CA2749983C - Wear resistant alloy - Google Patents
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- CA2749983C CA2749983C CA2749983A CA2749983A CA2749983C CA 2749983 C CA2749983 C CA 2749983C CA 2749983 A CA2749983 A CA 2749983A CA 2749983 A CA2749983 A CA 2749983A CA 2749983 C CA2749983 C CA 2749983C
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- 239000000956 alloy Substances 0.000 title claims abstract description 91
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 90
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 58
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 44
- 239000000463 material Substances 0.000 claims abstract description 39
- 239000011651 chromium Substances 0.000 claims abstract description 27
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 21
- 238000000576 coating method Methods 0.000 claims abstract description 20
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 18
- 229910052796 boron Inorganic materials 0.000 claims abstract description 16
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 14
- 229910052750 molybdenum Inorganic materials 0.000 claims abstract description 14
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 14
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 10
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 9
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000011733 molybdenum Substances 0.000 claims abstract description 9
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims abstract description 8
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 7
- 239000010703 silicon Substances 0.000 claims abstract description 7
- 239000000843 powder Substances 0.000 claims description 42
- 239000000203 mixture Substances 0.000 claims description 24
- 229910052751 metal Inorganic materials 0.000 claims description 12
- 239000002184 metal Substances 0.000 claims description 11
- 239000010949 copper Substances 0.000 claims description 10
- 229910052742 iron Inorganic materials 0.000 claims description 9
- 239000012535 impurity Substances 0.000 claims description 7
- 239000011248 coating agent Substances 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 238000002844 melting Methods 0.000 claims description 6
- 230000008018 melting Effects 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 5
- 229910052720 vanadium Inorganic materials 0.000 claims description 5
- 239000000758 substrate Substances 0.000 claims description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 claims description 3
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 claims 3
- 239000000126 substance Substances 0.000 abstract description 5
- 238000005260 corrosion Methods 0.000 description 23
- 230000007797 corrosion Effects 0.000 description 23
- 238000012360 testing method Methods 0.000 description 17
- 230000004580 weight loss Effects 0.000 description 9
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 7
- 229910017604 nitric acid Inorganic materials 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 238000007792 addition Methods 0.000 description 4
- 238000010285 flame spraying Methods 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 229910052721 tungsten Inorganic materials 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 3
- 238000005275 alloying Methods 0.000 description 3
- 229910052748 manganese Inorganic materials 0.000 description 3
- 239000011812 mixed powder Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000005496 eutectics Effects 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000011241 protective layer Substances 0.000 description 2
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 2
- 229940045605 vanadium Drugs 0.000 description 2
- 229910000521 B alloy Inorganic materials 0.000 description 1
- 229910000640 Fe alloy Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 238000009750 centrifugal casting Methods 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000007385 chemical modification Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000011876 fused mixture Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000005552 hardfacing Methods 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- OYIKARCXOQLFHF-UHFFFAOYSA-N isoxaflutole Chemical compound CS(=O)(=O)C1=CC(C(F)(F)F)=CC=C1C(=O)C1=C(C2CC2)ON=C1 OYIKARCXOQLFHF-UHFFFAOYSA-N 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000006072 paste Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 235000011149 sulphuric acid Nutrition 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
- C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
- C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/56—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.7% by weight of carbon
-
- 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
- C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Powder Metallurgy (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
In order to provide a material of low cost that is suitable to produce parts or coatings having a high wear and also high chemical resistance, an alloy is propsoed comprising 13 to 16 percent by weight nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B) and 1.5 to 2.1 percent by weight of carbon (C), balance iron (Fe).
Description
Wear resistant alloy Detailed description The invention relates to a material comprising an iron based alloy containing C, B, Cr, Ni, Si and Mo.
The material or alloy may be used for producing formed products, casted products, coatings, parts, coated parts, wires, electrodes, powders and powder mixtures.
Prior Art There is a need in industry for an alloy material which has excellent resistance aga ins wear and corrosion and a low cost.
The use of nickel-based alloys with additions of chromium and molybdenum to give protection from wear and corrosion has long been known. Such alloys are disclosed for example in the patents US 6,027,583 A, US 6,187,115 A and US 6,322,857 A.
EP 1 788 104 Al discloses a material for producing parts or coatings adapted for high wear and friction-intensive applications. The material comprises a nickel based alloy with the addition of hard particles such as WC.
The elements Ni and W are expensive and alternatives are sought.
Iron-based self-fluxing alloys are an alternative group of lower cost materials and many materials have been found that exhibit reasonable wear resistance.
