EP0203198B1 - Method of reinforcing a metallic article - Google Patents
Method of reinforcing a metallic article Download PDFInfo
- Publication number
- EP0203198B1 EP0203198B1 EP19850905667 EP85905667A EP0203198B1 EP 0203198 B1 EP0203198 B1 EP 0203198B1 EP 19850905667 EP19850905667 EP 19850905667 EP 85905667 A EP85905667 A EP 85905667A EP 0203198 B1 EP0203198 B1 EP 0203198B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- insert
- alloy
- plating
- plating bath
- aluminum
- Prior art date
- 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.)
- Expired
Links
- 238000000034 method Methods 0.000 title claims abstract description 36
- 230000003014 reinforcing effect Effects 0.000 title claims description 3
- 238000007747 plating Methods 0.000 claims abstract description 75
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 50
- 239000000463 material Substances 0.000 claims abstract description 29
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 21
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 21
- 229910000531 Co alloy Inorganic materials 0.000 claims abstract description 5
- 229910000990 Ni alloy Inorganic materials 0.000 claims abstract description 5
- 229910001069 Ti alloy Inorganic materials 0.000 claims abstract description 5
- 230000010355 oscillation Effects 0.000 claims description 47
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 24
- 229910000679 solder Inorganic materials 0.000 claims description 18
- 238000005266 casting Methods 0.000 claims description 16
- 229910052742 iron Inorganic materials 0.000 claims description 12
- 229910045601 alloy Inorganic materials 0.000 claims description 10
- 239000000956 alloy Substances 0.000 claims description 10
- 239000011701 zinc Substances 0.000 claims description 9
- 229910052725 zinc Inorganic materials 0.000 claims description 8
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 6
- 229910001297 Zn alloy Inorganic materials 0.000 claims description 4
- 239000011159 matrix material Substances 0.000 claims description 4
- 229910001316 Ag alloy Inorganic materials 0.000 claims description 2
- NSAODVHAXBZWGW-UHFFFAOYSA-N cadmium silver Chemical compound [Ag].[Cd] NSAODVHAXBZWGW-UHFFFAOYSA-N 0.000 claims description 2
- GZCWPZJOEIAXRU-UHFFFAOYSA-N tin zinc Chemical compound [Zn].[Sn] GZCWPZJOEIAXRU-UHFFFAOYSA-N 0.000 claims description 2
- 239000004411 aluminium Substances 0.000 claims 1
- 229910000831 Steel Inorganic materials 0.000 abstract description 17
- 239000010959 steel Substances 0.000 abstract description 17
- -1 FRM Inorganic materials 0.000 abstract 1
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 abstract 1
- 230000007547 defect Effects 0.000 abstract 1
- 238000001000 micrograph Methods 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 9
- 239000000725 suspension Substances 0.000 description 6
- 230000008018 melting Effects 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- 238000003466 welding Methods 0.000 description 5
- 238000003780 insertion Methods 0.000 description 4
- 230000037431 insertion Effects 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 229910001018 Cast iron Inorganic materials 0.000 description 3
- KCZFLPPCFOHPNI-UHFFFAOYSA-N alumane;iron Chemical compound [AlH3].[Fe] KCZFLPPCFOHPNI-UHFFFAOYSA-N 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 230000005496 eutectics Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000002203 pretreatment Methods 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 229910052581 Si3N4 Inorganic materials 0.000 description 2
- 230000002238 attenuated effect Effects 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000005238 degreasing Methods 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000005554 pickling Methods 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 229910007570 Zn-Al Inorganic materials 0.000 description 1
- VRAIHTAYLFXSJJ-UHFFFAOYSA-N alumane Chemical compound [AlH3].[AlH3] VRAIHTAYLFXSJJ-UHFFFAOYSA-N 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000004512 die casting Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0036—Casting in, on, or around objects which form part of the product gears
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0009—Cylinders, pistons
Definitions
- the present invention relates to a method for reinforcing a metallic article, according to the preamble of claim 1, wherein an aluminum alloy, and FRM (fiber reinforced material), steel, a Ti alloy, an Ni alloy, a Co alloy or the like is inserted in an aluminum alloy.
- FRM fiber reinforced material
- Aluminum alloy castings have the advantages of being lightweight, being usable in die-cast casting, molten-metal forging, and low-pressure casting, and having a high productivity. However, since they have lower strength, they have lower wear resistance, and the like, that iron castings, and their application range is limited.
- a high-strength material such as an iron-based material
- an iron-based material is inserted at a position of an aluminum alloy casting which requires high strength.
- simple insertion for example, when an iron-based material is inserted in an aluminum alloy, a non-welded portion remains at the iron-aluminum alloy boundary.
- alphine treatment As a method of eliminating such a non-welded portion and diffusion welding the iron-aluminum boundary, alphine treatment is known.
- the alphine treatment requires a great deal of labor, and increases the cost and weight of the resultant material.
- a precleaned higher melting point portion is provided with an irregular surface by submitting said portion to high frequency sonic vibrations in a molten bath of aluminum or aluminum alloy. After the higher melting point portion has been wetted with an aluminum layer, it is removed from the bath and placed in a mold cavity into which aluminum is cast.
- a method is described in US patent 3 401 026 to WALKER ET AL, upon which the preamble of claim 1 is based.
- an inert made of material such as an aluminum alloy, an FRM, steel, a Ti alloy, an Ni alloy, a Co alloy or the like is subjected to a pre-treatment, such as water rinsing, degreasing, pickling, drying, and the like.
- a pre-treatment such as water rinsing, degreasing, pickling, drying, and the like.
- the insert is then dipped in a plating bath, and is plated while oscillating an oscillating plate arranged near the insert in the plating bath. Subsequently, the insert is inserted in an insertee, such as an insertee composed of an aluminum alloy.
