WO2017059528A1 - Zinc en tant qu'additif pour limiter la corrosion provoquée par une contamination par du nickel dans des alliages d'aluminium - Google Patents

Zinc en tant qu'additif pour limiter la corrosion provoquée par une contamination par du nickel dans des alliages d'aluminium Download PDF

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WO2017059528A1
WO2017059528A1 PCT/CA2016/051131 CA2016051131W WO2017059528A1 WO 2017059528 A1 WO2017059528 A1 WO 2017059528A1 CA 2016051131 W CA2016051131 W CA 2016051131W WO 2017059528 A1 WO2017059528 A1 WO 2017059528A1
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concentration
aluminum alloy
maximum
aluminum
additive
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PCT/CA2016/051131
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English (en)
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James Frederick Major
Bruno BOURASSA
Danick GALLANT
Danny Jean
Raynald GUAY
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Rio Tinto Alcan International Limited
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/02Making non-ferrous alloys by melting
    • C22C1/026Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • C22C21/04Modified aluminium-silicon alloys

Definitions

  • the present disclosure relates to the use of a deliberate addition of zinc to aluminum alloys for limiting or delaying corrosion caused by the presence of a nickel contamination in such alloys.
  • One aim of the present disclosure is to provide zinc as an additive for limiting the corrosion caused by the presence of a nickel contaminant in an aluminum alloy.
  • the present disclosure provides an additive for an aluminum alloy comprising, in weight percentage (when compared to the weight of the aluminum alloy), Ni at a concentration of between about 0.004 and about 0.10, wherein the additive is Zn and is provided at a concentration, in weight percentage (when compared to the weight of the aluminum alloy), between about 0.02 and 0.10.
  • the concentration of Ni is between about 0.01 and 0.05. In another embodiment, the concentration of Ni is less than about 0.05.
  • the present disclosure provides an aluminum alloy comprising the additive as defined herein.
  • the aluminum alloy further comprises, in weight percentage (when compared to the total weight of the aluminum alloy):
  • Si at a concentration of between about 6.5 to about 7.5;
  • Mn at a concentration of a maximum of about 0.1 ;
  • - Mg at a concentration of between about 0.25 to about 0.45;
  • the concentration of Si is between about 7.0 and 7.2; the concentration of Fe is a maximum of about 0.1 ; the concentration of Cu is a maximum of about 0.1 ; the concentration of Cu is a maximum of about 0.01 and/or the concentration of Mg is between about 0.2 and about 0.3.
  • the present application provides a process for limiting corrosion of an aluminum product.
  • the process comprises (a) adding Zn to a first aluminum alloy at a concentration, in weight percentage (when compared to the total weight of the aluminum alloy), between about 0.02 to about 0.10, wherein the first aluminum alloy comprises a concentration, in weight percentage (when compared to the total weight of the aluminum alloy), of Ni between about 0.004 and 0.10; and (b) working the second aluminum alloy to obtain the aluminum product.
  • the concentration of Ni in the first aluminum alloy is between about 0.01 and 0.05.
  • the concentration of Ni in the first aluminum alloy is less than about 0.05.
  • the process further comprises, prior to step (a), providing the first aluminum alloy.
  • the first aluminum alloy further comprises, in weight percentage (when compared to the total weight of the aluminum alloy): Si at a concentration of between about 6.5 to about 7.5;
  • Mn at a concentration of a maximum of about 0.1 ; - Mg at a concentration of between about 0.25 to about 0.45; and
  • the aluminum product is a cast product and the process further includes, at step (b), casting the second aluminum alloy into the cast product.
  • the cast product is an automotive part (such as, for example, a wheel).
  • the process further comprises (c) coating the aluminum product.
  • Figure 1 illustrates that the presence of Zn in the alloys described in Example II limited filiform corrosion associated with the presence of a nickel contamination in such alloys. Results are shown as the filament length per 10 cm (in mm) in function of the concentration of Ni concentration (in ppm). Results are shown for alloys containing 120 ppm (A) or 200 ppm ( ⁇ ) Zn.