Such an iron-based alloy is known from DE 197 33 306 Cl. It discloses an iron-based thermal coating material. The alloy is used as additive material, in the form of a mixture, a gas atomized alloy, an agglomerated metal powder, a core-filled wire, a core-filled strip, a sintered strip or a cast sheathed rod electrode and used
The material or alloy may be used for producing formed products, casted products, coatings, parts, coated parts, wires, electrodes, powders and powder mixtures.
Prior Art There is a need in industry for an alloy material which has excellent resistance aga ins wear and corrosion and a low cost.
The use of nickel-based alloys with additions of chromium and molybdenum to give protection from wear and corrosion has long been known. Such alloys are disclosed for example in the patents US 6,027,583 A, US 6,187,115 A and US 6,322,857 A.
EP 1 788 104 Al discloses a material for producing parts or coatings adapted for high wear and friction-intensive applications. The material comprises a nickel based alloy with the addition of hard particles such as WC.
The elements Ni and W are expensive and alternatives are sought.
Iron-based self-fluxing alloys are an alternative group of lower cost materials and many materials have been found that exhibit reasonable wear resistance.
Such an iron-based alloy is known from DE 197 33 306 Cl. It discloses an iron-based thermal coating material. The alloy is used as additive material, in the form of a mixture, a gas atomized alloy, an agglomerated metal powder, a core-filled wire, a core-filled strip, a sintered strip or a cast sheathed rod electrode and used
2 for thermal coating of components exposed to friction. A preferred composition of the alloy for applying a low friction and low wear layer for a sliding component pairing with good fatigue and impact resistance is as follows (by weight): 20-25%
Mn, 13-20% Cr, 0.1-2% Ni, 3-6% W, 0.1-0.15% C, 1.5-2.5% B, balance Fe. An-other preferred composition of the alloy for applying a low friction layer with high abrasion resistance and higher thermal loading capacity is as follows (by weight):
18-25% Mn, 13-25% Cr, 0.1-2% Ni, 3-5% W, 0.1-0.15% C, 4-6% B, balance Fe.
DE 199 01 170 Al discloses another iron alloy with high carbon, boron, vana-dium, chromium, molybdenum and nickel contents. The following composition is proposed (by weight): 2.0-4.0% C, 2.0-4.5 % B, 0.5-3.5% Si, 6.0-15.0% Cr, 1.5-7.5 (:)/0 Mo, 6.0-14.0 (:)/0 V, 0-3.0 (:)/0 W, 0-1.5 (:)/0 Mn, 0-2.0 (:)/0 Cu, 2.0-7.0 (:)/0 Ni, bal-ance Fe and impurities. The alloy is used for internal hard facing of metal cylin-ders by centrifugal casting or hot isostatic pressing.
CA 2 416 950 Al discloses a material for the manufacture of parts and tools for use at elevated temperature, comprising an iron-based alloy comprising C, Si, Mn, Cr, Ni and N in certain concentrations. The alloy is cold formed to a hardness of at least 230 HB.
However, there remain two problems with such Fe-based alloys. First, the wear resistance of these Fe-based alloys is still inferior to Ni-based alloys with WC. To get close to those properties, the base alloy must use expensive alloying elements such as W, Nb or add large quantities of WC particles. These alloying elements increase the price and make the material very hard (more than 65 HRC), which poses additional processing and application problems with cracking.
Secondly, the Fe-based materials do not have a good corrosion resistance, like that of Ni based alloys, particularly in mixed corrosion environments.
Mn, 13-20% Cr, 0.1-2% Ni, 3-6% W, 0.1-0.15% C, 1.5-2.5% B, balance Fe. An-other preferred composition of the alloy for applying a low friction layer with high abrasion resistance and higher thermal loading capacity is as follows (by weight):
18-25% Mn, 13-25% Cr, 0.1-2% Ni, 3-5% W, 0.1-0.15% C, 4-6% B, balance Fe.
DE 199 01 170 Al discloses another iron alloy with high carbon, boron, vana-dium, chromium, molybdenum and nickel contents. The following composition is proposed (by weight): 2.0-4.0% C, 2.0-4.5 % B, 0.5-3.5% Si, 6.0-15.0% Cr, 1.5-7.5 (:)/0 Mo, 6.0-14.0 (:)/0 V, 0-3.0 (:)/0 W, 0-1.5 (:)/0 Mn, 0-2.0 (:)/0 Cu, 2.0-7.0 (:)/0 Ni, bal-ance Fe and impurities. The alloy is used for internal hard facing of metal cylin-ders by centrifugal casting or hot isostatic pressing.
CA 2 416 950 Al discloses a material for the manufacture of parts and tools for use at elevated temperature, comprising an iron-based alloy comprising C, Si, Mn, Cr, Ni and N in certain concentrations. The alloy is cold formed to a hardness of at least 230 HB.