- the present invention is characterized in that the insert is placed with respect to the oscillation plate so that the gap therebetween is 0.5 mm or less, that the oscillation plate, the plating bath and the insert are submitted to ultrasonic oscillations until an oxide film on said insert is removed and that the plating of said insert is continued until the plating layer deposited on said insert has reached a thickness of 5 um.
- the plating bath is oscillated to remove the surface oxide of the insert and to form a uniform plating layer.
- the insert is inserted in an insertee, such as an aluminum alloy, with the plating-layer between them. Next, the insert and the insertee are completely welded together, and a diffusion welding region is formed between the two materials.
- the insert and insertee material are securely bonded together, and an inserted article having a satisfactory strength can be manufactured. Since the plating bath need only be oscillated, the manufacturing process is easy, and the cost is low.
- Fig. 1 is a sectional view of a plating device used in Example 1 of the present invention
- Fig. 2 shows a tapered shaft manufactured by the method of Example 1
- Fig. 3 is a microphotograph (x 100) of a boundary portion between insert and insertee of an inserted article manufactured by the method in Example 1 of the present invention
- Fig. 4 is a microphotograph (x 100) of a boundary portion between insert and insertee of an article of a Comparative Example obtained by inserting an insert in an insertee without plating the former [the article corrsponding to the non-preheated, no treatment section for the Comparative Example in the table]:
- Fig. 3 is a microphotograph (x 100) of a boundary portion between insert and insertee of an inserted article manufactured by the method in Example 1 of the present invention
- Fig. 4 is a microphotograph (x 100) of a boundary portion between insert and insertee of an article of a Comparative Example obtained by inserting an insert in an
- FIG. 5 is a microphotograph (x 100) of a boundary portin between piston main body 13 and anti-wear ring 12 of a piston of Example 2;
- Fig. 6 is a sectional view of mold 19 in Example 5;
- Fig. 7 is a microphotograph (x 100) of a boundary portion between steel wire 14 and aluminum alloy 20 of test piece No. 4 of Example 5;
- Fig. 8 is a microphotograph (x 100) of a boundary portion between steel wire 14 and aluminum alloy 20 of test piece No. 6 of Example 5;
- Fig. 9 is a sectional view of an engine connecting rod of Example 5;
- Fig. 10 is a perspective view of cam 18 of Example 6;
- Fig. 11 is a sectional view of a cam shaft of Example 6;
- Fig. 12 is a sectional view of a piston of Example 7;
- Fig. 13 is a sectional view of a cylinder head of Example 4;
- Fig. 14 is a sectional view of an engine including a cylinder head of Example 8; and
- Fig. 15 is a front view of a rocker arm of an internal engine according to the present invention.
- An insert is prepared from JISA2024S aluminum alloy.
- the insert is subjected to cleaning/drying, i.e., a pre-treatment in the order of rinsing with water, degreasing, rinsing with water, pickling, rinsing with water, and drying by a pre-treatment device.
- cleaning/drying i.e., a pre-treatment in the order of rinsing with water, degreasing, rinsing with water, pickling, rinsing with water, and drying by a pre-treatment device.
- Plating is then performed in plating device 1 shown in Fig. 1.
- Plating device 1 consists of solder melting furnace 2 and ultrasonic wave oscillator 3.
- Furnace 2 consists of solder tank 5 containing plating bath 4 at its upper portion, and heating section (heating coil) 6 arranged below tank 5 for heating it.
- One of oscillating plates 8 branching in a Y-shape is fixed to oscillation horn 7 of oscillator 3, and the other plate 8 is dipped in plating bath 4 in tank 5.
- Insert material 9 is inserted between two oscillating plates 8 and is located with a gap of 1.0 mm with respect to two plates 8 by the surface tension of the plating bath.
- Insert 9 is plated under the following conditions:
- Insert 9 plated with Zn-5A alloy is set in a mold of a casting device (not shown). Molten AC4B aluminum alloy is gravity-cast as an insertee, thereby molding tapered shaft 10 shown in Fig. 2. Tapered shaft 10 consists of AC4B main body 11 and insert 9.
- Insert materials were molded from JISA2024S material and were respectively subjected to non-treated Zn plating, Sn plating, kanigen plating, and molten aluminum solder plating. Thereafter, each material was inserted in AC4B aluminum alloy to manufacture a tapered shaft (similar to Example 1).
- Example 1 The welding performance and pressure/absence of insert loss in Example 1 and the Comparative Example were tested. The obtained results are shown in Table 1.
- Example 1 provides better results than the Comparative Example, and no insert loss is experienced.
- the insert is subjected to ultrasonic oscillation while molten aluminum plating is performed, thereby removing the oxide layer formed on the surface of the insert and forming a uniform eutectic layer of aluminum-aluminum solder.
- the eutectic layer has a low melting point, easily melts in an insertee molten aluminum alloy bath, and mixes therewith.
- An anti-wear ring of a piston for a diesel engine was prepared as an insert. Following the same procedures as in Example 1, Zn-5AI solder was melted and used to plate the ring, the plated ring was set in a mold, and AC8A aluminum alloy as an insertee was injected into the mold to form a piston. The casting temperature was 700°C.
- the anti-wear ring consisted of ADC10 aluminum alloy in which an Si 3 N 4 powder was dispersed.
- a microphotograph (x 100; Fig. 5) of a texture at a boundary between anti-wear ring 12 and piston main body 13 cast from AC8A aluminum alloy reveals that no nonwelded portion remains between anti-wear ring 12 and piston main body 13, and that the two materials are completely welded.
- a cylinder liner of ADC10 aluminum alloy in which an Si 3 N 4 powder was dispersed was prepared, and was plated with aluminum alloy solder using Zn-5AI alloy as in Example 1.
