WO2006130153A2 - Procede et composition de fabrication d'un fil - Google Patents

Procede et composition de fabrication d'un fil Download PDF

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Publication number
WO2006130153A2
WO2006130153A2 PCT/US2005/024032 US2005024032W WO2006130153A2 WO 2006130153 A2 WO2006130153 A2 WO 2006130153A2 US 2005024032 W US2005024032 W US 2005024032W WO 2006130153 A2 WO2006130153 A2 WO 2006130153A2
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WO
WIPO (PCT)
Prior art keywords
wire
feedstock
green
binder
metal powder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2005/024032
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English (en)
Other versions
WO2006130153A3 (fr
Inventor
Laxmappa Hosamani
Kenneth Endo
Andrew Meschke
David M. Harmon
Saul Encinia
Jeffrey Davenport
Emil Sokol, Jr.
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Precision Castparts Corp
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Precision Castparts Corp
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 Precision Castparts Corp filed Critical Precision Castparts Corp
Publication of WO2006130153A2 publication Critical patent/WO2006130153A2/fr
Anticipated expiration legal-status Critical
Publication of WO2006130153A3 publication Critical patent/WO2006130153A3/fr
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • B22F3/225—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip by injection molding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B22F1/148—Agglomerating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B22F3/1025—Removal of binder or filler not by heating only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/12—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/40—Making wire or rods for soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/20—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by extruding
    • B22F2003/208—Warm or hot extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding

Definitions

  • Welding and hardfacing wires of superalloy and high temperature materials are used to repair, rebuild, and manufacture gas turbine engines for aircraft and land-based applications and other parts used in structures that are subject to high working temperatures.
  • welding and hardfacing wires typically are manufactured by casting superalloy material into cast ingot having a diameter much larger than the final diameter of the wire. The cast ingot is then hot worked and extruded multiple times until the desired diameter of the wire is achieved (e.g., 0.045 inch). As can be appreciated, this process is time consuming and expensive.
  • the present disclosure concerns embodiments of a method for making wires, which method is particularly suited for making welding and hardfacing wires of superalloy materials used for manufacturing or repairing parts of aerospace structures, such as gas turbine aircraft engines.
  • superalloys can include, but are not limited to, cobalt-based, titanium-based, iron-based, and nickel-based superalloys.
  • the method is accomplished by forming a "green"-state wire from a feedstock comprising a metal powder and a binder, such as by extruding the feedstock through a die.
  • the green-state wire is then sintered to effect consolidation and densif ⁇ cation of the wire.
  • the wire can be further subjected to any of various processing techniques depending on the requirements of its intended application.
  • the method can be used to form various types of wires, such as welding or hardfacing wires. Weld wires produced by the method can be used in various welding processes, such as TIG or MIG welding.
  • the feedstock is formed by mixing or blending the metal powder and the binder and heating the mixture to a temperature sufficient to cause the binder to melt and form a paste-like mixture.
  • the mixture can be solidified and pelletized to create a plurality of feedstock pellets with thermoplastic properties.
  • the feedstock pellets are loaded into an injection molding machine or another type of extrusion apparatus and are heated to a temperature sufficient to cause the binder to melt and form an extrudable, feedstock paste.
  • the paste is extruded through a die of the extrusion apparatus to form a green-state wire.
  • the feedstock can be formed and extruded using an extrusion apparatus having mixing and extrusion capabilities so as to eliminate the intermediate step of solidifying and pelletizing the feedstock.
  • the green-state wire can formed by methods other than extrusion through a die orifice.
  • the green- state wire can be formed using rollers.
  • the green-state wire can be formed by injecting the feedstock into a mold.
  • the feedstock can be flowed or otherwise placed into a die and then pressed into a green-state wire.
  • Other types of molding processes that can be used to form the green-state wire include, without limitation, compression molding, transfer molding, and plunger molding.
  • the green-state wire After forming the green-state wire, it can be placed in the groove of a tray or mold to maintain its shape during subsequent processing.
  • the wire can be chemically treated to remove at least a portion of the binder by immersing the wire in a suitable solvent, such as trichloroethylene or water.
  • the binder can be partially or completely removed by thermal processing.
  • the wire After debinding, the wire is sintered at high temperature to effect consolidation and densification of the wire. Sintering also is effective to remove the remaining portion of the binder, hi another embodiment, the extruded wire can be sintered without first being chemically or thermally treated to extract a portion of the binder. If desired, the sintered wire can be subjected to further processing.
  • the wire can be further densified, such as via cold isostatic pressing or hot isostatic pressing, and/or the surface of the wire can be finished using conventional surface-finishing techniques, such as centerless grinding.