However, there remain two problems with such Fe-based alloys. First, the wear resistance of these Fe-based alloys is still inferior to Ni-based alloys with WC. To get close to those properties, the base alloy must use expensive alloying elements such as W, Nb or add large quantities of WC particles. These alloying elements increase the price and make the material very hard (more than 65 HRC), which poses additional processing and application problems with cracking.
Secondly, the Fe-based materials do not have a good corrosion resistance, like that of Ni based alloys, particularly in mixed corrosion environments.
3 Object of the invention It is therefore an object of the invention to provide an alternative material of lower cost that is suitable to produce parts or coatings having a high wear and also high chemical resistance.
The object is achieved by a material comprising an alloy containing 13 to 16 percent by weight nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B), 1.5 to 2.1 percent by weight of carbon ( C) and 0.2 to 0.5 percent by weight of copper (Cu), balance iron (Fe).
It was found that such iron based alloys with C, B, Cr, Ni, Si and Mo exhibit high wear and surprisingly high chemical resistance.
The material comprises an iron based alloy with the further components C, B, Cr, Ni, Si and Mo. The material includes the pure alloy and coatings with a composi-tion of the alloy.
The alloy contains only C, B, Cr, Ni, Si and Mo as major components besides the main component Fe. Generally the alloy contains traces or minor amounts of other elements, which are generally common impurities. Less preferred, the alloy may contain other elements in concentrations, which do not alter its chemical be-havior significantly. Such optional additives are named accompanying elements.
The alloy is useful for producing either coatings on a metal substrate or for producing formed products, casted products, coatings, parts, coated parts, wires, electrodes or powders.
In general the alloy consists of 13 to 16 percent by weight (wt.-%) nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B) and 1.5 to 2.1 percent by weight of carbon (C),, balance iron (Fe) and possible impurities.
=
The object is achieved by a material comprising an alloy containing 13 to 16 percent by weight nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B), 1.5 to 2.1 percent by weight of carbon ( C) and 0.2 to 0.5 percent by weight of copper (Cu), balance iron (Fe).
It was found that such iron based alloys with C, B, Cr, Ni, Si and Mo exhibit high wear and surprisingly high chemical resistance.
The material comprises an iron based alloy with the further components C, B, Cr, Ni, Si and Mo. The material includes the pure alloy and coatings with a composi-tion of the alloy.
The alloy contains only C, B, Cr, Ni, Si and Mo as major components besides the main component Fe. Generally the alloy contains traces or minor amounts of other elements, which are generally common impurities. Less preferred, the alloy may contain other elements in concentrations, which do not alter its chemical be-havior significantly. Such optional additives are named accompanying elements.
The alloy is useful for producing either coatings on a metal substrate or for producing formed products, casted products, coatings, parts, coated parts, wires, electrodes or powders.
In general the alloy consists of 13 to 16 percent by weight (wt.-%) nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B) and 1.5 to 2.1 percent by weight of carbon (C),, balance iron (Fe) and possible impurities.
=
4 Impurities are normally present and are generally unavoidable. The content of impurities in the alloy is generally less than 1 percent by weight, preferably less than 0.5 percent by weight and most preferred less than 0.2 percent by weight. All weight percentages mentioned are based on the weight of the total composition, which is 100 percent by weight. All numerical values are approximate values.
In a less preferred alternative the alloy may contain one or more accompanying elements. The content of an accompanying element in the alloy is generally less than 3 percent by weight, preferably less than 2 percent by weight and most preferred less than 1 percent by weight. The whole content of accompanying elements in the alloy is generally less than 5 percent by weight, preferably less than 3 percent by weight and most preferred less than 2 percent by weight.
A preferred composition of the alloy is 13 to 14 percent by weight of nickel (Ni), 14 to 16 percent by weight of chromium (Cr), 1 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B), 1.8 to 2.1 percent by weight of carbon (C) and 0.2 to 0.5 percent by weight of copper (Cu), balance iron (Fe) and possible impurities.
In an embodiment, the invention relates to a material comprising an alloy containing 13 to 16 percent by weight nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B) and 1.5 to 2.1 percent by weight of carbon (C), 0.2 to 0.5 percent by weight of copper, 0 to 1 percent by weight of vanadium, and a balance being of iron (Fe).
The alloy has an unusual good corrosion resistance in mixed corrosion conditions where most Ni-based or Fe-based wear resistant materials do not satisfy. It is remarkable that the Fe-based alloy contains no addition of other hard particles to increase its hardness, such as Tungsten Carbide (WC).
4a Generally the alloys have a hardness in the range of 35 HRC to 60 HRC, particularly in the range of 55 HRC to 60 HRC, typically around 58 HRC, which is unusually low for such a wear resistant material. It gives an advantage in processing and operation as it makes the alloy less sensitive to cracking.
