WO1998021376A1 - Alliages coules de beryllium et d'aluminium a haute resistance contenant du magnesium - Google Patents
Alliages coules de beryllium et d'aluminium a haute resistance contenant du magnesium Download PDFInfo
- Publication number
- WO1998021376A1 WO1998021376A1 PCT/US1997/020748 US9720748W WO9821376A1 WO 1998021376 A1 WO1998021376 A1 WO 1998021376A1 US 9720748 W US9720748 W US 9720748W WO 9821376 A1 WO9821376 A1 WO 9821376A1
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- WO
- WIPO (PCT)
- Prior art keywords
- beryllium
- aluminum
- phase
- alloy
- containing magnesium
- Prior art date
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Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C25/00—Alloys based on beryllium
Definitions
- the present invention relates generally to alloys and, more particularly, to a novel cast aluminum-beryllium alloy having superior strength, corrosion resistance, x-ray cross-section, and environmental acceptability.
- Aluminum-beryllium alloys are known for their unique combination of properties, including strength, stiffness, lightness, machinability and corrosion resistance. Their appeal for commercial applications ranging from aircraft components to actuator armsets for computer disk drives has been recognized for some time.
- Still another object of the present invention is to provide a high performance aluminum-beryllium alloy suitable for investment casting processes.
- Another object of the present invention is the production of a high strength, cast aluminum-beryllium alloy containing magnesium.
- Yet another object of the present invention is to provide an aluminum-beryllium-copper alloy containing magnesium with improved ductility without sacrificing investment castability.
- a further object of the present invention is to provide an aluminum-beryllium-nickel alloy containing magnesium with improved ductility and phase sintering, without sacrificing investment castability.
- Still a further object of the present invention is to provide simple and efficient production of investment cast aluminum-beryllium alloy products.
- Yet a further object of the present invention is to provide economical, high strength, investment cast products of aluminu - beryllium-copper alloys containing magnesium.
- Another object of the present invention is to provide economical, high strength, investment cast products of aluminum- beryllium-nickel alloys containing magnesium.
- a rotatable armset of an actuator comprising a bore for rotating about a shaft of a disk drive for positioning a head radially across a disk of the disk drive, wherein the armset is a one piece unit consisting essentially of an aluminum-beryllium-copper alloy containing magnesium.
- a rotatable armset of an actuator comprising a bore for rotating about a shaft of a disk drive for positioning a head radially across a disk of the disk drive, wherein the armset is a one piece unit consisting essentially of an aluminum-beryllium-cobalt alloy containing magnesium. - r -
- an aluminum-beryllium-nickel alloy containing magnesium the alloy having a first phase consisting of a primary solid solution based on the Be - ⁇ -phase with a microhardness H u of about 285 KSI, a second phase consisting of a solid solution based on the Al - ⁇ -phase with a microhardness H ⁇ of about 85 KSI, and a phase of unknown nature having a microhardness H ⁇ of about 714 KSI.
- a beryllium-aluminum-copper eutectic class alloy system the system structure being characterized by the presence of a Be phase ( ⁇ -phase) and a degenerated eutectic that consists of a slightly alloyed solid solution of beryllium in aluminum.
- a beryllium-aluminum-nickel eutectic class alloy system the system structure being characterized by the presence of a Be phase ( ⁇ -phase) and a degenerated eutectic that consists of a slightly alloyed solid solution of beryllium in aluminum.
- an end effector for a robot arm consisting essentially of an aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al) +
- According to another aspect of the present invention is a method of producing a high strength cast aluminum-beryllium alloy containing magnesium.
- the method comprises the steps of initially melting charges of aluminum-beryllium under vacuum, then pressuring the melt with an inert gas. Magnesium is added under a selected pressure to retard boiling. The resulting material is then cast also under a selected pressure, and cooled in an inert gas atmosphere. Alternatively or concurrently therewith, the material is cooled, again under a selected pressure.
- the present invention is shown and described in connection with aluminum-beryllium alloys containing magnesium, it may be adapted for improving casting characteristics of other materials such as precious metals, aluminum, titanium, nickel, iron, cobalt or copper-based alloys.
