WO2004042101B1 - High temperature alloys - Google Patents

High temperature alloys

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Publication number
WO2004042101B1
WO2004042101B1 PCT/GB2003/004754 GB0304754W WO2004042101B1 WO 2004042101 B1 WO2004042101 B1 WO 2004042101B1 GB 0304754 W GB0304754 W GB 0304754W WO 2004042101 B1 WO2004042101 B1 WO 2004042101B1
Authority
WO
WIPO (PCT)
Prior art keywords
hafnium
alloy
max
chromium
zirconium
Prior art date
Application number
PCT/GB2003/004754
Other languages
French (fr)
Other versions
WO2004042101A2 (en
WO2004042101A3 (en
Inventor
Dominique Flahaut
Original Assignee
Dominique Flahaut
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dominique Flahaut filed Critical Dominique Flahaut
Priority to JP2004549337A priority Critical patent/JP2006517255A/en
Priority to AU2003301837A priority patent/AU2003301837A1/en
Priority to CA002504937A priority patent/CA2504937A1/en
Priority to EP03810516A priority patent/EP1560940A2/en
Publication of WO2004042101A2 publication Critical patent/WO2004042101A2/en
Publication of WO2004042101A3 publication Critical patent/WO2004042101A3/en
Publication of WO2004042101B1 publication Critical patent/WO2004042101B1/en
Priority to US10/533,850 priority patent/US20060096673A1/en
Priority to US12/561,057 priority patent/US20100175508A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/002Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C32/00Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/001Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides
    • C22C32/0015Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with only oxides with only single oxides as main non-metallic constituents
    • C22C32/0026Matrix based on Ni, Co, Cr or alloys thereof
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/02Making ferrous alloys by powder metallurgy
    • C22C33/0207Using a mixture of prealloyed powders or a master alloy
    • C22C33/0228Using a mixture of prealloyed powders or a master alloy comprising other non-metallic compounds or more than 5% of graphite
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/02Making ferrous alloys by powder metallurgy
    • C22C33/0257Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/02Ferrous alloys, e.g. steel alloys containing silicon
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/04Ferrous alloys, e.g. steel alloys containing manganese
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/34Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/48Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
  • Powder Metallurgy (AREA)
  • Ceramic Products (AREA)
  • Glass Compositions (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Abstract

An improved nickel-chromium-iron alloy is provided, which comprises up to about 5 % of hafnium-containing particles. In one embodiment, an improved creep resistant castable oxide dispersion strengthened nickel-chromium-iron alloy comprises up to about 5 % of hafnium, with at least part of the hafnium being present as finely dispersed oxidised particles. Further embodiments of the improved alloy can comprise additionally up to about 15 % by weight aluminium. The alloy is particularly useful in the production of creep resistant tubes and castings, for example, for the petrochemical market.