Here, the unit "HR" represents the so called "Rockwell hardness". There are several Rockwell scales for different ranges of hardness. The most common are the B
scale (HRB), which is appropriate for soft metals, and the C scale (HRC) for hard metals.
The method for measuring hardness according to Rockwell is specified in DIN EN ISO 6508- ASTM E-18. Rockwell hardness numbers are not proportional to Vickers hardness readings, but there exist conversion tables, according to which the above range of 35 to 60 HRC is corresponding a Vickers hardness of between 345 and 780 HV/10.
In a less preferred alternative the alloy may contain one or more accompanying elements. The content of an accompanying element in the alloy is generally less than 3 percent by weight, preferably less than 2 percent by weight and most preferred less than 1 percent by weight. The whole content of accompanying elements in the alloy is generally less than 5 percent by weight, preferably less than 3 percent by weight and most preferred less than 2 percent by weight.
A preferred composition of the alloy is 13 to 14 percent by weight of nickel (Ni), 14 to 16 percent by weight of chromium (Cr), 1 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B), 1.8 to 2.1 percent by weight of carbon (C) and 0.2 to 0.5 percent by weight of copper (Cu), balance iron (Fe) and possible impurities.
In an embodiment, the invention relates to a material comprising an alloy containing 13 to 16 percent by weight nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B) and 1.5 to 2.1 percent by weight of carbon (C), 0.2 to 0.5 percent by weight of copper, 0 to 1 percent by weight of vanadium, and a balance being of iron (Fe).
The alloy has an unusual good corrosion resistance in mixed corrosion conditions where most Ni-based or Fe-based wear resistant materials do not satisfy. It is remarkable that the Fe-based alloy contains no addition of other hard particles to increase its hardness, such as Tungsten Carbide (WC).
4a Generally the alloys have a hardness in the range of 35 HRC to 60 HRC, particularly in the range of 55 HRC to 60 HRC, typically around 58 HRC, which is unusually low for such a wear resistant material. It gives an advantage in processing and operation as it makes the alloy less sensitive to cracking.
Here, the unit "HR" represents the so called "Rockwell hardness". There are several Rockwell scales for different ranges of hardness. The most common are the B
scale (HRB), which is appropriate for soft metals, and the C scale (HRC) for hard metals.
The method for measuring hardness according to Rockwell is specified in DIN EN ISO 6508- ASTM E-18. Rockwell hardness numbers are not proportional to Vickers hardness readings, but there exist conversion tables, according to which the above range of 35 to 60 HRC is corresponding a Vickers hardness of between 345 and 780 HV/10.
5 The alloys generally have a melting point in the range of 1.000 to 1.150 C, typically around 1080 C. This a very low melting temperature for such an alloy with these properties, which reduces costs in processing and gives application advantages.
The alloy is produced in the conventional manner by melting of the components or blending of powders or compounds.
The alloy can be cast to products of any shape.
The alloy is used for the production of parts or coatings on parts, which are generally metal substrates or metal parts, especially made of steel. Metal parts are e.g. rotors, sleeves, bearings, screws, blades, etc.
The material, in particular the alloy, is preferably used for the production of wires, filling wires, bands, strand-shaped products, electrodes, powders, pastes, slurries, or cast bar material, which are used e.g. for casting, welding, plasma transferred arc welding (PTA), plasma powder build-up welding or arc welding, brazing, flame spraying, in particular high-speed flame spraying (HVOF), sinter fusing and similar processes.
The invention also comprises a process for applying a material according to the invention for the production of coatings with a high level of resistance to corrosion and wear on a workpiece by a thermal coating process, in which the coating material in powder form is alloyed and atomized from the melt or agglomerated from various alloyed and non-alloyed metal powders.
The coatings or protective layers of the alloy on parts, in particular metal parts, are produced preferably by conventional methods of applying a powder by
The alloy is produced in the conventional manner by melting of the components or blending of powders or compounds.
The alloy can be cast to products of any shape.
The alloy is used for the production of parts or coatings on parts, which are generally metal substrates or metal parts, especially made of steel. Metal parts are e.g. rotors, sleeves, bearings, screws, blades, etc.
The material, in particular the alloy, is preferably used for the production of wires, filling wires, bands, strand-shaped products, electrodes, powders, pastes, slurries, or cast bar material, which are used e.g. for casting, welding, plasma transferred arc welding (PTA), plasma powder build-up welding or arc welding, brazing, flame spraying, in particular high-speed flame spraying (HVOF), sinter fusing and similar processes.
The invention also comprises a process for applying a material according to the invention for the production of coatings with a high level of resistance to corrosion and wear on a workpiece by a thermal coating process, in which the coating material in powder form is alloyed and atomized from the melt or agglomerated from various alloyed and non-alloyed metal powders.