- FIG. 1 is a graph showing the relationship between magnesium content and its absorption coefficient vs. duration of melted alloy exposure, in accordance with one aspect of the present invention
- FIG. 2 is a graph showing the influence of the melted alloy exposure duration on the mechanical properties of the alloy, in accordance with the present invention
- FIG. 3 is a graph showing the relationship between mechanical properties of a Be-(36-40)Al-(4.5-5.5)Ni alloy and its magnesium content, in accordance with the present invention
- FIG. 4 is a graph illustrating mold fill-up dependence on magnesium content, according to the present invention
- FIG. 5 is a graph of the ⁇ - and ⁇ -phase copper concentration vs. concentration of copper in the alloy, according to the present invention
- FIG. 6 is a graph illustrating lattice parameters of the ⁇ - phase vs. copper content in the alloy, in accordance with the present invention. - i -
- FIG. 7 is a graph showing the width of aluminum lines in the alloy (1) and ⁇ -phase (2) vs. copper content, according to the present invention.
- FIG. 8 is a graph of ⁇ -phase lattice parameters vs. quenching temperature
- FIG. 9 is a graph illustrating a relationship between ultimate tensile strength (KSI) of the Be- (20-40) Al alloy and its copper content (wt.%);
- FIG. 10 is a graph which illustrates a relationship between elongation of the Be-(20-40)Al alloy and its Cu content (wt.%);
- FIG. 11 shows an avionics box according to one aspect of the present invention
- FIG. 12 shows an actuator armset for a computer disk drive according to one aspect of the present invention
- FIG. 13 shows a single actuator arm from the disk drive of FIG. 12. Forces exerted on the arm are represented by vectors;
- FIG. 14 shows an actuator armset for a computer disk drive according to another aspect of the present invention.
- FIG. 15 shows an end effector for a robot arm according to one aspect of the present invention
- FIG. 16 is a plan view of a metal wood golf club head in accordance with one aspect of the present invention.
- FIG. 17 is a sectional view taken along line 2-2 of FIG. 16;
- FIG. 18 is a sectional view taken along line 3-3 of FIG. 16;
- FIG. 19 shows a golf club head in accordance with another aspect of the present invention.
- FIG. 20 is a bottom view of the golf club head show in FIG. 19.
- the present invention relates to the discovery that a selected concentration of magnesium generally within a range of 0.1 and 1.25%, in combination with selected methods of combining magnesium with aluminum-beryllium alloys, has considerable positive influence on the alloys' physical and mechanical properties.
- a high strength cast aluminum-beryllium alloy containing magnesium represented by the formula (25-60% Al) + (40-75% Be) + (0.1-
- According to another aspect of the present invention is a method of producing a high strength cast aluminum-beryllium alloy containing magnesium.
- the method comprises the steps of initially melting charges of aluminum-beryllium under vacuum, then pressuring the melt with an inert gas. Magnesium is added under a selected pressure to retard boiling. The resulting material is then cast also under a selected pressure, and cooled in an inert gas atmosphere. Alternatively or concurrently therewith, the material is cooled under a selected pressure.
- EXAMPLE I A variety of tests have been conducted on alloys of the present invention. For example, according to one aspect of the present invention, a 50% Mg-Al master alloy was placed in Al foil, and hung above a crucible containing an Al-Be alloy in an air vacuum. The Al-Be alloy was then melted. During melting, the vacuum was substituted by Ar gas under a pressure equal to about 650 mm Hg. The master alloy was then heated above the melted metal surface for a selected time, and immersed in the melted metal. Intensive boiling of the melted metal resulted, accompanied by considerable emission of Mg vapor. - 1 ⁇
- EXAMPLE II A Mg master alloy was placed in a container of Ni. The container was heated initially to about 873°K. A 50% Mg-Al master alloy was then introduced into the container. This resulted in intense evaporation of Mg and splashing of melted metal. Introduction of a less concentrated Mg master alloy did not appear to affect reaction intensity. Absorption of Mg was more unsteady than in Example I. Similar results occurred upon use of a Ni-Mg master alloy.
