GB2143812A - Manufacture of ceramics - Google Patents

Manufacture of ceramics Download PDF

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Publication number
GB2143812A
GB2143812A GB08418736A GB8418736A GB2143812A GB 2143812 A GB2143812 A GB 2143812A GB 08418736 A GB08418736 A GB 08418736A GB 8418736 A GB8418736 A GB 8418736A GB 2143812 A GB2143812 A GB 2143812A
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Prior art keywords
matrix
ceramic
fibre layer
fibre
sintering
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Granted
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GB08418736A
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GB2143812B (en
GB8418736D0 (en
Inventor
Axel Rossmann
Werner Huther
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MTU Aero Engines GmbH
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MTU Motoren und Turbinen Union Muenchen GmbH
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Publication of GB2143812A publication Critical patent/GB2143812A/en
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    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71Ceramic products containing macroscopic reinforcing agents
    • C04B35/78Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80Fibres, filaments, whiskers, platelets, or the like
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00Layered products essentially comprising ceramics, e.g. refractory products
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/01Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/10Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
    • C04B35/111Fine ceramics
    • C04B35/117Composites
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    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/5216Inorganic
    • C04B2235/522Oxidic
    • C04B2235/5224Alumina or aluminates
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/5216Inorganic
    • C04B2235/524Non-oxidic, e.g. borides, carbides, silicides or nitrides
    • C04B2235/5244Silicon carbide
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/5252Fibers having a specific pre-form
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52Constituents or additives characterised by their shapes
    • C04B2235/5208Fibers
    • C04B2235/5268Orientation of the fibers
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
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    • C04B2235/6027Slip casting
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    • C04B2235/604Pressing at temperatures other than sintering temperatures
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    • C04B2235/616Liquid infiltration of green bodies or pre-forms
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/656Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes characterised by specific heating conditions during heat treatment
    • C04B2235/6567Treatment time
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/65Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
    • C04B2235/658Atmosphere during thermal treatment
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    • C04B2237/00Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32Ceramic
    • C04B2237/34Oxidic
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    • C04B2237/00Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32Ceramic
    • C04B2237/36Non-oxidic
    • C04B2237/365Silicon carbide
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    • C04B2237/00Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32Ceramic
    • C04B2237/38Fiber or whisker reinforced
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    • C04B2237/50Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/70Forming laminates or joined articles comprising layers of a specific, unusual thickness
    • C04B2237/704Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the ceramic layers or articles

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Laminated Bodies (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)

Abstract

Ceramic components are made by forming, prior to sintering, a green ceramic matrix with at least one fibre layer consisting of similar ceramic material in or on the matrix with no, or only partial, infiltration of the matrix material into the fibre layer, and then sintering the matrix and fibre layer together. The matrix and fibre layer may be formed together by putting the latter in a mould and slip casting the matrix, or by isostatic pressing the matrix and fibre layer(s) together in a mould. Owing to the partially homogeneous union between similar composite materials the reinforcing fibre layer produces a crack-stopping and fragment-containing effect in the event of rupture of the ceramic component.