The coatings or protective layers of the alloy on parts, in particular metal parts, are produced preferably by conventional methods of applying a powder by
6 pouring, casting, dipping, spraying, spinning followed by a thermal fusion treatment or by thermal methods like flame spraying, and preferably by high velocity flame spraying (HVOF), or by plasma transferred are welding. Such coating methods are described, for example, in US 6,187,115 A and US
6,322,857 A, which can be applied analogously, Such coatings can be produced as mentioned above in the thermal processes by using materials containing the alloy, like powders, wires, electrodes or other conventional forms, or by applying two or more materials, which deviate in the composition from the resulting final alloy, where the materials are separate or mixed, e.g. different electrodes or mixed powders, resulting in a coating with the composition of the alloy.
Such coatings or protective layers serve to give protection from wear and corrosion in the chemical industry, the pharmaceutical industry, the paper industry, the glass industry, power industry, cement industry, waste and recycling, pulp and paper industry and the plastics-processing industry. Coated parts are also used advantageously for oil and gas exploration applications.
Generally the coating has a thickness in the range of 0.1 to 20 mm, preferably 1 to 10 mm.
Detailed description of preferred embodiments The invention shall now be explained in more detail with reference to an embodi-ment and a drawing which shows in detail in Fig. 1 a diagram on the degree of volume loss in a standardized abrasion testing (ASTM G65) in dependence upon the alloy composition, Fig. 2 a diagram on the degree of weight loss in a standardized corrosion test in contact with HCI in dependence upon the Ni content of the X5 alloy; and
6,322,857 A, which can be applied analogously, Such coatings can be produced as mentioned above in the thermal processes by using materials containing the alloy, like powders, wires, electrodes or other conventional forms, or by applying two or more materials, which deviate in the composition from the resulting final alloy, where the materials are separate or mixed, e.g. different electrodes or mixed powders, resulting in a coating with the composition of the alloy.
Such coatings or protective layers serve to give protection from wear and corrosion in the chemical industry, the pharmaceutical industry, the paper industry, the glass industry, power industry, cement industry, waste and recycling, pulp and paper industry and the plastics-processing industry. Coated parts are also used advantageously for oil and gas exploration applications.
Generally the coating has a thickness in the range of 0.1 to 20 mm, preferably 1 to 10 mm.
Detailed description of preferred embodiments The invention shall now be explained in more detail with reference to an embodi-ment and a drawing which shows in detail in Fig. 1 a diagram on the degree of volume loss in a standardized abrasion testing (ASTM G65) in dependence upon the alloy composition, Fig. 2 a diagram on the degree of weight loss in a standardized corrosion test in contact with HCI in dependence upon the Ni content of the X5 alloy; and
7 Fig. 3 a diagram on the degree of weight loss in a standardized corrosion test in contact with HNO3 in dependence upon the Ni content of the X5 alloy.
Example 1 (Sample X5) A series of alloys is prepared by the fusion of metal elements and compounds into a melt and producing two powders which are given in table 1 below:
Table 1 Fe C Si Cr Ni Mo B
PoNder 3.7 0.26 4.58 16.4 59.76 12.9 2.87 A
PoNder 71.47 2.03 3.12 14.01 5.62 0 3.59 B
The Powder B (which is a Fe-based alloy) was blended with varying wt% of Pow-der A (which is a Ni based wear resistant alloy which is also designated by No.
"53606") and then fused at 1.080 C. It was found that there was an optimal (:)/0 of powder A for wear and corrosion results that lay between 10 and 40 weight (:)/0 and that best results were obtained with 15% of Powder A mixed with Powder B
This illustrated in Fig 1. The 3 curves are wear rate data points obtained from the same fused mixtures but tested with the ASTM G65 method at three independent test series (different times and places). The volume loss is plotted on the y-axis in [mm3] in dependence of the content of the Powder A in [wt%]. For all three test series a characteristical low volume loss and therefore best wear resistance were obtained with about 15% of Powder A mixed with Powder B.
In the following this 15% mixture of Powder A in Powder B alloy is called "X5".
"X5" is a Fe-based alloy containing no addition of other hard particles to increase its hardness, such as Tungsten Carbide (WC). The following table 2 shows the composition of the X5 alloy in comparison with an Fe-based alloy as it is disclosed in DE 199 01 170 Al. It is obvious that the Ni-content of the X5-alloy is higher and
Example 1 (Sample X5) A series of alloys is prepared by the fusion of metal elements and compounds into a melt and producing two powders which are given in table 1 below:
Table 1 Fe C Si Cr Ni Mo B
PoNder 3.7 0.26 4.58 16.4 59.76 12.9 2.87 A
PoNder 71.47 2.03 3.12 14.01 5.62 0 3.59 B
The Powder B (which is a Fe-based alloy) was blended with varying wt% of Pow-der A (which is a Ni based wear resistant alloy which is also designated by No.