  • Figures 3A to C illustrate corrosion susceptibility/resistance of various alloys comprising no or a low concentration of Zn (0.01 wt%) and varying concentrations of Ni (0.004 to 0.015 wt%).
  • A Average filament length (in mm), (B) number of filaments per 10 cm and (C) maximum filament length (in mm) are shown in function of Ni and Zn concentrations.
  • Figures 4A and B illustrate corrosion susceptibility/resistance of various alloys comprising different ratios of Zn/Ni and varying concentrations of Ni (0.004 to 0.015 wt%).
  • A) Average filament length (in mm) and (B) number of filaments per 10 cm are shown in function of Ni concentration and Zn/Ni ratio.
  • an additive for limiting the corrosion associated with nickel contamination present in aluminum that can be obtained, for example, from nickel-contaminated petroleum coke.
  • zinc when used as an additive in a nickel-contaminated aluminum alloy, it delays or reduces the corrosion of the nickel-contaminated aluminum alloy.
  • nickel-contaminated aluminum alloy or “Ni-contaminated aluminum alloy” refers to an aluminum alloy comprising Ni, as a contaminant and not a deliberate addition, at a concentration favoring the corrosion of the aluminum alloy when compared to a corresponding aluminum alloy having less or no Ni contamination.
  • the Ni-contaminated aluminum alloy comprises, in weight percentage, at least about 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01 , 0.01 1 , 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062, 0.063, 0.064,
  • the Ni-contaminated aluminum alloy comprises, in weight percentage, at most about 0.1 , 0.099, 0.098, 0.097, 0.096, 0.095, 0.094, 0.093, 0.092, 0.091 , 0.09, 0.089, 0.088, 0.087, 0.086, 0.085, 0.084, 0.083, 0.082, 0.081 , 0.08, 0.079, 0.078, 0.077, 0.076, 0.075, 0.074, 0.073, 0.072, 0.071 , 0.07, 0.069, 0.068, 0.067, 0.066, 0.065, 0.064, 0.063, 0.062, 0.061 , 0.06, 0.059, 0.058, 0.057, 0.056, 0.055, 0.054, 0.053, 0.052, 0.051 , 0.05, 0.049, 0.048, 0.047, 0.046, 0.045, 0.044, 0.043, 0.042, 0.041 ,
  • the Ni- contaminated aluminum alloy comprises, in weight percentage, between about 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01 , 0.011 , 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062, 0.063, 0.064,
  • the Zn additive is provided in the Ni-contaminated aluminum alloy at a concentration which limits or reduces corrosion (when compared to a corresponding Ni-contaminated aluminum alloy which does not include the Zn additive).
  • Zn is provided at a minimal concentration of 200 ppm in the Ni-contaminated aluminum alloy.
  • Zn can be provided in the Ni-contaminated aluminum alloy at a concentration, in weight percentage, of at least about 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062, 0.063, 0.064, 0.065, 0.066, 0.067, 0.068, 0.069, 0.07, 0.071 , 0.072, 0.073, 0.074, 0.075, 0.076,
  • Zn can be provided, in the Ni-contaminated aluminum alloy at a concentration, in weight percentage, of at most about 0.1 , 0.099, 0.098, 0.097, 0.096, 0.095, 0.094, 0.093, 0.092, 0.091 , 0.09, 0.089, 0.088, 0.087, 0.086, 0.085, 0.084, 0.083, 0.082, 0.081 , 0.08, 0.079, 0.078, 0.077, 0.076, 0.075, 0.074, 0.073, 0.072, 0.071 , 0.07, 0.069, 0.068, 0.067, 0.066, 0.065, 0.064, 0.063, 0.062, 0.061 , 0.06, 0.059, 0.058, 0.057, 0.056, 0.055, 0.054, 0.053, 0.052, 0.051 , 0.05, 0.049, 0.048, 0.047, 0.046, 0.045, 0.044, 0.043
  • Zn can be provided, in the Ni- contaminated aluminum alloy at a concentration, in weight percentage, between about 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062, 0.063, 0.064, 0.065, 0.066, 0.067, 0.068, 0.069, 0.07, 0.071 , 0.072, 0.073, 0.074, 0.075, 0.076, 0.077
  • the Zn additive can be used to limit, prevent or reduce corrosion of any Ni-contaminated aluminum alloy or products made from such Ni-contaminated aluminum alloy.