Description

SPECIFICATION Manufacture of highly heat-resistant ceramic components This invention relates to a method of manufacturing highly heat-resistant ceramic components and, more particularly, to a component manufactured by such a method.
Owing to the brittleness of ceramic materials, cracking will normally lead to the failure of the component by fracture. A fractured ceramic component may have catastrophic consequences, e.g.
when the ceramic component is a rotor blade of a gas turbine.
In the case of wired glass, (metal) wires are imbedded, for example by fusion, to keep fragments of a broken component in the structure of the component despite cracking. This is an important consideration especially when loose fragments might cause further damage by way of chain reaction, so that minor initial damage could produce considerable consequential damage.
In highly heat-resistant ceramic components it is difficult, for a number of reasons, to imbed metal wires. Ceramic materials have a clearly higher modulus of elasticity than metal wire. Unlike the case of using wires in glass, therefore, any strengthening effect of wires under tensile load in ceramic components is not anticipated. Also, the thermal service range of highly heat-resistant ceramic materials is clearly higher than that of metal wire. Metal wire will usually melt in the normal thermal service range of heat-resistant ceramic materials. Another consideration is that undesirable (chemical) reactions may occur between metal wire and ceramic material when they are being joined together or in service.Also, in the case of structured ceramic components having an internal metal structure the metal structure might overheat if fracture or cracking of the component allows hot gas to impinge directly on the metal. Additionally, differences in thermal expansion do not make the use of the two materials in a composite component desirable.
In a broad aspect of the present invention a method of manufacturing highly heat-resistant components is provided which is remarkably simply and permits the manufacture of high-strength ceramic components, in which even in the event of cracking or fracture of the components, an otherwise loose fragment will remain in the component structure.
It is a particular object of he present invention to deposit, before sintering, at least one layer of fibre of a similar ceramic material on or in the ceramic matrix of a green compact to be sintered.
According to the present invention, there is provided a method of manufacturing a highly heat-resistant ceramic product, comprising the steps of forming, prior to sintering, a composite body consisting of a green ceramic matrix with at least one fibre layer, or continuous structure of fibres, of the same or a similar ceramic material, on or in the matrix such that the fibre layer or structure is not, or is at most only partially, infiltrated or penetrated by the ceramic matrix material, and thereafter sintering together the fibre layer or stucture and the ceramic matrix.
The layer of similar ceramic material fibre may, e.g., be SiC fibre if SiC ceramic material is used as the matrix, or Awl203 fibre if AT203 material is used.
During sintering, the non-reinforced ceramic body and the ceramic fibre will partially unite to provide a homogeneous unit. In the process the fibre layer is not to be fully infiltrated into the ceramic matrix; otherwise, the fibre will rupture concurrently and the crack-stopping and fragment-containing effect is lost if the ceramic matrix is ruptured.
The method may consist of the steps of depositing, prior to sintering, at least one fibre layer of a similar ceramic material on or into a green ceramic that the said fibre layer is not, or is at most only partially, infiltrated by the ceramic matrix material, and thereafter sintering together the fibre layer and the ceramic matrix.
As long as the ceramic material is undamaged the intermediate fibre layer provided in accordance with the present invention prevents an undesirably high degree of heat transfer by radiation and/or convection. The intermediate layer may also serve for the soft (i.e. damped) transfer of forces to supporting structures and to balance differences in thermal expansion between the ceramic material and supporting cores, if used. In the event of cracking or fracture the fail-safe performance is improved for the reason that ceramic fibre is not nearly as sensitive to hot gas as would be metal wire or the like.
In an advantageous manufacturing method, the fibre layer is deposited in a slip mould before the actual sintering process commences. The viscosity of the slip and/or the composition of the fibre layer must be such that no, or at most only partial, infiltration of the fibre layer by the slip with respect to the entire thickness of the fibre layer occurs.
Alternatively the fibre layer is deposited, prior to isostatic pressing, in a mould and is then pressed into the ceramic matrix.
The ceramic fibre layer to be used is preferably made up of randomly oriented fibre layers, such as felt matting, or directionally oriented fibre layers (fabric, unidirectional material). Advantageously, the fibre layer is a mat made of fabric with threedimensionally oriented ceramic fibres and high lateral strength, that is, strength in a direction perpendicular to the plane of the mat.
In accordance with the present invention, therefore, similar materials are used for both the actual component and the reinforcement, in order to preclude conflicting material characteristics as described in the cited state of the art.
A ceramic composite component manufactured in accordance with the method of the present invention has a uniform modulus of elasticity. The thermal service range is clearly higher than that for components using metal wire reinforcement. Apart from the chemical sintering process no other chemical reactions occur between the individual materials. No differences in thermal expansion oc cur between the fibre layer and the ceramic matrix.
The invention clearly improves especially the failsafe protection from catastrophic failure of components as might occur with a fracture involving loose fragments. Ceramic components manufactured in accordance with the present invention would be advantageous, especially for combustion chamber tubes and turbine blades exposed to high thermal and/or mechanical stresses.
The invention may be put into practice in a number of ways but certain specific embodiments will now be described, by way of example, with reference to the drawings, in which: Figure 1 illustrates a (simple) component manufactured in accordance with the method of the present invention; and Figure 2 illustrates an alternative component having an integrated layer of reinforcing fibre.
The ceramic component illustrated in Figure 1 consists of a non-reinforced ceramic matrix 1 laterally deposited on which is a fibre layer of a similar ceramic material. For manufacturing the ceramic component, the ceramic fibre layer 2, which may be randomly oriented fibre felt matting or directionally oriented fibre material, is deposited on the green, i.e. unfired, compact or matrix. Subsequent sintering unites the ceramic matrix 1 with the reinforcing fibre layer 2, though the fibre layer is not fully infiltrated into the ceramic matrix but the matrix and fibre layer form a partially homogeneous sintered union. The partially formed sintered union between the composite materials ensures that fracture of the matrix will not be attended by fibre fracture. This enables the similar ceramic fibre layer to act as a reinforcing layer of the green ceramic compact proper.
The ceramic component illustrated in Fig. 2 consists of a fibre layer 2 completely imbedded in the green compact or matrix before sintering. The reinforcing fibre layer (2), therefore, is sandwiched between two ceramic matrix layers to reinforce them.
In the manufacture of ceramic components$, the fibre layer can be deposited by, e.g., a slip moulding process, the fibre layer being placed in the mould cavity into which ceramic slip is then introduced which casts to form the matrix. The viscosity of the slip and/or the composition of the fibre layer must be such that no, or at most only partial, infiltration or penetration of the slip into the whole thickness of the fibre layer occurs.
Alternatively, the fibre layer can be deposited in the mould, perhaps over a core, and pressed into place by isostatic pressing.
For example, in a preferred embodiment of a method in accordance with the invention, a ceramic fibre layer of SiC material having a thickness of Imm is deposited on a matrix material consisting of SiC and an organic binder (e.g. thermoplastic binder) and having a thickness of 5 mm. The ceramic fibre layer and ceramic matrix layer are cold isostatically pressed together under a pressure of 2000 bar. Thereafter, the organic binder is burned out. Then the component is sintered in inert gas for 20 minutes at a temperature of 1700"C. 2000"C.
In summary, in accordance with the invention, ceramic components are made by forming, prior to sintering, a green ceramic matrix with at least one fibre layer consisting of similar ceramic material in or on the matrix with no, or only partial, infiltration of the matrix material into the fibre layer, and then sintering the matrix and fibre layer together. The matrix and fibre layer may be formed together by putting the latter in a mould and slip casting the matrix, or by isostatic pressing the matrix and fibre layer(s) together in a mould. Owing to the partially homogeneous union between similar composite materials the reinforcing fibre layer produces a crack-stopping and fragment-containing effect in the event of rupture of the ceramic component.