"53606") and then fused at 1.080 C. It was found that there was an optimal (:)/0 of powder A for wear and corrosion results that lay between 10 and 40 weight (:)/0 and that best results were obtained with 15% of Powder A mixed with Powder B
This illustrated in Fig 1. The 3 curves are wear rate data points obtained from the same fused mixtures but tested with the ASTM G65 method at three independent test series (different times and places). The volume loss is plotted on the y-axis in [mm3] in dependence of the content of the Powder A in [wt%]. For all three test series a characteristical low volume loss and therefore best wear resistance were obtained with about 15% of Powder A mixed with Powder B.
In the following this 15% mixture of Powder A in Powder B alloy is called "X5".
"X5" is a Fe-based alloy containing no addition of other hard particles to increase its hardness, such as Tungsten Carbide (WC). The following table 2 shows the composition of the X5 alloy in comparison with an Fe-based alloy as it is disclosed in DE 199 01 170 Al. It is obvious that the Ni-content of the X5-alloy is higher and
8 its V-content is lower (namely zero) and the carbon and chrome levels are also different.
Table 2 =
C Si Cr Ni Mo B V
X5 1.7 3.5 16.0 16.0 2.0 3.5 0 DE 199 01 170 2.0-4.0 0.5-3.5 6.0-15 2.0-7.0 1.5-7.5 2.0-4.5 6.0-14.0 For both alloys: the balance is Fe (in the case of X5 the Fe balance is 57 wt%).
The X5 alloy has a melting temperature of 108000. and low hardness of 58 H RC.
Wear test In the ASTM G65 rubber wheel sand abrasion wear test the standard wear value of 13.68 mm3 loss was recorded after 2000 revolutions of the wheel. This result-ing wear resistant value is at a similar to the well established nickel-based wear resistant material called "12112", sold by Castolin Eutectic. This 12112 alloy is a blend of a NiCrBSi 12496 alloy matrix with 35% WC, which has the following composition:
Table 3 Fe C Cr B Ni Si Mo Alloy 12496 3.88 0.78 14.8 3.13 73.31 4.1 0 malrix This Ni based 12112 alloy (= blend of alloy 12496 alloy with 35% WC) has been sold for at least 20 years and have been used to make Fused powder plates, sold under the name of OP 112, by Castolin Eutectic.
The fact that the Alloy X5 achieved the same G65 wear resistance result as the established 12112 is a surprise and a breakthrough, as the 12112 needs to have
Table 2 =
C Si Cr Ni Mo B V
X5 1.7 3.5 16.0 16.0 2.0 3.5 0 DE 199 01 170 2.0-4.0 0.5-3.5 6.0-15 2.0-7.0 1.5-7.5 2.0-4.5 6.0-14.0 For both alloys: the balance is Fe (in the case of X5 the Fe balance is 57 wt%).
The X5 alloy has a melting temperature of 108000. and low hardness of 58 H RC.
Wear test In the ASTM G65 rubber wheel sand abrasion wear test the standard wear value of 13.68 mm3 loss was recorded after 2000 revolutions of the wheel. This result-ing wear resistant value is at a similar to the well established nickel-based wear resistant material called "12112", sold by Castolin Eutectic. This 12112 alloy is a blend of a NiCrBSi 12496 alloy matrix with 35% WC, which has the following composition:
Table 3 Fe C Cr B Ni Si Mo Alloy 12496 3.88 0.78 14.8 3.13 73.31 4.1 0 malrix This Ni based 12112 alloy (= blend of alloy 12496 alloy with 35% WC) has been sold for at least 20 years and have been used to make Fused powder plates, sold under the name of OP 112, by Castolin Eutectic.
The fact that the Alloy X5 achieved the same G65 wear resistance result as the established 12112 is a surprise and a breakthrough, as the 12112 needs to have
9 35% of expensive WC added to achieve this value and an expensive Ni-based matrix. Alloy X5 is an Fe-based product and has no WC present.
Corrosion tests For corrosion tests specimens with near cylindrical shape were prepared by melt-ing of the test material in ceramic crucibles and cut into sliced with two exposed circular surfaces. The measurement of weight and surface area was recorded.
The test material are the above mentioned Fe-based powder B (table 1) and Ni-powders A (table 1, No. 53606) as well as powders of standard Ni-based alloys known as "12496" and õ12497"( a slight chemical modification of alloy 12496).
Said Ni-based powders were mixed with the Fe-based powder B (table 1) at vari-ous mixing ratios.
The slice specimens were exposed to HCI (33%), HNO3 (55%), H2504(96%) and acidic acid (80%) and the weight loss after 24h, 48h and 120h was measured.
