with properties that vary across the cross-section

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1996-03-05
1997-09-10
Sprayforming Dev Ltd
Filling porosity or voids in articles formed by spray deposition

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1999-11-19
2001-05-23
Basf Ag

Process for combinatorial production of a library of materials

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2000-02-29
2001-09-06
Bosch Gmbh Robert

Method and device for depositing a coating on a substrate by spraying a liquid

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2000-05-08
2005-06-28
Intematix Corporation
Combinatorial synthesis of material chips

DE102004031164B4
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2004-06-28
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Federal-Mogul Burscheid Gmbh

Cast body with external coating for the production of composite bodies

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2004-11-02
2012-12-18
Sulzer Metco Ag
A thermal spraying apparatus and also a thermal spraying process

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2006-11-01
2014-03-20
Zollern Bhw Gleitlager Gmbh & Co. Kg

Process for producing two interconnected layers and functional component which can be produced by the process

CN102151828A
(en)

2011-03-18
2011-08-17
西南交通大学
Method for preparing gradient materials through multi-crucible and multi-nozzle spray forming

FR2991216B1
(en)

2012-05-29
2014-07-04
Snecma

METHOD FOR COMPACTING ANODIC PAINTS WITH COLLISION OF SANDBLASTING JETS

EP2874159A3
(en)

2013-05-14
2015-10-07
Longke Electronics (Huiyang) Co., Ltd.
Base metal combination electrode of electronic ceramic component and manufacturing method thereof

CN104087891B
(en)

2014-07-12
2016-06-22
卢玉锋
A kind of injection and spraying process prepare method and the device of composite material

JP6481154B2
(en)

2014-10-18
2019-03-13
エムテックスマート株式会社

How to apply powder

CN104561884B
(en)

2014-12-22
2017-01-04
浙江灿根机械制造有限公司
Forcing press ball bowl automatic complex copper bed device and use this device complex copper layer method

CN105458263B
(en)

2015-12-10
2018-05-11
安徽相邦复合材料有限公司
A kind of preparation method of aluminum matrix composite-aluminum alloy interlayer plate

US20170216918A1
(en)

2016-02-02
2017-08-03
Melissa E. Orme-Marmarelis
Methods and systems for fabrication using multi-material and precision alloy droplet jetting

CN207699655U
(en)

2017-06-30
2018-08-07
爱普科斯电子元器件(珠海保税区)有限公司
A kind of preparation facilities of electronic component combination electrode

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1986

1986-11-14
GB
GB868627308A
patent/GB8627308D0/en
active
Pending

1987

1987-11-01
BR
BR8706130A
patent/BR8706130A/en
unknown

1987-11-09
ZA
ZA878404A
patent/ZA878404B/en
unknown

1987-11-11
DE
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patent/DE3780131T2/en
not_active
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1987-11-11
EP
EP87309972A
patent/EP0270265B1/en
not_active
Revoked

1987-11-13
JP
JP62287202A
patent/JPS63145762A/en
active
Pending

1987-11-13
KR
KR870012803A
patent/KR880006378A/en
not_active
Application Discontinuation

1987-11-13
CA
CA000551752A
patent/CA1269284A/en
not_active
Expired – Fee Related

1987-11-13
AU
AU81191/87A
patent/AU612609B2/en
not_active
Ceased

1987-11-14
CN
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Bullen Russell
Hose delivery guide

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R Brooks
Method and apparatus for manufacturing precision articles from molten articles

AU8226487A
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1986-12-09
1988-06-09
Alcan International Limited
Production of billet or tube

Also Published As

Publication number
Publication date

EP0270265A1
(en)

1988-06-08

CN1011389B
(en)

1991-01-30

GB8627308D0
(en)

1986-12-17

CN87107803A
(en)

1988-07-27

AU8119187A
(en)

1988-05-19

ZA878404B
(en)

1988-05-05

EP0270265B1
(en)

1992-07-01

JPS63145762A
(en)

1988-06-17

KR880006378A
(en)

1988-07-22

BR8706130A
(en)

1988-06-21

DE3780131D1
(en)

1992-08-06

CA1269284A
(en)

1990-05-22

DE3780131T2
(en)

1993-01-14

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