- the obtained cylinder liner was set in a mold, and molten aluminum alloy was injected into the mold to cast a cylinder block main body, thereby obtaining a cylinder block in which the cylinder block is inserted in the cylinder block main body.
- a roof member for constituting a refractory combustion chamber wall of a cylinder head was prepared from an FRM having a great thermal fatigue strength (i.e., containing long carbon fiber and JISA6061 aluminum alloy as a matrix).
- the roof member was plated with aluminum alloy solder, the plated roof member was set in a mold, and an aluminum alloy as an insertee was injected into the mold to cast a cylinder main body.
- roof member 32 was inserted in cylinder head main body 31 to complete cylinder head 33.
- Each tensile strength test piece 15 has a size of 7 (diameter) x 32 mm at a parallel portion thereof (marked distance: 25 mm).
- a chuck portion thereof had threads of M12 and P1.5 so as to eliminate the influence of chucking on the insertee in the tensile strength test.
- Fig. 7 corresponds to test piece No. 4 in Table 2.
- MASIC steel wire 16 having a diameter of 4.0 mm was subjected to plating with aluminum solder under the same conditions as test piece No. 4 in Example 4. After the wire was preheated to 300°C, it was set in a mold and ADC10 aluminum alloy was cast by the non-porous die cast method, thereby molding connecting rod 17 for an automobile engine as shown in Fig. 9.
- the resultant connecting rod 17 exhibited about 50% improvement in strength as compared to that when a similar wire was not inserted in MASIC steel.
- the MASIC steel and ADC10 material were completely welded together through the aluminum solder.
- Internal engine cams 18 shown in Fig. 10 were made by an iron-based sintered alloy.
- the side and inner circumferential surfaces of cams 18 were pre-treated and plated after the same procedures as in Example 1.
- aluminum solder-plated cams 18 were preheated to 300°C, they were set in a mold for casting an internal engine cam shaft, and ADC10 aluminum alloy was injected into the mold and cast by the die cast method, thereby mounting cams 18 on shaft 19, as shown in Fig. 11.
- Cams 18 and shaft 19 were completely welded together through the aluminum solder.
- Diesel engine anti-wear ring 21 of Ni-resist cast iron was plated with aluminum solder in the same manner as test piece No. 4 in Example 5. After the anti-wear ring was preheated to 300°C, it was set in a mold, and ADC10 aluminum alloy was injected by gravity casting to mold diesel engine piston 22 as shown in Fig. 12.
- the anti-wear ring and ADC10 aluminum alloy were completely welded together through the aluminum solder.
- a cylinder liner was molded with ADC10 aluminum alloy in which an Si 3 Ni 4 powder was dispersed.
- the cylinder liner was pre-treated and plated with pure zinc under ultrasonic oscillation.
- the plating conditions were as follows:
- the zinc-plated cylinder liner was inserted into a mold, and molten aluminum alloy (ADC10 alloy) was injected into th mold to mold cylinder block 35, in which cylinder liner 34 was inserted as shown in Fig. 14.
- ADC10 alloy molten aluminum alloy
- the zinc plating bath temperature was 500°C
- the plating time was 5 minutes
- the ultrasonic oscillation application time was 5 seconds.
- the ultrasonic oscillation frequency is 18 kHz.
- the ultrasonic oscillation frequency can be within a range of 1 to 1,000 kHz, and preferably 1 to 100 kHz.
- the ultrasonic oscillation frequency is below 1 kHz, the repeating number within a unit time is small, the oxide film formed on the surface of the material to be plated cannot be removed, complete plating cannot be performed, the plating layer is easily peeled off, and a uniform plating layer cannot be formed.
- the ultrasonic oscillation frequency exceeds 1,000 kHz, the plating bath cannot follow oscillation of the oscillation plate, and the plating bath is peeled from the surface of the oscillation plate to cause cavitation, which damages the oscillation plate.
- the plating film thickness is set to be 50 pm or 100 ⁇ m. According to the present invention, the plating film thickness is preferably within a range of 5 to 300 p m, and in particular, 30 to 100 um. When the plating film thickness is below 5 um, welding with the aluminum alloy during the insertion process is incomplete. Since a complete welding between the insert and insertee can be achieved with plating film thicknesses of 300 urn or less, plating exceeded a thickness of 300 ⁇ m is superfluous.
- the amplitude of the oscillation plate was 20 pm.
- the amplitude is preferably within a range of 5 to 35 p m.
- the amplitude is less than 5 um, sufficient energy cannot be applied to the plating to the plating bath, the oxide formed on the surface of the insert material cannot be removed, and a uniform plating layer cannot be formed.
- the amplitude exceeds 35 p m, the plating bath cannot follow movement of the oscillation plate, and cavitation may cause damage to the oscillation plate.
- the distance between the oscillation plate and the plating surface of the insert was 0.1 mm.
- the distance can be 0.5 mm or less to allow the presence of the plating bath between the oscillation plate and the insert.
- wave force of the plating bath applied by oscillation of the oscillation plate is not sufficiently transmitted to the insert, and a uniform, strong plating layer cannot be formed.
- the plating bath composition was Zn-Al alloy or pure zinc.
- any aluminum solder according to JISZ3281, SAL-BQZ, or SAL-CRZ can be used.
- a cadmium-silver alloy [Cd: 95%, Ag: 5% (by weight)]
- a tin-zinc alloy [Sn: 85%, Zn: 15% (% by weight)]
- Sn 85%, Zn: 15% (% by weight
- the insert material was an aluminum alloy, stainless steel, high strength steel, cast iron, an FRM (an aluminum alloy containing carbon fiber), or an iron-based sintered alloy.
- iron steel including stainless steel or heat-resistant steel
- a titanium alloy a nickel alloy, a cobalt alloy, an FRM using an aluminum or zinc alloy as a matrix, or the like can be used.
- constituent parts such as a connecting rod were prepared.