  • conventional methods for manufacturing welding and hardfacing wires made of superalloys require multiple extrusion steps to achieve the final shape of the wire.
  • An advantage of the present method is that the final shape of a wire can be achieved by a single molding or extrusion step, and therefore is less expensive and less time consuming than conventional methods.
  • FIG. 1 is a flowchart illustrating a method for making a wire, according to one embodiment.
  • FIG. 1 shows a flowchart, indicating generally at 10, that illustrates a method for making a wire, according to one embodiment.
  • the method generally includes forming a feedstock comprising a metal powder and a binder (indicated at 12), forming a green-state wire (indicated at 14), debinding the green-state wire (indicated at 16), and sintering the wire (indicated at 18).
  • the metal powder can be manufactured using conventional techniques, such as vacuum or inert gas melting of virgin raw materials or a combination of virgin materials and revert material, and then atomizing the metal to form a powder.
  • the powder desirably is screened using a screen having a mesh size of about -325, although smaller or larger mesh sizes also could be used.
  • the methods described herein are particularly useful for making welding and hardfacing wires of superalloys that typically are used for repairing, rebuilding, or manufacturing parts of aerospace structures.
  • Such superalloys include, for example, cobalt-based superalloys, titanium-based superalloys (e.g., titanium aluminide, Ti-6- 4), iron-based superalloys, and nickel-based superalloys (e.g., Rene' ® 142, Rene' ® 195, or alloy 718).
  • the methods described herein also can be used to manufacture hardfacing wires from any of various hardfacing alloys or wires from more conventional metals, such as stainless steels (e.g., 17-4 PH stainless steel, 316 stainless steel, or 316L stainless steel) or any of various other metals. Any suitable binder can be used to form the feedstock.
  • the binder generally can comprise a plasticizer or an oil.
  • various water-soluble binders can be used.
  • the binder comprises a plasticizer, a strengthener, a compatibilizer for the plasticizer and strengthener, and a surfactant.
  • plasticizers include paraffin wax, carnauba wax, polyethylene wax, or microcrystalline wax
  • strengtheners include polypropylene, polystyrene, and polyacetal
  • compatibilizers include styrene-butadiene block copolymer (e.g., Kraton ® commercially available from Shell) and ethyl vinyl acetate copolymer
  • surfactants include stearic acid, and zinc stearate.
  • a binder typically has a composition in weight percent of about 45% to 55% plasticizer, 45% to 55% strengthener, 3% to 6% compatibilizer, and 0.25% to 0.5% surfactant, with 48.5% paraffin wax, 48.5% polypropylene, 3% styrene-butadiene, and 0.25% stearic acid being a specific example.
  • the concentration of the metal powder and the binder in the feedstock can vary between about 50% to 70% by volume for each component.
  • a metal, in powder form, and a binder are mixed and heated to a temperature sufficient to cause the binder to melt and form a paste- like mixture.
  • Any of various conventional mixers such as a planetary mixer or equivalent mechanism, can be used to mix the metal powder and the binder.
  • the temperature at which the mixture is heated depends on the composition of the binder. Generally, any temperature greater than room temperature may be sufficient to melt the binder.
  • the binder composition described above is heated to a temperature of about 300° F to 400° F, and more preferably 325° F to 350° F.
  • the feedstock is allowed to cool and form a solidified mass, which is then pelletized or otherwise fractionated to form a plurality of smaller, feedstock particles or pellets with thermoplastic properties.
  • the green-state wire is formed by extruding the feedstock, in the form of a paste, through the die orifice of an extruder.
  • the feedstock particles are loaded into an extruder, which can be a conventional barrel and ram extruder, an injection molding machine, or an equivalent mechanism, and the particles are heated at a temperature sufficient to cause the binder to melt and form an extrudable paste.
  • the extrusion temperature can vary depending on the composition of the binder used.
  • a feedstock comprising a metal powder and a binder having the composition described above generally is heated to a temperature of about 300° F to 400° F, and more preferably 325° F to 350° F to form an extrudable paste.
  • the feedstock can be transferred directly from the mixer to the extruder without the intermediate steps of solidifying and fractionating the feedstock into smaller particles.
  • an extruder having mixing and extruding capabilities can be used.
  • the feedstock is formed by mixing the metal powder and binder in the extruder itself prior to extrusion.
  • the feedstock paste is extruded through the orifice of a die to form one or more green-state wires of a desired length.
  • the size of the orifice can be selected to produce wires of any diameter.