  • corrosion includes, but is not limited to, filiform corrosion, pitting corrosion and/or general corrosion.
  • the present disclosure also provides a Ni-contaminated aluminum alloy comprising the Zn additive described herein.
  • the aluminum alloys that can include the Zn additive as described herein have a Ni concentration, in weight percentage, of at most about 0.05 and, in some embodiments, of less than about 0.05. Further, the aluminum alloy that can comprise the Zn additive, prior to the addition of such additive, has a Zn concentration of less than about 0.06.
  • the Zn additive described herein can be used, for example, in cast alloys for casting operations.
  • Cast alloys are usually directly cast into their final form by sand casting, die casting or pressure-die casting.
  • Exemplary cast alloys which can include the zinc additive described herein include, but are not limited to, 1xx.x series alloys, 2xx.x series alloys, 3xx.x series alloys, 4xx.x series alloys, 5xx.x series alloys, 6xx.x series alloys, 8xx.x series alloys and some 9xx.x series alloys.
  • the zinc additive is used in 3xx.xx series alloys, such as, for example in the A356.0 alloy and the A357 alloy .
  • the Zn additive described herein can be used, for example, in wrought alloys for casting ingots or billets which will be subsequently worked mechanically into the desired form.
  • the ingots or billets made from wrought alloys can be rolled (into sheets, foil or plates for example), extruded (into produce profiles, tubes or rods for example), forged (into complex shapes for example) or formed (into complex shape for example).
  • Exemplary wrought alloys which can contain the Zn additive of the present disclosure include, but are not limited to, 1xxx series alloys, 2xxx series alloys, 3xxx series alloys, 4xxx series alloys, 5xxx series alloys, 6xxx series alloys and 8xxx series alloys.
  • the Zn additive is used in 2xxx series alloys (for example in 2024 or 2014 alloys), 5xxx series alloys (for example in 5083, 5182 or 5754) as well as in 6xxx series alloys (for example 6016, 6061 , 6063 or 61 1 1 alloys).
  • the Zn additive described herein is used to supplement an aluminum alloy which also comprises (besides a Ni contamination), in weight percentage:
  • Si at a concentration of between about 6.5 to about 7.5;
  • Mg at a concentration of between about 0.25 to about 0.45
  • each impurity is present at a concentration, in weight percentage of a maximum of about 0.05 and the total unavoidable impurities is present at a concentration, in weight percentage, of less than about 0.15.
  • the Zn additive described herein is used to supplement a A356 aluminum alloy (which usually contains Zn at a maximum concentration, in weight percentage, of about 0.10).
  • the concentration of Si can be between about 7.0 and 7.2. In other embodiments of the aluminum alloy presented herein, the concentration of Fe can be a maximum of about 0.1. In still alternative embodiments of the aluminum alloy described herein, the concentration of Cu can be a maximum of about 0.1 or of about 0.01. In the context of the present disclosure, Cu can be used to further limit the corrosion of the aluminum alloy (see, for example, US Patent Serial Number 6,939,417). In yet other embodiments of the aluminum alloy presented herein the concentration of Mg can be between about 0.2 and about 0.3. The present disclosure also includes a process for limiting corrosion (filiform, pitting and/or general corrosion) of an aluminum product made from a Ni-contaminated aluminum alloy.
  • limiting corrosion refers to the ability of the Zn addition to reduce or delay the onset of corrosion in a product made from an aluminum alloy containing the additive when compare to a corresponding product made from a corresponding aluminum alloy which does not contain the additive.
  • the process can be used to limit corrosion of product made from any Ni-contaminated aluminum alloy (referred herein as the "first aluminum alloy") and is especially useful for limiting the corrosion of products made from a Ni-contaminated aluminum alloy comprising a concentration of Ni, in weight percentage, between about 0.004 and 0.10.