- constituent parts such as a crank shaft, a rocker arm, an automobile suspension part (e.g., a suspension arm), a differential gear carrier, a disk brake caliper, and various gears can also be prepared.
- a rocker arm consists of chip 37 of an iron-based sintered alloy and rocker arm main body 36 of an aluminum alloy, and chip 37 is in slidable contact with a cam, as shown in Fig. 15.
- a Zu-Al alloy or the like is plated on the outer surface of chip 37 under ultrasonic oscillation, and is inserted in rocker arm main body 36.
- a suspension arm steel is inserted in the longitudinal direction thereof, a bush, as a mount portion of the arm to the vehicle body, and a joint member to a wheel are inserted, the outer surface of the wire is plated by the method of the present invention, the joint surface between the steel outer cylinder of the bush and the joint member is plated by the method of the present invention, and the three members are inserted in an aluminum alloy to prepare a suspension arm.
- the method of the present invention is used in the same manner as for a mount bush to the vehicle body and a suspension arm.
- a wire, an FRM or the like is inserted by the method of the present invention.
- any one of sand mold casting, mold gravity casting, low-pressure casting, die-casting, molten metal forging and the like can be used.
- the insert when the insert is an iron-based material, it is preheated before insertion.
- preheating is not always necessary, and can be performed at 400°C or lower. Whether or not to perform preheating can be determined in accordance with the material of the insert used.
- plating is performed while ultrasonic oscillation is applied to the plating bath.
- the gap between the insert and oscillation plate is set to be 0.1 mm. However, the gap can be 0.5 mm or less: the plating bath need only be present between the two materials.
- oscillation applied to the plating bath by the oscillation plate is reflected by the insert.
- the reflected wave is amplified with the oscillation energy by the oscillation plate, and the amplified energy reaches the surface of the insert to remove the oxide on the surface of the insert and to form a uniform plating layer.
- the gap exceeds 0.5 mm, the wave reflected by the insert is attenuated.
- the oscillation wave cannot have sufficient oscillation energy. Therefore, oxide on the surface of the insert material cannot be completely removed, a uniform plating layer cannot be formed, and a non-welded portion is formed between the insert and insertee.
- the present invention can be applied to the manufacture of cylinder heads, pistons, connecting rods, cam shafts pistons, and cylinder blocks, of engines, crank shafts, rocker arms, suspension arms, differential gear carriers, disk brake calipers, and various gears.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Cylinder Crankcases Of Internal Combustion Engines (AREA)
- Electroplating Methods And Accessories (AREA)
- Molten Solder (AREA)
- Valve-Gear Or Valve Arrangements (AREA)
Abstract
Description
- The present invention relates to a method for reinforcing a metallic article, according to the preamble of claim 1, wherein an aluminum alloy, and FRM (fiber reinforced material), steel, a Ti alloy, an Ni alloy, a Co alloy or the like is inserted in an aluminum alloy.
- Aluminum alloy castings have the advantages of being lightweight, being usable in die-cast casting, molten-metal forging, and low-pressure casting, and having a high productivity. However, since they have lower strength, they have lower wear resistance, and the like, that iron castings, and their application range is limited.
- In view of the above situation, a high-strength material, such as an iron-based material, is inserted at a position of an aluminum alloy casting which requires high strength. However, when simple insertion is performed, for example, when an iron-based material is inserted in an aluminum alloy, a non-welded portion remains at the iron-aluminum alloy boundary.
- Since the iron-aluminum alloy boundary remains non-welded, a strength of insertion product is not sufficient.
- As a method of eliminating such a non-welded portion and diffusion welding the iron-aluminum boundary, alphine treatment is known. The alphine treatment, however, requires a great deal of labor, and increases the cost and weight of the resultant material.
- In a known method for forming a bimetallic article comprised of two dissimilar metallic portions (such as steel or cast iron and aluminum or an aluminum alloy), a precleaned higher melting point portion is provided with an irregular surface by submitting said portion to high frequency sonic vibrations in a molten bath of aluminum or aluminum alloy. After the higher melting point portion has been wetted with an aluminum layer, it is removed from the bath and placed in a mold cavity into which aluminum is cast. Such a method is described in US patent 3 401 026 to WALKER ET AL, upon which the preamble of claim 1 is based.
- According to the present invention, an inert made of material such as an aluminum alloy, an FRM, steel, a Ti alloy, an Ni alloy, a Co alloy or the like is subjected to a pre-treatment, such as water rinsing, degreasing, pickling, drying, and the like. The insert is then dipped in a plating bath, and is plated while oscillating an oscillating plate arranged near the insert in the plating bath. Subsequently, the insert is inserted in an insertee, such as an insertee composed of an aluminum alloy.
- The present invention is characterized in that the insert is placed with respect to the oscillation plate so that the gap therebetween is 0.5 mm or less, that the oscillation plate, the plating bath and the insert are submitted to ultrasonic oscillations until an oxide film on said insert is removed and that the plating of said insert is continued until the plating layer deposited on said insert has reached a thickness of 5 um.
- The plating bath is oscillated to remove the surface oxide of the insert and to form a uniform plating layer. The insert is inserted in an insertee, such as an aluminum alloy, with the plating-layer between them. Next, the insert and the insertee are completely welded together, and a diffusion welding region is formed between the two materials.
- The insert and insertee material are securely bonded together, and an inserted article having a satisfactory strength can be manufactured. Since the plating bath need only be oscillated, the manufacturing process is easy, and the cost is low.