  • welding or hardfacing wires having a diameter of about 0.015 to 0.100 inch are formed, such as typically used in TIG or MIG welding, although wires having a diameter greater than 0.100 inch or less than 0.015 inch also can be produced. Since sintering generally will cause the wires to densify, the size of the orifice is selected such that the diameter of the extruded wires is slightly greater than the required final diameter after sintering.
  • the die orifice can be of any desirable geometric profile such as a circle, oval, triangle, square, rectangle, diamond, or various combinations thereof.
  • the die may be provided with a single orifice or multiple orifices.
  • the green-state wire can be formed by methods other than extrusion through a die orifice.
  • the green- state wire can be formed using rollers.
  • the green-state wire can be formed by injecting the feedstock into a mold.
  • the feedstock can be flowed or otherwise placed into a die and then pressed into a green-state wire.
  • Other types of molding processes that can be used to form the green-state wire include, without limitation, compression molding, transfer molding, and plunger molding.
  • the green-state wires desirably are placed in respective grooves of a tray or similar structure so that the wires remain substantially straight during subsequent processing. Alternatively, subsequent processing of the wires can be carried out without placing the wires in such a tray.
  • the tray can be made from any of various suitable materials, such as molybdenum, aluminum, or various ceramics, and can have various surface coatings, such as a spray-coating of yttria.
  • the unsintered, green-state wires are debound
  • the binder can be removed by thermal treatment.
  • the wires can be placed in a bath of a heated solvent.
  • the binder can be removed by heat treating the wires in a furnace in lieu of or in addition to chemically treating the wires with a solvent.
  • debinding means to remove or extract at least a portion of the binder from the wires. Hence, debinding can include, but does not require, removal of the entire binder phase from the wires.
  • the solvent is effective to extract about 30% to 60% of the binder from the wires.
  • the tray of wires is placed in a furnace or similar device for sintering.
  • the specific sintering conditions can vary depending on the metal and the binder used. However, in general, sintering is carried out at a temperature of about 1800° F to about 3000° F for a period of about 0.5 to 10 hours for the materials noted above. In addition, the sintering temperature can be varied to achieve a desired wire density.
  • the wire desirably (although not necessarily) is sintered to densify the wire to at least about 90% of the theoretical density of the metal, and more desirably to at least about 95% of the theoretical density of the metal.
  • the wires can be pre-heated at one or more temperature levels less than the final sintering temperature.
  • the wires desirably are sintered under conditions that minimize oxidation of the wires.
  • Such conditions can include, for example, sintering in a partial vacuum, in an atmosphere of an inert gas (e.g., argon or nitrogen), in a reducing atmosphere (e.g., a hydrogen atmosphere), or a combination of any of the foregoing conditions.
  • Sintering is effective to remove most, if not all, of the binder remaining in the wires after the debinding step.
  • the wires can be cooled in the furnace to a temperature of about 100° F, after which the wires can be removed from the furnace.
  • an inert gas e.g., argon
  • argon an inert gas
  • the extruded wires can be sintered without first subjecting the wires to a separate debinding step (e.g., the debinding step indicated at 16 in FIG. 1).
  • the sintered wires can be subjected to further processing.
  • the wires can be further densified by, for example, conventional hot isostatic pressing or conventional cold isostatic pressing.
  • the wires can be ground using conventional techniques to further reduce their diameter.
  • the surfaces of the wires can be finished using conventional surface-finishing techniques, such as centerless grinding.
  • the resulting wires as provided to the user can be straight or can be wound around a spool to form a continuous coil or spool of wire.
  • Rene' ® 142 powder was blended with 6% by weight of a binder.
  • the binder had a composition in weight percent of about 48.5% wax, about 48.5% polypropylene, about 3% styrene-buta-diene, and about 0.25% stearic acid.
  • the composition of Rene' ® 142 in this example comprised, in weight percent, about 1.30-1.70% Hf, about 11.45-12.05% Co, about 6.20-6.50% Ta, about 6.80-7.00% Cr, about 1.30-1.70% Mo, about 4.7-5.10% W, about 5.90-6.30% Al, about 2.60- 3.00% Re, about 4.70- 5.10% Ti, about 0.00-0.02% O and the balance Ni and incidental impurities.
  • Rene' ® 142 can also have other compositions that vary slightly from the composition used in this example, such as described in U.S. Pat. No. 5,173,255.
  • the powder and binder were heated to about 325° F to 350° F and blended in a planetary mixture.
  • the blend was allowed to cool to form a solidified mass, which was pelletized into a plurality of feedstock pellets.
  • Pellets were loaded into the hopper of an injection molding machine and heated to a temperature of about 325° F to form an extrudable paste.
  • the injection molding machine had a 22-mm screw and barrel and was fitted with a die having a 0.070 inch diameter orifice.