Claims (8)

1. A method of manufacturing a highly heat-resistant ceramic product, comprising the steps of forming, prior to sintering, a composite body consisting of a green ceramic matrix with at least one fibre layer, or continuous structure of fibres, of the same or a similar ceramic material, on or in the matrix such that the fibre layer or structure is not, or is at most only partially, infiltrated or penetrated by the ceramic matrix material, and thereafter sintering together the fibre layer or stucture and the ceramic matrix.
2. A method as claimed in claim 1, in which the fibre layer or structure is formed in or on the matrix in a slip moulding process, the viscosity of the slip being such that no, or at most only partial, infiltration of the slip matrix material with respect to the thickness of the fibre layer or structure occurs.
3. A method as claimed in claim 1, in which the fibre layer or structure is deposited in or on the matrix in a mould, and the fibre layer or structure and the matrix are then pressed together isostatically in a pressing operation.
4. A method as claimed in any one of claims 1 to 3, in the fibre layer or structure is made of randomly oriented ceramic fibre.
5. A method as claimed in any one of claims 1 to 3, in which the fibre layer or structure is a mat made of fabric with three-dimensionally oriented ceramic fibres and high lateral strength (in a direction perpendicular to the plane of the mat).
6. A method of manufacturing a highly heat-resistant ceramic component substantially as specifically described herein with reference to any one of the embodiments.
7. A highly heat-resistant ceramic product or component made in accordance with the method of any one of the preceding claims.
8. A highly heat-resistant ceramic component comprising a sintered body consisting of a ceramic matrix and a layer or structure of fibres of the same or similar ceramic material formed in or on the matrix with no, or only partial, infiltration of the fibre layer or structure by the matrix prior to sintering.
GB08418736A 1983-07-28 1984-07-23 Manufacture of ceramics Expired GB2143812B (en)