- Fig. 1 is a sectional view of a plating device used in Example 1 of the present invention; Fig. 2 shows a tapered shaft manufactured by the method of Example 1: Fig. 3 is a microphotograph (x 100) of a boundary portion between insert and insertee of an inserted article manufactured by the method in Example 1 of the present invention; Fig. 4 is a microphotograph (x 100) of a boundary portion between insert and insertee of an article of a Comparative Example obtained by inserting an insert in an insertee without plating the former [the article corrsponding to the non-preheated, no treatment section for the Comparative Example in the table]: Fig. 5 is a microphotograph (x 100) of a boundary portin between piston main body 13 and anti-wear ring 12 of a piston of Example 2; Fig. 6 is a sectional view of
mold 19 in Example 5; Fig. 7 is a microphotograph (x 100) of a boundary portion betweensteel wire 14 andaluminum alloy 20 of test piece No. 4 of Example 5; Fig. 8 is a microphotograph (x 100) of a boundary portion betweensteel wire 14 andaluminum alloy 20 of test piece No. 6 of Example 5; Fig. 9 is a sectional view of an engine connecting rod of Example 5; Fig. 10 is a perspective view ofcam 18 of Example 6; Fig. 11 is a sectional view of a cam shaft of Example 6; Fig. 12 is a sectional view of a piston of Example 7; Fig. 13 is a sectional view of a cylinder head of Example 4; Fig. 14 is a sectional view of an engine including a cylinder head of Example 8; and Fig. 15 is a front view of a rocker arm of an internal engine according to the present invention. - The present invention will now be described by way of its Examples.
- An insert is prepared from JISA2024S aluminum alloy.
- The insert is subjected to cleaning/drying, i.e., a pre-treatment in the order of rinsing with water, degreasing, rinsing with water, pickling, rinsing with water, and drying by a pre-treatment device.
- Plating is then performed in plating device 1 shown in Fig. 1.
- Plating device 1 consists of solder melting
furnace 2 and ultrasonic wave oscillator 3. Furnace 2 consists of solder tank 5 containing plating bath 4 at its upper portion, and heating section (heating coil) 6 arranged below tank 5 for heating it. One of oscillating plates 8 branching in a Y-shape is fixed tooscillation horn 7 of oscillator 3, and the other plate 8 is dipped in plating bath 4 in tank 5.Insert material 9 is inserted between two oscillating plates 8 and is located with a gap of 1.0 mm with respect to two plates 8 by the surface tension of the plating bath. -
Insert 9 is plated under the following conditions: - 1. Plating bath composition ... molten aluminum solder [eutectic Zn-5AI alloy (95% Zn - 5% Al): melting point = 380°C)
- 2. Ultrasonic oscillation conditions ... oscillation frequency: 18 kHz, amplitude: 20 pm, application time: 2 to 3 sec
- 3. Plating bath temperature ... 400 to 420°C
- 4. Plating film thickness ... 50 pm
- 5. Plating time ... 7 min
- Insert 9 plated with Zn-5A alloy is set in a mold of a casting device (not shown). Molten AC4B aluminum alloy is gravity-cast as an insertee, thereby molding
tapered shaft 10 shown in Fig. 2. Taperedshaft 10 consists of AC4Bmain body 11 andinsert 9. - Insert materials were molded from JISA2024S material and were respectively subjected to non-treated Zn plating, Sn plating, kanigen plating, and molten aluminum solder plating. Thereafter, each material was inserted in AC4B aluminum alloy to manufacture a tapered shaft (similar to Example 1).
-
- As can be seen from this Table, Example 1 provides better results than the Comparative Example, and no insert loss is experienced.
- When a comparison is made between a microphotograph of x 100 (Fig. 3) of a texture at the boundary between
insert 9 andmain body 11 of Example 1 and a microphotograph of x 100 (Fig. 4) of the boundary between the insert and the main body of the Comparative Example obtained with no treatment and no preheating, no nonwelded portion is observed between the insert and the main body in Example 1, whereas a non-welded portion is present between the two materials in the Comparative Example: Therefore, the products of the Comparative Example apparently have low strength. - The insert is subjected to ultrasonic oscillation while molten aluminum plating is performed, thereby removing the oxide layer formed on the surface of the insert and forming a uniform eutectic layer of aluminum-aluminum solder. The eutectic layer has a low melting point, easily melts in an insertee molten aluminum alloy bath, and mixes therewith.
- An anti-wear ring of a piston for a diesel engine was prepared as an insert. Following the same procedures as in Example 1, Zn-5AI solder was melted and used to plate the ring, the plated ring was set in a mold, and AC8A aluminum alloy as an insertee was injected into the mold to form a piston. The casting temperature was 700°C. The anti-wear ring consisted of ADC10 aluminum alloy in which an Si3N4 powder was dispersed. A microphotograph (x 100; Fig. 5) of a texture at a boundary between anti-wear ring 12 and piston main body 13 cast from AC8A aluminum alloy reveals that no nonwelded portion remains between anti-wear ring 12 and piston main body 13, and that the two materials are completely welded.
- A cylinder liner of ADC10 aluminum alloy in which an Si3N4 powder was dispersed was prepared, and was plated with aluminum alloy solder using Zn-5AI alloy as in Example 1. The obtained cylinder liner was set in a mold, and molten aluminum alloy was injected into the mold to cast a cylinder block main body, thereby obtaining a cylinder block in which the cylinder block is inserted in the cylinder block main body.
- The boundary between the cylinder block main body and the cylinder liner was completely welded.
- A roof member for constituting a refractory combustion chamber wall of a cylinder head was prepared from an FRM having a great thermal fatigue strength (i.e., containing long carbon fiber and JISA6061 aluminum alloy as a matrix). Next, following the same procedures as in Example 1, the roof member was plated with aluminum alloy solder, the plated roof member was set in a mold, and an aluminum alloy as an insertee was injected into the mold to cast a cylinder main body. Thus, as shown in Fig. 13, roof member 32 was inserted in cylinder head
main body 31 to completecylinder head 33. - In this case, no non-welded portion was observed between the roof member and the cylinder head main body, and the two materials were completely welded to each other.