- EXAMPLE III Initially, a Mg master alloy was refined, cooled about 80- 100°K below the liquidus temperature of the melt, wrapped in Al foil, and introduced into a crucible under air vacuum conditions. Next, the melting chamber was filled with Ar gas, also wrapped in an Al foil master alloy, and placed on a solidified surface of the melted metal. Gradually, the master alloy was heat melted. The actual temperature of the surface was between about 1000° and about 1100°K. Further heating was done simultaneously with heating of the melted metal. The master alloy was then introduced into the crucible, the melted liquid master alloy being mixed with the melted liquid metal at about the same temperature. By this method, metal splashing was eliminated and Mg evaporation was less intensive. Further, an adoption coefficient was provided equal to about 0.7 while reliable alloy fabrication was maintained at a desirable Mg concentration. This is demonstrated in TABLE I below.
- EXAMPLE IV A charge consisting of 1100 grade Al, vacuum cast Be lump, and Ni shot was measured out in the following proportions: 31% Al, 65% Be and 4% Ni. These materials were placed in a Be crucible and induction heated in a vacuum below about 250 microns. When the alloy reached a temperature of about 1250°C, the vacuum furnace was backfilled with Ar gas until the vacuum was just below 1 atmosphere. A Mg ribbon of sufficient quality to produce about a 1.5% Mg level in the alloy was then run into the melt. The melt was stirred by induction for several minutes to promote mixing. After mixing, the melt was poured into a graphite mold and cooled in He, Ar, or N gas.
- Example IV but then poured into a net-shape investment casting mold made using lost wax or a similar method.
- a process of this general description is shown, for example, in U.S. Patent No. 5,642,773, which issued on July 1, 1997, entitled "Aluminum Alloys Containing Beryllium And Investment Casting Of Such Alloys", the disclosure of which is hereby incorporated by reference it its entirety. Thereafter, the mold was cooled in an inert gas such as N or Ar.
- an inert gas such as N or Ar.
- An alloy melt was processed, as described in Examples IV and V, except that after pouring the mold was placed in a pressure vessel and pressurized. A pressure of 180 psi was found optimum for minimizing boiling and casting porosity. Pressures higher and lower than 180 psi may be used successfully.
- the general concept of using high pressure to retard Mg boiling may be used during any combination of melting, casting, and cooling. This technology can also be applied to maintain Zn or Li additions in the melt. A different optimum pressure could be used for each alloying element.
- fillability i.e., the ability to fill in a casting mold
- introduction of Mg generally within a range of 0.2% and 0.4% did not permit the alloy melt to fill in test probe walls about 5 mm thick or less. This generally worsened with changes in casting conditions (i.e., where pouring was performed not in an air vacuum but in an Ar gas environment near about atmospheric pressure) .
- FIG. 4 illustrates a dependence of probe half height filling criterion Z50 (which corresponds to a wall height equal to about 50 mm) on Mg content.
- Alloys containing about 0.6% to about 0.8% Mg were found not able to fill the 50 mm height wall with a thickness less than about 2.5 mm. Increased Mg concentration, it was found, further decreased the fill. Be-Al-Ni alloys containing Mg exhibited high strength characteristics with moderate castability. Use of special gating systems is preferred.
- X A1 and X Ni correspond to Al and Ni contents, respectively, in alloy.
- the alloy consisted of two main phases: (i) a primary solid solution based on the Be - ⁇ -phase having a microhardness H ⁇ of about 285 KSI, and (ii) a solid solution based on the Al - ⁇ - phase with a microhardness H u of about 85 KSI. Also present in the alloy was a phase of unknown nature having a microhardness H ⁇ of about 714 KSI. - IT -
- the alloys according to the present invention were corrosion resistant. During a 90-day test of alloy specimens at a relative humidity of about 98% and at a temperature of about 50°C, no corrosion was revealed.