  • the process includes a step of adding Zn to a first aluminum alloy at a concentration, in weight percentage, between about 0.01 to about 0.06 to obtain a second aluminum alloy.
  • the process can include a step of adding Zn to the first aluminum alloy at a concentration, in weight percentage, of at least about 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062, 0.063, 0.064, 0.065, 0.066
  • the process can include a step of adding Zn to the first aluminum alloy at a concentration, in weight percentage, of at most about 0.1 , 0.099, 0.098, 0.097, 0.096, 0.095, 0.094, 0.093, 0.092, 0.091 , 0.09, 0.089, 0.088, 0.087, 0.086, 0.085, 0.084, 0.083, 0.082, 0.081 , 0.08, 0.079, 0.078, 0.077, 0.076, 0.075, 0.074, 0.073, 0.072, 0.071 , 0.07, 0.069, 0.068, 0.067, 0.066, 0.065, 0.064, 0.063, 0.062, 0.061 , 0.06, 0.059, 0.058, 0.057, 0.056, 0.055, 0.054, 0.053, 0.052, 0.051 , 0.05, 0.049, 0.048, 0.047, 0.046, 0.045, 0.044, 0.0
  • the process can include a step of adding Zn to the first aluminum alloy at a concentration, in weight percentage, between about 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062, 0.063, 0.064, 0.065, 0.066, 0.067, 0.068, 0.069, 0.07, 0.071 , 0.072, 0.073, 0.074, 0.075, 0.076,
  • the process can include a step of adding Zn to the first aluminum alloy at a concentration, in weight percentage, between about 0.02 and 0.06 (for example between about 0.02 and 0.025 or between about 0.04 to about 0.06).
  • the process can also include a step of providing the first aluminum alloy (prior to the addition of the zinc additive).
  • the process comprises providing a first (Ni-contaminated) aluminum alloy comprising, in weight percentage, at least about 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01 , 0.01 1 , 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062
  • the process comprises providing a first (Ni-contaminated) aluminum alloy comprising, in weight percentage, at most about 0.1 , 0.099, 0.098, 0.097, 0.096, 0.095, 0.094, 0.093, 0.092, 0.091 , 0.09, 0.089, 0.088, 0.087, 0.086, 0.085, 0.084, 0.083, 0.082, 0.081 , 0.08, 0.079, 0.078, 0.077, 0.076, 0.075, 0.074, 0.073, 0.072, 0.071 , 0.07, 0.069, 0.068, 0.067, 0.066, 0.065, 0.064, 0.063, 0.062, 0.061 , 0.06, 0.059, 0.058, 0.057, 0.056, 0.055, 0.054, 0.053, 0.052, 0.051 , 0.05, 0.049, 0.048, 0.047, 0.046, 0.045, 0.044, 0.043,
  • the process comprises providing a first (Ni-contaminated) aluminum alloy comprising, in weight percentage, between about 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01 , 0.01 1 , 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.021 , 0.022, 0.023, 0.024, 0.025, 0.026, 0.027, 0.028, 0.029, 0.03, 0.031 , 0.032, 0.033, 0.034, 0.035, 0.036, 0.037, 0.038, 0.039, 0.04, 0.041 , 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, 0.05, 0.051 , 0.052, 0.053, 0.054, 0.055, 0.056, 0.057, 0.058, 0.059, 0.06, 0.061 , 0.062
  • the first aluminum alloy can be a cast alloy for casting operations.
  • Exemplary cast alloys include, but are not limited to, 1xx.x series alloys, 2xx.x series alloys, 3xx.x series alloys, 4xx.x series alloys, 5xx.x series alloys, 6xx.x series alloys, 8xx.x series alloys and some 9xx.x series alloys.
  • the Zn additive is used in 3xx.xx series alloys, such as, for example in the A356.0 alloy.
  • the first aluminum alloy can be a wrought alloy for casting ingots or billets.