Claims

40
AMENDED CLAIMS
[Received by the International Bureau on 09 August 2004 (09.08.2004); original claims 15-17, 22, 25, 44, 46-47, 50, 58-59 cancelled' original claims 37 and 38 replaced by amended claims 37 and 38
(14 pages)]
1. An oxide dispersion strengthened nickel-chromium-iron alloy comprising, by weight:
Carbon 0.01 - 0.7%
Silicon 0.1 - 3.0%
Manganese 0 - 2.5%
Nickel 15 - 90%
Chromium 5 - 40%
Molybdenum 0 - 3.0%
Niobium 0 - 2.0%
Tantalum 0 - 2.0%
Titanium 0 - 2.0%
Zirconium 0 - 2.0%
Cobalt 0 - 2.0%
Tungsten 0 - 4.0%
Hafnium 0.01 - 4.5%
Aluminium 0 - 15%
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7% balance iron and incidental impurities,
with the proviso, that at least one carbide forming element whose carbide is more stable than chromium carbide selected from niobium, titanium, tungsten, tantalum and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
2. An oxide dispersion strengthened nickel-chromium-iron alloy comprising, by weight:
Carbon 0.01 to 0.5% 41
Silicon 0.01 to 2.5%
Manganese 0 to 2.5%
Nickel 15 to 50%
Chromium 20 to 40%
Molybdenum 0 to 1.0%
Niobium 0 to 1.7%
Titanium 0 to 0.5%
Zirconium 0 to 0.5%
Cobalt 0 to 2.0%
Tungsten 0 to 1.0%
Hafnium 0.01 to 4.5%,
balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
3. An alloy according to claim 1 having the following composition, by weight:
Carbon 0.3 to 0.7%
Silicon 0.1 to 2.5%
Manganese 2.5% max.
Nickel 30 to 40%
Chromium 20 to 30%
Molybdenum 3.0% max.
Niobium 2.0% max.
Hafnium 0.01 to 4.5%
Titanium 0.5% max.
Zirconium 0.5% max.
Cobalt 2.0% max.
Tungsten 1.0% max. 42
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7%
Balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
4. An alloy according to claim 1 having the following composition, by weight:
Carbon 0.03 to 0.2%
Silicon 0.1 to 0.25%
Manganese 2.5% max.
Nickel 30 to 40%
Chromium 20 to 30%
Molybdenum 3.0% max.
Niobium 1.7% max.
Hafnium 0.01 to 4.5%
Titanium 0.5% max.
Zirconium 0.5% max.
Cobalt 2.05% max.
Tungsten 1.0% max.
Aluminium 0 - 15.0%
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7% balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
5. An alloy according to claim 1 having the following composition, by weight:
Carbon 0.3 to 0.7%
Silicon 0.01 to 2.5%
Manganese 2.5% max.
Nickel 40 to 60%
Chromium 30 to 40%
Molybdenum 3.0% max.
Niobium 2.0% max.
Hafnium 0.01 to 4.5%
Titanium 1.0% max.
Zirconium 1.0% max.
Cobalt 2.0% max.
Tungsten 1.0% max.,
Aluminium 0 - 15.0%
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7% balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
6. An alloy according to claim 1 having the following composition, by weight:
Carbon 0.03 to 0.2%
Silicon 0.1 to 2.5%
Manganese 2.5% max.
Nickel 40 to 50%
Chromium 30 to 40%
Molybdenum 3.0% max.
Niobium 2.0% max. 44
Hafnium 0.01 to 4.5%
Titanium 0.5% max.
Zirconium 0.5% max.
Cobalt 2.0% max.
Tungsten 1.0% max.,
Aluminium 0 - 15.0%
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7% balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
7. An alloy according to claim 1 having the following composition, by weight:
Carbon 0.3 to 0.7%
Silicon 0.01 to 2.5%
Manganese 2.5% max.
Nickel 19 to 22%
Chromium 24 to 27%
Molybdenum 3.0% max. Niobium 2.0% max
Hafnium 0.01 to 4.5%
Cobalt 2.0% max.
Tungsten 1.0% max.,
Aluminium 0 - 15.0%
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7% balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is 45
present and that at least part of the hafnium is present as finely divided oxide particles.
8. An alloy according to claim 1 having the following composition, by weight:
Carbon 0.03 to 0.2%
Silicon 0.1 to 2.5%
Manganese 2.5% max
Nickel 30 to 45%
Chromium 19 to 22%
Molybdenum 3.0% max.
Niobium 2.0% max.
Hafnium 0.01 to 4.5%
Titanium 0.5% max.
Zirconium 0.5% max.
Cobalt 2.0% max.
Tungsten 1.0% max.
Aluminium 0 - 15.0%
Nitrogen 0.001 - 0.5%
Oxygen 0.001 - 0.7% balance iron and incidental impurities,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
9. An alloy according to any one of claims 1 , 2, 3, 5, or 7, having a carbon content of from 0.3 to 0.5% by weight.
10. An alloy according to claim 1 or 2, having a carbon content of from 0.03 to 0.2% by weight. 46
11. An alloy according to claim 1 , in which the amount of carbon in the alloy, by weight, is from 0.3 to 0.6% and the amount of hafnium in the alloy, by weight, is from 0.01 to 3.0%.
12. An alloy according to claim 11 , in which the amount of carbon in the alloy, by weight, is from 0.3 to 0.6% and the amount of hafnium in the alloy, by weight, is from 0.1 % to 1.0%.
13. An alloy according to claim 11 or 12, in which the amount of carbon in the alloy, by weight, is from 0.3 to 0.6% and the amount of hafnium in the alloy, by weight, is from 0.2 to 0.5%.
14. An alloy according to any one of the preceding claims, in which the amount of carbon in the alloy, by weight, is from 0.03 to 0.2% and the amount of hafnium in the alloy, by weight, is from 1 to 4.5%.
18. An alloy according to any one of the preceding claims, in which the hafnium is present in the alloy in the form of finely divided oxidised particles having an average particle size of from 50 microns to 0.25 microns, or less.
19. An alloy according to any one of the preceding claims, in which the hafnium is present in the alloy in the form of finely divided oxidised particles having an average particle size of from 5 microns to 0.25 microns, or less.
20. An alloy having any one of the following compositions, by weight:
Carbon 0.45%
Silicon 1.3%
Manganese 0.9%
Nickel 33.8%
Chromium 25.7%
Molybdenum 0.03%
Niobium 0.85% 47
Hafnium 0.25%
Titanium 0.1%
Zirconium 0.01%
Cobalt 0.04%
Tungsten 0.01%
Nitrogen 0.1 %
Iron balance,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
Carbon 0.07%
Silicon 1.0%
Manganese 0.98%
Nickel 32.5%
Chromium 25.8%
Molybdenum 0.20%
Niobium 0.04%
Hafnium 1.1 %
Titanium 0.12%
Zirconium 0.01 %
Cobalt 0.04%
Tungsten 0.08%
Nitrogen 0.1 %
Iron balance,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
Carbon 0.34% 48
Silicon 1.68%
Manganese 1.10%
Nickel 32.0%
Chromium 21.3%
Molybdenum 0.01%
Niobium 0.80%
Hafnium 0.25%
Titanium 0.12%
Zirconium 0.01%
Aluminium 3.28%
Cobalt 0.04%
Tungsten 0.01%
Iron balance,
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
Carbon 0.42%
Silicon 1.79%
Manganese 1.17%
Nickel 33.2%
Chromium 23.3%
Molybdenum 0.02%