The corrosion resistance as specific weight loss (weight loss in mg per cm2and 24h) was determined.
The diagram of Fig. 2 illustrates the corrosion test results of three test series for different compositions exposed to HCI (33%). The three curves are weight loss data points obtained from the corrosion tests as explained above. The weight loss is plotted on the y-axis in [mg/(cm2x h)] in dependence of the fraction of the re-spective Ni-based A powder of the mixed powders for the preparation of the spe-cimens.
The diagram of Fig. 3 illustrates the corrosion test results of three test series for different alloys exposed to HNO3(55`)/0).The three curves are weight loss data points obtained from the corrosion tests as explained above. The weight loss is plotted on the y-axis in [mg/(cm2x h)] in dependence of the content of the respec-tive Ni-based A powder of the mixed powders for the preparation of the speci-mens.
The results are as follows:
= Ni-based alloys (A, 12496, 12497) show good corrosion resistance against HCI. Fe-based do not (Powder B). With increasing content of the Ni-based powder in the respective powder blends, the corrosion resistance against 5 HCI increases.
= Fe-based alloy (B) shows good corrosion resistance against HNO3. With increasing content of the Fe-based powder in the respective powder blends, the corrosion resistance against HNO3 increases.
= Ni and Fe-based alloys are resistant against acetic acid and H2SO4.
Corrosion tests For corrosion tests specimens with near cylindrical shape were prepared by melt-ing of the test material in ceramic crucibles and cut into sliced with two exposed circular surfaces. The measurement of weight and surface area was recorded.
The test material are the above mentioned Fe-based powder B (table 1) and Ni-powders A (table 1, No. 53606) as well as powders of standard Ni-based alloys known as "12496" and õ12497"( a slight chemical modification of alloy 12496).
Said Ni-based powders were mixed with the Fe-based powder B (table 1) at vari-ous mixing ratios.
The slice specimens were exposed to HCI (33%), HNO3 (55%), H2504(96%) and acidic acid (80%) and the weight loss after 24h, 48h and 120h was measured.
The corrosion resistance as specific weight loss (weight loss in mg per cm2and 24h) was determined.
The diagram of Fig. 2 illustrates the corrosion test results of three test series for different compositions exposed to HCI (33%). The three curves are weight loss data points obtained from the corrosion tests as explained above. The weight loss is plotted on the y-axis in [mg/(cm2x h)] in dependence of the fraction of the re-spective Ni-based A powder of the mixed powders for the preparation of the spe-cimens.
The diagram of Fig. 3 illustrates the corrosion test results of three test series for different alloys exposed to HNO3(55`)/0).The three curves are weight loss data points obtained from the corrosion tests as explained above. The weight loss is plotted on the y-axis in [mg/(cm2x h)] in dependence of the content of the respec-tive Ni-based A powder of the mixed powders for the preparation of the speci-mens.
The results are as follows:
= Ni-based alloys (A, 12496, 12497) show good corrosion resistance against HCI. Fe-based do not (Powder B). With increasing content of the Ni-based powder in the respective powder blends, the corrosion resistance against 5 HCI increases.
= Fe-based alloy (B) shows good corrosion resistance against HNO3. With increasing content of the Fe-based powder in the respective powder blends, the corrosion resistance against HNO3 increases.
= Ni and Fe-based alloys are resistant against acetic acid and H2SO4.
10 = Adding Ni-based powders (A, 12496, 12497) to Powder B improves the cor-rosion resistance against HCI but decreases the resistance against HNO3.
The best balance is achieved with a Ni-based powder percentage of 5-15%
as can be seen in Figs. 2 and 3.
The optimum alloy blend of Ni-based powder into the Fe-based Powder B compo-1 5 sition is 15% (in wt% of the Ni-based powder) for HCI and HNO3, with the use of Powder A as the best source of Ni-based alloy. This 15% / 85% mix gives the composition of X5 according to this preferred embodiment of the invention.
This X5 composition also gives the lowest G65 wear resistance results.
The best balance is achieved with a Ni-based powder percentage of 5-15%
as can be seen in Figs. 2 and 3.
The optimum alloy blend of Ni-based powder into the Fe-based Powder B compo-1 5 sition is 15% (in wt% of the Ni-based powder) for HCI and HNO3, with the use of Powder A as the best source of Ni-based alloy. This 15% / 85% mix gives the composition of X5 according to this preferred embodiment of the invention.
This X5 composition also gives the lowest G65 wear resistance results.
Claims (10)
1. A material comprising an alloy containing 13 to 16 percent by weight nickel (Ni), 13.5 to 16.5 percent by weight of chromium (Cr), 0.5 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B) and 1.5 to 2.1 percent by weight of carbon (C), 0.2 to 0.5 percent by weight of copper, 0 to 1 percent by weight of vanadium, and a balance being of iron (Fe).