  • Exemplary wrought alloys which can contain the zinc additive of the present disclosure include, but are not limited to, 1xxx series alloys, 2xxx series alloys, 3xxx series alloys, 4xxx series alloys, 5xxx series alloys, 6xxx series alloys and 8xxx series alloys.
  • the Zn additive is used in 2xxx series alloys (for example in 2024 or 2014 alloys), 5xxx series alloys (for example in 5083, 5182 or 5754) as well as in 6xxx series alloys (for example 6016, 6061 , 6063 or 61 1 1 alloys).
  • the first aluminum alloy can further comprise (besides Ni), in weight percentage:
  • Si at a concentration of between about 6.5 to about 7.5;
  • Mg at a concentration of between about 0.25 to about 0.45
  • first aluminum alloy Ti at a concentration of a maximum of about 0.2.
  • the balance of such first aluminum alloy being aluminum and unavoidable impurities.
  • each impurity is present at a concentration, in weight percentage of a maximum of about 0.05 and the total unavoidable impurities is present at a concentration, in weight percentage, of less than about 0.15.
  • the first aluminum alloy is a A356 aluminum alloy (which usually contains Zn at a maximum concentration, in weight percentage, of about 0.10).
  • the concentration of Si can be between about 7.0 and 7.2
  • the concentration of Fe can be a maximum of about 0.1
  • the concentration of Cu can be a maximum of about 0.1 or of about 0.01
  • the concentration of Mg can be between about 0.2 and about 0.3.
  • the process can include a step of determining the presence and level of contamination of Ni in the first aluminum alloy prior to submitting it to the addition of Zn.
  • the process can also include a step of adjusting the amount of Zn to be added to the first aluminum alloy or the concentration of Zn of the second aluminum alloy based on the level of contamination of Ni which was determined.
  • the process comprises working the latter to obtain the aluminum product.
  • This working step includes casting the aluminum alloy directly into a cast product billets or ingots or working the aluminum alloy billets into extrusion.
  • the term "aluminum product" can refer to a final cast products or to an intermediary ingot or billet which can further be worked into a differently shaped aluminum product.
  • the working step of the process can also include rolling (into sheets, foil or plates for example), extruding (into produce profiles, tubes or rods for example), forging or forming aluminum products from ingots or billets.

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Abstract

La présente invention concerne l'utilisation de zinc comme additif pour limiter ou retarder la corrosion associée à la présence d'une contamination par du nickel (0,004-0,10 % en poids de Ni) dans des alliages d'aluminium. Le Zn est ajouté à des alliages d'aluminium contaminés par du Ni pour obtenir au moins 200 ppm de Zn et jusqu'à 1000 ppm de Zn. L'additif de zinc peut être ajouté à un alliage d'aluminium comprenant, en pourcentage en poids, 6,5-7,5 % de Si, un maximum de 0,2 % de Fe, un maximum de 0,2 % de Cu, un maximum de 0,1 % de Mn, un maximum de 0,2 % de Ti, 0,25-0,45 % de Mg et le reste étant de l'Al et des impuretés inévitables. Un procédé pour limiter la corrosion d'un produit d'aluminium implique l'addition de Zn à un premier alliage d'aluminium contenant entre 0,004-0,10 % en poids de Ni, à une concentration comprise entre 0,02 et 0,1 % en poids, et ensuite le travail de l'alliage pour obtenir le produit.
PCT/CA2016/051131 2015-10-06 2016-09-28 Zinc en tant qu'additif pour limiter la corrosion provoquée par une contamination par du nickel dans des alliages d'aluminium WO2017059528A1 (fr)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108950268A (zh) * 2018-07-26 2018-12-07 湖北金洋资源股份公司 一种高效热传导铝合金锭生产方法
CN109022855A (zh) * 2018-07-26 2018-12-18 湖北金洋资源股份公司 一种制备高导热率铝合金锭的制备方法
WO2024074701A1 (fr) * 2022-10-07 2024-04-11 Renault S.A.S. Alliage d'aluminium et procédé de fabrication associé

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