Niobium 0.77%
Hafnium 0.24%
Titanium 0.10%
Zirconium 0.01%
Aluminium 1.64%
Cobalt 0.04%
Tungsten 0.08%
Iron balance, 49
with the proviso that at least one of niobium, titanium and zirconium is present and that at least part of the hafnium is present as finely divided oxide particles.
21. An alloy according to any one of the preceding claims substantially as described in Examples 1 to 4.
23. A nickel-chromium-iron alloy comprising up to about 5% of hafnium- containing particles.
24. An oxide dispersion strengthened nickel-chromium-iron alloy which comprises up to about 5% by weight of hafnium, with at least part of the hafnium being present as finely divided oxidised particles.
26. A method of manufacturing an oxide dispersion strengthened nickel-chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy before pouring, under conditions such that at least part of the hafnium is converted to oxide in the melt.
27. A method according to claim 26, in which the alloy is an alloy as claimed in any of claims 1 to 25.
28. A method according to claim 26 or 27, wherein the hafnium particles have a particle size of less than 50 microns.
29. A method according to any one of claims 26 to 28, in which the amount of hafnium added to the melt is from 0.01 to 3.0% by weight.
30. A method according to any one of claims 26 to 29, wherein the hafnium particles are added to the melt shortly before pouring the molten alloy into a mould.
31. A method according to claim 30, in which the hafnium particles are 50
added to the molten alloy in a ladle.
32. A method according to claim 30, in which the hafnium particles are added to the molten alloy in the furnace
33. A method according to anyone of claims 26 to 32, in which the hafnium is electrolytic hafnium.
34. A method according to any one of claims 26 to 33, wherein the level of oxygen in the melt is varied by the addition of one or more substance selected from the group: silicon, chromium, manganese, calcium,
CaSi,
CaSiMn, niobium, titanium, zirconium.
35. A method of manufacturing an oxide dispersion strengthened nickel-chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy and varying the level of oxygen in the melt by, the addition of at least one substance chosen from the group: silicon, chromium, manganese, calcium,
CaSi,
CaSiMn, niobium, titanium, 51
zirconium.
36. A method of manufacturing an oxide dispersion strengthened nickel- chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy before pouring, under conditions such that the formation of detrimental oxide from the reactive elements titanium, zirconium, aluminium is reduced.
37. A method according to any one of claims 26 to 36 wherein any one of the elements titanium or zirconium are added after hafnium into the melt.
38. A method as claimed in claim 37 wherein any one of the elements titanium or zirconium are added after the hafnium in the melt, and just before pouring in the mould.
39. A method of manufacturing an oxide dispersion strengthened nickel- chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy and which controls the partial pressure of oxygen to permit the oxidation of the hafnium in situ.
40. A method of manufacturing an oxide dispersion strengthened nickel- chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy and which controls the free oxygen content to permit the oxidation of the hafnium in situ.
41. A method of manufacturing an oxide dispersion strengthened nickel- chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy and which controls the partial pressure of at least one element selected from the following group:
oxygen, carbon, nitrogen, 52
hydrogen;
to permit the oxidation of the hafnium in situ.
42. A method of manufacturing an oxide dispersion strengthened nickel- chromium-iron alloy which comprises adding finely divided hafnium particles to a melt of the alloy and which permits the oxidation in situ of beneficial oxide dispersion as hafnium oxide, avoiding the formation of detrimental precipitates.
43. A method as claimed in claim 42 which limits in situ oxidation to beneficial oxide dispersion of hafnium oxides and avoid its reaction with slag.
45. A method according to any of claims 26 to 44, in which the melt temperature is in the range of from 1350°C to 1700°C.
48. A method according to any one of claims 26 to 47, in which the alloy is formed into a tube by rotational moulding.
49. A method according to any one of claims 26 to 48 substantially as described in Examples 1 to 4.
51. A method of manufacturing a nickel-chromium-iron alloy, which comprises adding finely divided hafnium particles to the melt before pouring.
52. A creep resistant alloy tube formed from a nickel-chromium-iron alloy comprising up to about 5% of hafnium-containing particles.
53. A tube according to claim 52, which comprises an oxide dispersion strengthened nickel-chromium-iron alloy comprising up to about 5% of hafnium.
54. A nickel-chromium-iron alloy tube comprising up to about 5% of 53
hafnium-containing particles substantially as herein before described.
55. A tube formed from an alloy according to any of claims 1 to 25 by rotational moulding.
56. A nickel-chromium-iron alloy having a structure and composition substantially as described and illustrated in any one of Figures 1 to 4 of the accompanying Drawings, wherein the tables represent percentages by weight of the alloy constituents.
57. A nickel-chromium-iron alloy having a structure substantially as described and illustrated in Figures 5 or 6 of the accompanying Drawings.
60. A tube formed from an alloy according to any of claims 1 to 25 by rotational moulding.
61. An alloy according to any one of claims 1 to 25, 56 and 57 produced by a method according to any one of claims 26 to 51.
PCT/GB2003/004754 2002-11-04 2003-11-04 High temperature alloys WO2004042101A2 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
JP2004549337A JP2006517255A (en) 2002-11-04 2003-11-04 High temperature alloy
AU2003301837A AU2003301837A1 (en) 2002-11-04 2003-11-04 High temperature alloys
CA002504937A CA2504937A1 (en) 2002-11-04 2003-11-04 Tube made from high temperature alloys
EP03810516A EP1560940A2 (en) 2002-11-04 2003-11-04 High temperature alloys
US10/533,850 US20060096673A1 (en) 2002-11-04 2004-11-04 High temperature alloys
US12/561,057 US20100175508A1 (en) 2002-11-04 2009-09-16 High temperature alloys