2. A material according to claim 1, wherein the alloy contains no elements other than Ni, Cr, Mo, Si, B, C, Cu and Fe, except impurities.
3. A material according to claim 1 or claim 2, wherein the alloy has a composition of 13 to 14 percent by weight of nickel (Ni), 14 to 16 percent by weight of chromium (Cr), 1 to 3 percent by weight of molybdenum (Mo), 3.5 to 4.5 percent by weight of silicon (Si), 3.5 to 4 percent by weight of boron (B), 1.8 to 2.1 percent by weight of carbon (C) and 0.2 to 0.5 percent by weight of copper (Cu), a balance being of iron (Fe).
4. A material according to any one of claims 1 to 3, wherein the alloy has a hardness of less than 60 HRC.
5. A material according to any one of claims 1 to 4, wherein the alloy has a melting point of less than 1150°C.
6. A material according to any one of claims 1 to 5, wherein the alloy is a powder or wire or the alloy is a coating on a metal substrate.
7. A material according to any one of claims 1 to 6, wherein the alloy is free from preformed hard particles.
8. A material according to claim 7, wherein the alloy is free from preformed hard particles of tungsten carbide.
9. A material according to any one of claims 1 to 8, wherein the alloy contains less than 1 percent of weight of vanadium.
10. A material according to claim 9, wherein the alloy is free of vanadium.
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EP09152975A EP2224031B1 (en) | 2009-02-17 | 2009-02-17 | Wear resistant alloy |
EP09152975.0 | 2009-02-17 | ||
PCT/EP2010/051990 WO2010094708A2 (en) | 2009-02-17 | 2010-02-17 | Wear resistant alloy |
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JP5606994B2 (en) * | 2010-09-30 | 2014-10-15 | 株式会社神戸製鋼所 | Machine parts welded with overlay welding material and overlay welding metal |
CN104685093A (en) * | 2012-08-03 | 2015-06-03 | 液态金属涂料有限公司 | Metal-containing coating and method of using and making same |
US9212421B2 (en) | 2013-07-10 | 2015-12-15 | Rec Silicon Inc | Method and apparatus to reduce contamination of particles in a fluidized bed reactor |
US10392685B2 (en) | 2013-10-31 | 2019-08-27 | The Regents Of The University Of Michigan | Composite metal alloy material |
US9849532B2 (en) * | 2014-06-12 | 2017-12-26 | Kennametal Inc. | Composite wear pad and methods of making the same |
CN106480450A (en) * | 2015-09-02 | 2017-03-08 | 沈阳大陆激光工程技术有限公司 | A kind of laser melting coating oil drilling tools wear resistant alloy powders material |
CN108431266A (en) * | 2015-11-02 | 2018-08-21 | 纳米钢公司 | The layered structure of metal matrix composite materials in situ |
CN105506505B (en) * | 2015-12-14 | 2017-02-01 | 西安文理学院 | Laser cladding Fe-base alloy powder for repairing damaged axial flow fan blade and repairing method |
RU2636210C2 (en) * | 2016-02-15 | 2017-11-21 | Общество С Ограниченной Ответственностью "Технологические Системы Защитных Покрытий" (Ооо "Тсзп") | Composition of corrosion-resistant coating for protection of technological petrochemical equipment |
CN106077618A (en) * | 2016-08-22 | 2016-11-09 | 兰州工业学院 | The nichrome dusty material containing rare earth and application thereof for abrasive wear resistance |
RU2750257C2 (en) * | 2019-11-29 | 2021-06-24 | Акционерное общество "Научно-производственное объединение "Центральный научно-исследовательский институт технологии машиностроения" АО "НПО "ЦНИИТМАШ" | Method of producing high-speed steel for manufacture of composite rolls |
RU2769682C1 (en) * | 2021-03-30 | 2022-04-05 | Федеральное государственное бюджетное образовательное учреждение высшего образования "Алтайский государственный аграрный университет" (ФГБОУ ВО Алтайский ГАУ) | Electrode for wear-resistant electric arc surfacing |
KR102462552B1 (en) * | 2022-05-30 | 2022-11-04 | 원스(주) | Composition for alloy powder having excellent strength with magnetic properties, manufacturing method for molded article using the same and molded article manufactured using the same |
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EP2224031B1 (en) | 2013-04-03 |
ES2418135T3 (en) | 2013-08-12 |
RU2530196C2 (en) | 2014-10-10 |
US20110300016A1 (en) | 2011-12-08 |
WO2010094708A2 (en) | 2010-08-26 |
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JP2012518082A (en) | 2012-08-09 |
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