- 3.0 mm diameter wires of SUS630 steel and MASIC steel were pre-treated. Thereafter, each wire was plated with aluminum solder using IAlmit AM3501 as JISZ3281 aluminum solder. After preheating each
wire 14 to 300°C, it was set inmold 19 shown in Fig. 6, andAC4B aluminum alloy 20 kept at 700°C as an insertee was injected into the mold to prepare a casting.Reference numeral 21 denotes a support jig for holdingsteel wire 14 inmold 19. JIS tensile strength test piece (No. 4) 15 (indicated by the alternate two long and one short dashed line in Fig. 6) was cut from each casting withwire 14 as the center, and each test piece was subjected to a tensile strength test. Each tensilestrength test piece 15 has a size of 7 (diameter) x 32 mm at a parallel portion thereof (marked distance: 25 mm). A chuck portion thereof had threads of M12 and P1.5 so as to eliminate the influence of chucking on the insertee in the tensile strength test. -
- The test results reveal that a uniform plating layer can be obtained by plating an iron-based insertee with aluminum solder under ultrasonic oscillation, and with such a uniform plating layer, the insert and the insertee (AC4B) are completely welded together at their boundary, as can be seen from the x 100 microphotograph of the texture in Fig. 7. Note that Fig. 7 corresponds to test piece No. 4 in Table 2.
- In the Comparative Example test piece (test piece No. 6) which was not subjected to ultrasonic oscillation, many non-welded portions remained in the boundary between the insert and insertee, as can be seen from the microphotograph (x 100) in Fig. 8.
-
MASIC steel wire 16 having a diameter of 4.0 mm was subjected to plating with aluminum solder under the same conditions as test piece No. 4 in Example 4. After the wire was preheated to 300°C, it was set in a mold and ADC10 aluminum alloy was cast by the non-porous die cast method, thereby molding connecting rod 17 for an automobile engine as shown in Fig. 9. - The resultant connecting rod 17 exhibited about 50% improvement in strength as compared to that when a similar wire was not inserted in MASIC steel. The MASIC steel and ADC10 material were completely welded together through the aluminum solder.
-
Internal engine cams 18 shown in Fig. 10 were made by an iron-based sintered alloy. The side and inner circumferential surfaces ofcams 18 were pre-treated and plated after the same procedures as in Example 1. After aluminum solder-platedcams 18 were preheated to 300°C, they were set in a mold for casting an internal engine cam shaft, and ADC10 aluminum alloy was injected into the mold and cast by the die cast method, thereby mountingcams 18 onshaft 19, as shown in Fig. 11. -
Cams 18 andshaft 19 were completely welded together through the aluminum solder. - Diesel engine
anti-wear ring 21 of Ni-resist cast iron was plated with aluminum solder in the same manner as test piece No. 4 in Example 5. After the anti-wear ring was preheated to 300°C, it was set in a mold, and ADC10 aluminum alloy was injected by gravity casting to molddiesel engine piston 22 as shown in Fig. 12. - The anti-wear ring and ADC10 aluminum alloy were completely welded together through the aluminum solder.
- A cylinder liner was molded with ADC10 aluminum alloy in which an Si3Ni4 powder was dispersed. In the same procedures as in Example 1, the cylinder liner was pre-treated and plated with pure zinc under ultrasonic oscillation. The plating conditions were as follows:
- 1. Plating bath composition ... pure zinc
- 2. Plating bath temperature ... 440-450°C
- 3. Plating film thickness ... 50 µm
- 4. Ultrasonic oscillation conditions...
oscillation frequency 18 kHz, amplitude 20 pm, application time: 2 sec - The zinc-plated cylinder liner was inserted into a mold, and molten aluminum alloy (ADC10 alloy) was injected into th mold to mold
cylinder block 35, in whichcylinder liner 34 was inserted as shown in Fig. 14. - The boundary between the cylinder liner and the cylinder block was completely welded.
- Internal engine cams were prepared from an iron-based sintered alloy as in Example 6. The cams were pre-treated and then plated with pure zinc following the same procedures as in Example 8. After the cams were preheated to 300°C, they were set in a mold and ADC10 aluminum alloy was injected to cast a cam shaft in which the cams were inserted, by the dye cast method.
- When the boundary between the cams and cam shaft was examined, the two materials were completely welded.
- The zinc plating bath temperature was 500°C, the plating time was 5 minutes, and the ultrasonic oscillation application time was 5 seconds.
- In the above-described Examples, the ultrasonic oscillation frequency is 18 kHz. However, according to the present invention, the ultrasonic oscillation frequency can be within a range of 1 to 1,000 kHz, and preferably 1 to 100 kHz. When the ultrasonic oscillation frequency is below 1 kHz, the repeating number within a unit time is small, the oxide film formed on the surface of the material to be plated cannot be removed, complete plating cannot be performed, the plating layer is easily peeled off, and a uniform plating layer cannot be formed. When the ultrasonic oscillation frequency exceeds 1,000 kHz, the plating bath cannot follow oscillation of the oscillation plate, and the plating bath is peeled from the surface of the oscillation plate to cause cavitation, which damages the oscillation plate.
- In the above-described Examples, the plating film thickness is set to be 50 pm or 100 µm. According to the present invention, the plating film thickness is preferably within a range of 5 to 300 pm, and in particular, 30 to 100 um. When the plating film thickness is below 5 um, welding with the aluminum alloy during the insertion process is incomplete. Since a complete welding between the insert and insertee can be achieved with plating film thicknesses of 300 urn or less, plating exceeded a thickness of 300 µm is superfluous.
- In the above-described Examples, the amplitude of the oscillation plate was 20 pm. The amplitude is preferably within a range of 5 to 35 pm. When the amplitude is less than 5 um, sufficient energy cannot be applied to the plating to the plating bath, the oxide formed on the surface of the insert material cannot be removed, and a uniform plating layer cannot be formed. However, when the amplitude exceeds 35 pm, the plating bath cannot follow movement of the oscillation plate, and cavitation may cause damage to the oscillation plate.