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0225648.5 2002-11-04
GB0225648A GB2394959A (en) 2002-11-04 2002-11-04 Hafnium particle dispersion hardened nickel-chromium-iron alloys

Related Parent Applications (2)

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PCT/GB2003/004665 Continuation WO2004042100A2 (en) 2002-11-04 2003-10-30 High temperature resistant alloys
US11/533,034 Continuation US20070010534A1 (en) 1999-11-22 2006-09-19 Novel compounds

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US12/561,057 Continuation US20100175508A1 (en) 2002-11-04 2009-09-16 High temperature alloys

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WO2004042101A2 WO2004042101A2 (en) 2004-05-21
WO2004042101A3 WO2004042101A3 (en) 2004-08-12
WO2004042101B1 true WO2004042101B1 (en) 2004-09-30

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US (2) US20060096673A1 (en)
EP (1) EP1560940A2 (en)
JP (1) JP2006517255A (en)
AT (1) ATE404706T1 (en)
AU (1) AU2003301837A1 (en)
CA (1) CA2504937A1 (en)
DE (1) DE60322935D1 (en)
ES (1) ES2312831T3 (en)
GB (2) GB2394959A (en)
WO (1) WO2004042101A2 (en)

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CA2504937A1 (en) 2004-05-21
GB0225648D0 (en) 2002-12-11
US20100175508A1 (en) 2010-07-15
WO2004042101A2 (en) 2004-05-21
ES2312831T3 (en) 2009-03-01
DE60322935D1 (en) 2008-09-25
GB2394959A (en) 2004-05-12
AU2003301837A1 (en) 2004-06-07
US20060096673A1 (en) 2006-05-11
ATE404706T1 (en) 2008-08-15
WO2004042101A3 (en) 2004-08-12
JP2006517255A (en) 2006-07-20
EP1560940A2 (en) 2005-08-10
GB0228576D0 (en) 2003-01-15

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