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DE3327219 1983-07-28

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GB8418736D0 GB8418736D0 (en) 1984-08-30
GB2143812A true GB2143812A (en) 1985-02-20
GB2143812B GB2143812B (en) 1986-10-29

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FR (1) FR2549823B1 (en)
GB (1) GB2143812B (en)
SE (1) SE461275B (en)

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GB2212152A (en) * 1987-10-26 1989-07-19 Central Glass Co Ltd Glass or ceramic plate reinforced with fibrous or flaky material and method of producing same
AU620177B2 (en) * 1988-12-08 1992-02-13 Imperial Chemical Industries Plc Production of fibre reinforced ceramic composite
US5589115A (en) * 1987-11-16 1996-12-31 Corning Incorporated Method for making fiber-reinforced ceramic matrix composite
EP0794403A3 (en) * 1996-03-06 1998-08-05 Solar Turbines Incorporated High pressure ceramic heat exchanger
CN102537155A (en) * 2011-12-29 2012-07-04 中国科学院过程工程研究所 C/C-SiC-ZrC-ZrB2 complex-phase ceramic-based frictional braking material and preparation method thereof

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JPS63173635A (en) * 1987-01-14 1988-07-18 株式会社イナックス Large-sized pottery board having multilayer structure

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EP0073024A2 (en) * 1981-08-21 1983-03-02 Mtu Motoren- Und Turbinen-Union MàœNchen Gmbh Laminated wall of a hollow body and process for manufacturing the same

Cited By (11)

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GB2212152A (en) * 1987-10-26 1989-07-19 Central Glass Co Ltd Glass or ceramic plate reinforced with fibrous or flaky material and method of producing same
US4987028A (en) * 1987-10-26 1991-01-22 Central Glass Company, Limited Glass or ceramic plate reinforced with fibrous or flaky material and method of producing same
GB2212152B (en) * 1987-10-26 1991-10-02 Central Glass Co Ltd Glass or ceramic plate reinforced with fibrous or flaky material and method of producing same
US5589115A (en) * 1987-11-16 1996-12-31 Corning Incorporated Method for making fiber-reinforced ceramic matrix composite
AU620177B2 (en) * 1988-12-08 1992-02-13 Imperial Chemical Industries Plc Production of fibre reinforced ceramic composite
EP0794403A3 (en) * 1996-03-06 1998-08-05 Solar Turbines Incorporated High pressure ceramic heat exchanger
US5954128A (en) * 1996-03-06 1999-09-21 Solar Turbines High pressure ceramic heat exchanger
CN102537155A (en) * 2011-12-29 2012-07-04 中国科学院过程工程研究所 C/C-SiC-ZrC-ZrB2 complex-phase ceramic-based frictional braking material and preparation method thereof
CN102537155B (en) * 2011-12-29 2014-02-26 中国科学院过程工程研究所 C/C-SiC-ZrC-ZrB2 complex-phase ceramic-based frictional braking material and preparation method thereof
CN103693984A (en) * 2011-12-29 2014-04-02 中国科学院过程工程研究所 Carbon fiber enhanced multiphase ceramic-based friction baking material and preparation method thereof
CN103693984B (en) * 2011-12-29 2015-08-26 中国科学院过程工程研究所 Fibre reinforced complex phase ceramic base friction braking material and preparation method thereof

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GB2143812B (en) 1986-10-29
FR2549823B1 (en) 1991-11-22
FR2549823A1 (en) 1985-02-01
SE8402907L (en) 1985-01-29
JPS6044344A (en) 1985-03-09
GB8418736D0 (en) 1984-08-30
SE8402907D0 (en) 1984-05-29
SE461275B (en) 1990-01-29

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