- In the above-described Examples, the distance between the oscillation plate and the plating surface of the insert was 0.1 mm. However, the distance can be 0.5 mm or less to allow the presence of the plating bath between the oscillation plate and the insert. When the distance exceeds 0.5 mm, wave force of the plating bath applied by oscillation of the oscillation plate is not sufficiently transmitted to the insert, and a uniform, strong plating layer cannot be formed.
- In the above-described Examples, the plating bath composition was Zn-Al alloy or pure zinc. However, any aluminum solder according to JISZ3281, SAL-BQZ, or SAL-CRZ can be used. In addition, a cadmium-silver alloy [Cd: 95%, Ag: 5% (by weight)], a tin-zinc alloy [Sn: 85%, Zn: 15% (% by weight)], or the like can also be used.
- In the above-described Examples, the insert material was an aluminum alloy, stainless steel, high strength steel, cast iron, an FRM (an aluminum alloy containing carbon fiber), or an iron-based sintered alloy. However, iron steel (including stainless steel or heat-resistant steel), a titanium alloy, a nickel alloy, a cobalt alloy, an FRM using an aluminum or zinc alloy as a matrix, or the like can be used.
- In the above-described Examples, internal engine constituent parts such as a connecting rod were prepared. However, constituent parts such as a crank shaft, a rocker arm, an automobile suspension part (e.g., a suspension arm), a differential gear carrier, a disk brake caliper, and various gears can also be prepared.
- More specifically, a rocker arm consists of
chip 37 of an iron-based sintered alloy and rocker armmain body 36 of an aluminum alloy, andchip 37 is in slidable contact with a cam, as shown in Fig. 15. A Zu-Al alloy or the like is plated on the outer surface ofchip 37 under ultrasonic oscillation, and is inserted in rocker armmain body 36. - In the case of a suspension arm, steel is inserted in the longitudinal direction thereof, a bush, as a mount portion of the arm to the vehicle body, and a joint member to a wheel are inserted, the outer surface of the wire is plated by the method of the present invention, the joint surface between the steel outer cylinder of the bush and the joint member is plated by the method of the present invention, and the three members are inserted in an aluminum alloy to prepare a suspension arm.
- In the case of a differential gear, the method of the present invention is used in the same manner as for a mount bush to the vehicle body and a suspension arm. A wire, an FRM or the like is inserted by the method of the present invention.
- In the case of a gear, after an FRM formed in a ring form is plated by the method of the present invention, the FRM is inserted in an aluminum alloy to provide a gear element. The FRM is then cut to form gear teeth.
- As the casting method for inserting an insert plated by the method of the present invention with an insertee, any one of sand mold casting, mold gravity casting, low-pressure casting, die-casting, molten metal forging and the like can be used.
- In the above-described Examples, when the insert is an iron-based material, it is preheated before insertion. However, preheating is not always necessary, and can be performed at 400°C or lower. Whether or not to perform preheating can be determined in accordance with the material of the insert used.
- In the above-described Examples, plating is performed while ultrasonic oscillation is applied to the plating bath. The gap between the insert and oscillation plate is set to be 0.1 mm. However, the gap can be 0.5 mm or less: the plating bath need only be present between the two materials. However, if the gap is 0.5 mm or less, oscillation applied to the plating bath by the oscillation plate is reflected by the insert. The reflected wave is amplified with the oscillation energy by the oscillation plate, and the amplified energy reaches the surface of the insert to remove the oxide on the surface of the insert and to form a uniform plating layer. However, if the gap exceeds 0.5 mm, the wave reflected by the insert is attenuated. Then, even if the attenuated reflected wave is amplified by the oscillation plate, the oscillation wave cannot have sufficient oscillation energy. Therefore, oxide on the surface of the insert material cannot be completely removed, a uniform plating layer cannot be formed, and a non-welded portion is formed between the insert and insertee.
- The present invention can be applied to the manufacture of cylinder heads, pistons, connecting rods, cam shafts pistons, and cylinder blocks, of engines, crank shafts, rocker arms, suspension arms, differential gear carriers, disk brake calipers, and various gears.