- a Be-Al-Cu eutectic class alloy system The system structure is characterized by the presence of a Be phase ( ⁇ -phase) and a degenerated eutectic that consists of a slightly alloyed solid solution of beryllium in aluminum. To improve mechanical characteristics of these alloys, additional alloying is provided using appropriate alloying elements. The elements are selected according to Be-metal diagrams. From analysis of these diagrams, Cu was found promising as a main alloying element. Cu is known for its effectiveness as a strengthening element. This is believed due to the solubility of Cu both in Be and Al, as illustrated by the Be-Cu and Al-Cu diagrams. Specimens tested were Be-Al-Cu alloys comprising about 60% to about 70% Be, about 20% to about 40% Al, and about 2% to about 10% Cu. - ⁇ g -
- Dissolution of the Al-phase in 2% NaOH solution was accompanied by the precipitation of Cu.
- Solubility of the BeSAlMe phase in the same solution was accompanied by the transition of Cu into solution, the solubility of Cu in concentrated HN0 3 solution, and the solubility of the Be-phase in the 2% solution.
- the absolute copper content in various phases of aluminum-beryllium-copper alloys, and the amount of copper in the ⁇ -phase is about 80% of the total copper present in the alloy.
- Alloy Copper content in phases (weight of copper in composition phase/weight of copper in alloy). %. weight %.
- micro-additions such as Mg, Mn, Cr and impurity distributions in the ⁇ - and ⁇ - phases.
- the distribution of Cu and Al was also determined.
- Mg was found uniformly distributed in the ⁇ -phase.
- Cu was present in each phase, i.e., in the ⁇ -phase and ⁇ -phases, and interme- tallic particles.
- Table VIII shows the results of metallographic analysis of the alloys.
- the addition of Cu increased the interphase size by precipitating Cu on the Be grain boundaries in the form of a Be- Cu type phase.
- the volume fraction of Be-Cu phase generally increased with increasing Cu content, while the volume fraction of large beryllium intermetallics remained relatively constant at about 1%.
- magnesium may be added to aluminum-beryllium alloys in a variety of ways, including addition to the initial charge, placement on the foil or the charge, melting separately and then adding to the melt, through plunging a solid into the melt, or pouring the melt over or into a tundish containing a desired magnesium content prior to filling the mold.
- magnesium is added by pouring a molten magnesium master alloy onto a molten aluminum-beryllium alloy, or by running magnesium ribbon/wire or magnesium master alloy ribbon/wire into the melt.
- either pure magnesium or a magnesium master alloy such as a 50-50 magnesium-aluminum alloy, may serve as an acceptable source of magnesium, though modifications may be warranted in input charge chemistry where a master alloy is used.
- Aluminum-beryllium is a principle alloy to which additions of ternary magnesium and higher order elements are made. Alloys of the present invention are made by measuring out the required elements, melting according to various methods as presented herein, and adding magnesium accordingly. Additions of elements labeled "Z" may be made anytime before the addition of magnesium. - 3-3 -
- a magnesium to silicon ratio of 2:1 by weight is considered optimum for mechanical strength. Silicon contents may be increased above the ideal ratio to improve castability. It is noted that silicon additions up to about 6% are possible, provided the total of nickel, cobalt, copper, zinc and iron remains below about 2%. Additions of about 0.2% strontium or other silicon modifier are considered relatively important to alloy performance.
- the present invention is advantageous in facilitating investment casting of high strength aluminum- beryllium alloys containing magnesium.
- the resulting alloy has low x-ray cross-section and good corrosion resistance.
- replacement of silver by magnesium, as an additive eliminates environmental and other water pollution concerns during processing and recycling.
- the present invention further provides the feature of adding magnesium to the melt just before casting and after vacuum refining. This is done to reduce magnesium loss due to boiling and vaporization.
- an avionics box is formed of the alloys, as illustrated in FIG. 11, preferably by investment casting.
- This box has characteristics desirable for modern aircraft, including high stiffness, good mechanical support, low weight and excellent heat removal characteristics, with a coefficient of thermal expansion low enough to ensure stability during temperature cycling.
- an actuator armset constructed of a high strength cast aluminum-beryllium alloy containing magnesium.