  • the feedstock paste was extruded through the die to form multiple welding/hardfacing wires having a diameter of about 0.070 inch and a length of about 24 inches.
  • Pellets were also loaded into the barrel of a barrel-and-ram machine and heated at a temperature of about 325° F to 350° F.
  • the barrel-and-ram machine was fitted with a die having a 0.070 inch diameter orifice.
  • the feedstock paste was extruded through the die to form multiple welding/hardfacing wires having a diameter of about 0.070 inch.
  • the extruded weld wires were placed in the grooves of molybdenum trays having a spray coating of yttria.
  • the trays were placed in a bath of trichloroethylene heated to a temperature of about 155° F for about 30 to 90 minutes, which removed about 40-50% of the binder. After debinding in the trichloroethylene, the trays were placed in a furnace for sintering.
  • the conditions for sintering were as follows. The atmosphere inside furnace was evacuated using a vacuum pump, after which argon was introduced into the furnace until the pressure inside the furnace was about 3 torr. The temperature inside the furnace was increased from room temperature to about 500° F at a rate of about 5° F/min. and held at about 500° F for about 30 minutes, increased from 500° F to about 1200° F at a rate of about 2° F/min.
  • the pressure of the argon inside the furnace was increased to about 10 torr.
  • the temperature of the furnace was further increased from about 2230° F to about 2340° F at a rate of about 4°
  • the wires were allowed to cool inside the furnace to a temperature of about 1500° F, at which point the wires were cooled to a temperature of about 100° F with high pressure argon introduced into the furnace. The furnace door was then opened to allow the wires to cool to room temperature.
  • the wires exhibited a theoretical density of about 95% and had a diameter of about 0.058 inch and a length of about 22 inches.
  • the oxygen content in the wires was less than 100 PPM.
  • Example 2 17-4 stainless steel powder was blended with 6% by weight of a binder comprising in weight percent about 48.5% wax, about 48.5% polypropylene, about 3% styrene-buta-diene, and about 0.25% stearic acid.
  • the powder and binder were heated to about 325° F and blended in a planetary mixture.
  • the feedstock was allowed to solidify and was pelletized.
  • the pellets were loaded into the hopper an injection molding machine and heated to a temperature of about 325° F.
  • the injection molding machine was fitted with a die having a 0.054 inch diameter orifice.
  • the heated feedstock was extruded through the die to form multiple welding/hardfacing wires having a diameter of about 0.054 inch.
  • the wires were placed in the grooves of a ceramic tray and a length of about 10 inches.
  • the tray and wires were immersed in a bath of trichloroethylene heated to a temperature of about 155° F for about 30 to 90 minutes. Thereafter, the wires were sintered in an argon atmosphere at about 2480° F for about 60 minutes.
  • the sintered wires exhibited a density of about 7.6 g/cm3 (which is a theoretical density of about 98%) and had a diameter of about 0.04 inch and a length of about 10 inches.
  • Gamma titanium-aluminide powder was blended with 9.5% by weight of a binder.
  • the binder had a composition of about 46.5% wax, about 48.0% polypropylene, about 5.0% thermoplastic elastomer, and about 0.5% stearic acid.
  • the gamma titanium-aluminide in this example comprised, in weight percent, about 32-33.5% Al, about 4.5-5.1% Mb, about 2.4-2.7% Cr, and the balance titanium. Titanium aluminide can also have other compositions that vary from the composition used in this example.
  • the powder and binder were heated in a mixture to 325° F to form a feedstock.
  • the feedstock was allowed to solidify and was pelletized.
  • the pellets were loaded in to a barrel of a barrel and ram machine and heated to a temperature of 325° F.
  • the material was extruded to form several welding/hardfacing wires. Some of the binder was subsequently removed by chemically debinding, after which the wires were sintered at about 2500° F for 10 hours.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention porte sur un procédé de production de fils tels que des fils de soudure ou de recharge, qui dans une exécution consiste: à former un fil à l'état vert à partir d'un apport fait d'une poudre métallique et d'un liant par exemple en extrudant l'apport dans une filière, puis à fritter le fil ainsi obtenu pour en effectuer la consolidation et la densification.
PCT/US2005/024032 2004-07-23 2005-07-06 Procede et composition de fabrication d'un fil Ceased WO2006130153A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/897,643 US20060018780A1 (en) 2004-07-23 2004-07-23 Method and composition for making a wire
US10/897,643 2004-07-23

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WO2006130153A2 true WO2006130153A2 (fr) 2006-12-07
WO2006130153A3 WO2006130153A3 (fr) 2007-10-25

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TW (1) TW200618893A (fr)
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