Claims (12)
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP234595/84 | 1984-11-07 | ||
JP59234595A JPS61115658A (en) | 1984-11-07 | 1984-11-07 | Insert-casting method |
JP247665/85 | 1985-11-05 | ||
JP24766585A JPS62107854A (en) | 1985-11-05 | 1985-11-05 | Method and apparatus for insert casting and insert-casting thereof |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0203198A1 EP0203198A1 (en) | 1986-12-03 |
EP0203198A4 EP0203198A4 (en) | 1988-04-26 |
EP0203198B1 true EP0203198B1 (en) | 1991-01-30 |
Family
ID=26531651
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19850905667 Expired EP0203198B1 (en) | 1984-11-07 | 1985-11-07 | Method of reinforcing a metallic article |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0203198B1 (en) |
AU (1) | AU574541B2 (en) |
DE (2) | DE3590587T1 (en) |
GB (1) | GB2184048B (en) |
WO (1) | WO1986002862A1 (en) |
Families Citing this family (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1989009669A1 (en) * | 1988-04-15 | 1989-10-19 | Sandvik Australia Pty. Limited | Composite hard metal-metal components |
FR2663250A1 (en) * | 1990-06-19 | 1991-12-20 | Peugeot | METHOD FOR MANUFACTURING ALUMINUM COLOR ALLOY PARTS COMPRISING AN INSERT AND CULASSE OF AN INTERNAL COMBUSTION ENGINE OBTAINED BY THIS PROCESS. |
FR2665383A1 (en) * | 1990-07-31 | 1992-02-07 | Pechiney Recherche | PROCESS FOR OBTAINING MOLDING BIMATERIAL PARTS. |
EP0787557A3 (en) * | 1996-01-30 | 1998-07-22 | Suzuki Motor Corporation | Method of bonding aluminum members |
DE19650056A1 (en) * | 1996-12-03 | 1998-06-04 | Thyssen Guss Ag | Method for producing a brake disc, in particular as an axle or wheel brake disc for rail vehicles |
DE19755557C1 (en) * | 1997-12-13 | 1999-02-04 | Vaw Alucast Gmbh | Mould for producing an engine block |
FR2831845B1 (en) * | 2001-11-07 | 2004-05-21 | Peugeot Citroen Automobiles Sa | METHOD AND DEVICE FOR CASTING A METAL PART COMPRISING A REINFORCING ELEMENT |
DE10205798A1 (en) * | 2002-02-13 | 2003-09-04 | Federal Mogul Wiesbaden Gmbh | Metallic insert for inserting in an upper part and/or a lower part or a reinforcing rib of a bearing block made of cast aluminum alloy or cast aluminum has on its outer peripheral surface a cover layer made of aluminum alloy or aluminum |
DE102005041410A1 (en) * | 2005-09-01 | 2007-03-08 | Mahle International Gmbh | Method for coating the outer surface of a cylinder liner |
BRPI0709431A2 (en) * | 2006-03-30 | 2011-07-05 | Zf Group North American Operations Inc | process for manufacturing a multilayer duplex material article |
DE102006033770B4 (en) * | 2006-07-21 | 2014-01-16 | Bayerische Motoren Werke Aktiengesellschaft | Front end of a motor vehicle body with a composite of a light metal cast component and several steel components |
DE102008054007B4 (en) * | 2008-10-30 | 2019-09-12 | Volkswagen Ag | Internal combustion engine and method for producing connecting rods and piston pins for an internal combustion engine |
DE102020100640A1 (en) * | 2020-01-14 | 2021-07-15 | Stahlzentrum Freiberg e.V. | Process for improving the corrosion resistance of fastening and / or reinforcement components made of high-alloy steels and fastening and / or reinforcement components made of high-alloy steels |
CN115971704B (en) * | 2022-12-15 | 2023-07-14 | 兰州理工大学 | Aluminum/titanium composite board and preparation method thereof |
Family Cites Families (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB651996A (en) * | 1947-06-19 | 1951-04-11 | Gen Motors Corp | Improved method of bonding aluminium or aluminium alloys to ferrous metals |
DE871096C (en) * | 1951-04-29 | 1953-03-19 | Siemens Ag | Device for the production of metallic coatings |
GB708846A (en) * | 1951-09-28 | 1954-05-12 | Glacier Co Ltd | Improvements in or relating to plain bearings |
DE974552C (en) * | 1952-06-07 | 1961-02-02 | Aluminium Giesserei Villingen | Process for the pretreatment of inserts made of iron or steel for the casting of workpieces made of aluminum or aluminum alloy |
DE1091712B (en) * | 1954-02-08 | 1960-10-27 | Metallgesellschaft Ag | Process for casting light metal onto iron or steel |
US2895845A (en) * | 1955-12-07 | 1959-07-21 | Aeroprojects Inc | Method for applying metallic coatings |
DE1100235B (en) * | 1958-03-26 | 1961-02-23 | Aluminiumwerke Nuernberg G M B | Process for the seamless pouring of insert parts made of heavy metal into castings made of aluminum and its alloys |
US3371703A (en) * | 1964-03-30 | 1968-03-05 | Gen Motors Corp | Sonic method and apparatus for tinning and casting metals |
US3401026A (en) * | 1966-01-19 | 1968-09-10 | Gen Motors Corp | Method of forming a bimetallic article |
US3969544A (en) * | 1975-02-14 | 1976-07-13 | Branson Ultrasonics Corporation | Method for plating metallic workpieces, particularly aluminum |
AU515375B2 (en) * | 1980-02-20 | 1981-04-02 | Nakamura Kinzoku Kogyosho | Manifold |
GB2074912A (en) * | 1980-05-01 | 1981-11-11 | Amsted Ind Inc | Ferrous metal castings with high hardness inserts |
AU543430B2 (en) * | 1981-09-22 | 1985-04-18 | Ae Plc | Pistons |
DE3511542A1 (en) * | 1985-03-29 | 1986-10-02 | Kolbenschmidt AG, 7107 Neckarsulm | COMPOSITE CASTING PROCESS |
JPH05298621A (en) * | 1992-04-15 | 1993-11-12 | Sumitomo Metal Ind Ltd | Thin film magnetic head and its manufacture |
-
1985
- 1985-11-07 WO PCT/JP1985/000619 patent/WO1986002862A1/en active IP Right Grant
- 1985-11-07 DE DE19853590587 patent/DE3590587T1/en active Pending
- 1985-11-07 AU AU50680/85A patent/AU574541B2/en not_active Ceased
- 1985-11-07 GB GB08615801A patent/GB2184048B/en not_active Expired
- 1985-11-07 EP EP19850905667 patent/EP0203198B1/en not_active Expired
- 1985-11-07 DE DE19853590587 patent/DE3590587C2/en not_active Expired
Also Published As
Publication number | Publication date |
---|---|
GB2184048B (en) | 1988-11-23 |
GB8615801D0 (en) | 1986-08-06 |
DE3590587C2 (en) | 1988-06-23 |
AU574541B2 (en) | 1988-07-07 |
AU5068085A (en) | 1986-06-03 |
GB2184048A (en) | 1987-06-17 |
EP0203198A1 (en) | 1986-12-03 |
EP0203198A4 (en) | 1988-04-26 |
DE3590587T1 (en) | 1986-11-20 |
WO1986002862A1 (en) | 1986-05-22 |
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