- a rotatable armset of an actuator has a bore for rotating about the shaft of a disk drive for positioning a head radially across a disk.
- the armset is a one piece unit consisting essentially of an alloy of aluminum containing from about 1 to 99 weight percent beryllium and about 0.1 to 1.25 weight percent magnesium made preferably by investment casting.
- FIG. 12 illustrates a read ⁇ write assembly for a hard disk drive having multiple heads 12 mounted on actuator arms 14.
- Heads 12 and actuator arms 14 are assembled together on actuator shaft 13 which is rotated by the interaction of wire coil 18 and magnet 20 disposed in magnet housing 22.
- Actuator arms 14 are spring loaded to rest on the disk when it is stationary. When the disk is rotated, air pressure develops beneath head 12 and lifts it slightly above the disk. Actuator arms 14 are subjected to vertical forces 24 and angular forces 26 as shown in FIG. 13. Actuator arms 14 should be sufficiently stiff to minimize the amplitude of vertical vibration and avoid damaging the disks above and below actuator arms 14. Likewise, actuator arms 14 should be sufficiently stiff to minimize the amplitude of lateral vibration and provide a more rapid response time for reading or writing at an appropriate address on the disk. Laminated materials are effective in minimizing deflections principally in the vertical direction. The aluminum-beryllium alloy containing magnesium according to the present invention is effective to minimize deflections in both the vertical and lateral directions.
- Actuator 11 includes an armset 15, a plurality of suspensions 16, a plurality of transducers 17, a voice coil 18, and crash stop 20.
- Armset 15 includes a body 26. The body mounts brackets 28 and 29 which hold the voice coil 18 and a plurality of arms 30 positioned above and below each hard disk of disk drive assembly.
- jaws 33 and 34 are constructed, at least in part, of a high strength cast aluminum-beryllium alloy containing magnesium according to the present invention.
- End effectors serve a variety functions including not only holding objects and/or materials during rapid, i.e., high velocity, operations, but also high precision/locating tasks.
- a golf club head constructed in whole or in part of a high strength cast aluminum-beryllium alloy containing magnesium of the present invention. As shown in FIGS.
- a golf metal wood driver 40 is fabricated from two cast half sections 42 and 44, joined together along a seam 46 which extends generally parallel to the club face 50 and behind hosel 52.
- the two half sections when joined, define a hollow metal wood club with face region 50, hosel 52, sole region 54, and crown 56.
- Illustrated in FIGS. 19 and 20 is a golf club head 60 constructed in whole or in part of a high strength cast aluminum-beryllium alloy containing magnesium according to the present invention.
- the head has a front wall 62 and a bottom wall 64.
- the bottom wall includes a plurality of threaded inserts 66a,b received in counterbores 68a,b.
- the inserts are constructed of a relatively heavier material such as a copper alloy or steel.
- alloys of the present invention are shown and described with reference to avionics boxes, actuator ar sets, end effectors, and golf clubs, they have been found suitable for other applications including pistons for automobile engines and brake calipers, such applications being considered within the spirit and scope of the present invention. - n -
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- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
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Abstract
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP52282498A JP2001503818A (ja) | 1996-11-15 | 1997-11-14 | マグネシウムを含む高強度鋳造アルミニウム―ベリリウム合金 |
EP97946667A EP0946773A4 (fr) | 1996-11-15 | 1997-11-14 | Alliages coules de beryllium et d'aluminium a haute resistance contenant du magnesium |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US3094996P | 1996-11-15 | 1996-11-15 | |
US60/030,949 | 1996-11-15 |
Publications (1)
Publication Number | Publication Date |
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WO1998021376A1 true WO1998021376A1 (fr) | 1998-05-22 |
Family
ID=21856855
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1997/020748 WO1998021376A1 (fr) | 1996-11-15 | 1997-11-14 | Alliages coules de beryllium et d'aluminium a haute resistance contenant du magnesium |
Country Status (4)
Country | Link |
---|---|
EP (1) | EP0946773A4 (fr) |
JP (1) | JP2001503818A (fr) |
CA (1) | CA2246540A1 (fr) |
WO (1) | WO1998021376A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0921203A1 (fr) * | 1997-12-08 | 1999-06-09 | Ngk Insulators, Ltd. | Une alliage de béryllium-aluminium |
Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3456322A (en) * | 1967-08-14 | 1969-07-22 | Mallory & Co Inc P R | Beryllium-aluminum composite |
US3506438A (en) * | 1967-07-24 | 1970-04-14 | Mallory & Co Inc P R | Method of producing beryllium composites by liquid phase sintering |
US3558305A (en) * | 1966-11-28 | 1971-01-26 | Mallory & Co Inc P R | Chill cast particulate composites |
US5169462A (en) * | 1991-12-09 | 1992-12-08 | Reynolds Metals Company | Low density aluminum alloy for engine pistons |
US5184260A (en) * | 1990-07-19 | 1993-02-02 | Ency Nova Inc. | Magnetic tape drive with integral multiple-cassette removable magazine |
US5260847A (en) * | 1991-10-18 | 1993-11-09 | Maxtor Corporation | Sleeveless rotatable beryllium/aluminum actuator arm for a magnetic disc drive |
WO1995006760A1 (fr) * | 1993-09-03 | 1995-03-09 | Nuclear Metals, Inc. | Alliage de beryllium-aluminium leger et a haute resistance |
US5620652A (en) * | 1994-05-25 | 1997-04-15 | Ashurst Technology Corporation (Ireland) Limited | Aluminum alloys containing scandium with zirconium additions |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE1608248A1 (de) * | 1966-11-28 | 1970-10-15 | Mallory & Co Inc P R | Metallzusammensetzungen |
US5667600A (en) * | 1991-10-02 | 1997-09-16 | Brush Wellman, Inc. | Aluminum alloys containing beryllium and investment casting of such alloys |
-
1997
- 1997-11-14 WO PCT/US1997/020748 patent/WO1998021376A1/fr not_active Application Discontinuation
- 1997-11-14 EP EP97946667A patent/EP0946773A4/fr not_active Withdrawn
- 1997-11-14 CA CA 2246540 patent/CA2246540A1/fr not_active Abandoned
- 1997-11-14 JP JP52282498A patent/JP2001503818A/ja active Pending
Patent Citations (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3558305A (en) * | 1966-11-28 | 1971-01-26 | Mallory & Co Inc P R | Chill cast particulate composites |
US3506438A (en) * | 1967-07-24 | 1970-04-14 | Mallory & Co Inc P R | Method of producing beryllium composites by liquid phase sintering |
US3456322A (en) * | 1967-08-14 | 1969-07-22 | Mallory & Co Inc P R | Beryllium-aluminum composite |
US5184260A (en) * | 1990-07-19 | 1993-02-02 | Ency Nova Inc. | Magnetic tape drive with integral multiple-cassette removable magazine |
US5260847A (en) * | 1991-10-18 | 1993-11-09 | Maxtor Corporation | Sleeveless rotatable beryllium/aluminum actuator arm for a magnetic disc drive |
US5169462A (en) * | 1991-12-09 | 1992-12-08 | Reynolds Metals Company | Low density aluminum alloy for engine pistons |
WO1995006760A1 (fr) * | 1993-09-03 | 1995-03-09 | Nuclear Metals, Inc. | Alliage de beryllium-aluminium leger et a haute resistance |
US5620652A (en) * | 1994-05-25 | 1997-04-15 | Ashurst Technology Corporation (Ireland) Limited | Aluminum alloys containing scandium with zirconium additions |
Non-Patent Citations (1)
Title |
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See also references of EP0946773A4 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0921203A1 (fr) * | 1997-12-08 | 1999-06-09 | Ngk Insulators, Ltd. | Une alliage de béryllium-aluminium |
Also Published As
Publication number | Publication date |
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CA2246540A1 (fr) | 1998-05-22 |
EP0946773A1 (fr) | 1999-10-06 |
EP0946773A4 (fr) | 1999-12-22 |
JP2001503818A (ja) | 2001-03-21 |
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