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WO1992008909A1 - Elements a frottement - Google Patents

Elements a frottement Download PDF

Info

Publication number
WO1992008909A1
WO1992008909A1 PCT/GB1991/001992 GB9101992W WO9208909A1 WO 1992008909 A1 WO1992008909 A1 WO 1992008909A1 GB 9101992 W GB9101992 W GB 9101992W WO 9208909 A1 WO9208909 A1 WO 9208909A1
Authority
WO
WIPO (PCT)
Prior art keywords
surface layer
friction member
bulk
ceramic
friction
Prior art date
Application number
PCT/GB1991/001992
Other languages
English (en)
Inventor
John Anthony Mudway
John Campbell Watson
Alfred James Taylor
David Andrew Hubbard
Original Assignee
Lucas Industries Public Limited Company
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 Lucas Industries Public Limited Company filed Critical Lucas Industries Public Limited Company
Publication of WO1992008909A1 publication Critical patent/WO1992008909A1/fr

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • F16D69/02Composition of linings ; Methods of manufacturing
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C23C4/11Oxides
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D13/00Friction clutches
    • F16D13/58Details
    • F16D13/60Clutching elements
    • F16D13/64Clutch-plates; Clutch-lamellae
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D65/12Discs; Drums for disc brakes
    • F16D65/127Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/60Efficient propulsion technologies, e.g. for aircraft

Definitions

  • This invention relates to friction members, for example brake members, clutch members and other members which are subjected to frictional heating in service.
  • friction members which take the form of brake discs
  • such discs are usually formed of cast iron or steel, although there have been proposals to form them of aluminium alloy and other materials.
  • one of the primary causes of premature failure of brake discs is as a result of the intensive thermal cycling which takes place under braking conditions.
  • US Patent No. 4290510 describes a brake disc or rotor which is formed from aluminium or other lightweight metal to achieve a weight saving, the rotor having a wear resistant coating thereon in order to improve the abrasion resistance of the otherwise low abrasion- resistant aluminium.
  • the wear resistant coating includes about 30 to 70% by volume of a ceramic particulate material of which stated examples are the metal carbides, ie chromium carbide, tungsten carbide, molybdenum carbide, silicon carbide; the nitrides, ie silicon nitride, boron nitride; and the oxides ie aluminates and zirconia, the remainder being binder metal.
  • the preferred ceramics are stated to be the metal carbides and the metal nitrides which are stable materials not readily fluxed by metals or metal oxides such as iron or ferrous oxide. Also, a preference is expressed for the metal carbides on the basis that they have the best heat transfer characteristics of the ceramic materials which aids in dissipating heat from the coating to the rotor. Thus, there is no teaching in US 4290510 to control the rate of heat transfer to the bulk of the brake disc in order to overcome the above-mentioned thermal fatigue cracking problems.
  • US Patent No. 4715486 discloses brake discs wherein wear of the brake disc is reduced by applying thereto a wear- reducing coating comprising a substantial proportion of tungsten carbide, the object being to provide a virtually abrasion-free brake disc. Thus, US Patent No. 4715486 is also not concerned with controlling the rate of heat transfer to the bulk of the brake disc to reduce thermal fatigue cracking problems.
  • WO89/09889 discloses an asbestos free disc brake device for automobiles and similar vehicles wherein the brake disc is a cast iron body whose opposite lateral faces are cast together with comparatively thin wearing linings having a metallic surface layer with considerably increased wearability.
  • the metallic surface layer is provided by the so-called "Osprey” process and, in a particular embodiment, is said to contain aluminium oxide as its main component.
  • the use of the thin surface layer is said to be for ensuring great hardness and wearability, and a thickness in the range of 50 to 100 ⁇ m is disclosed for the surface layer.
  • GB-A-2191156 discloses a wheel rim for a two-wheeled vehicle, eg a bicycle or a motor bicycle, having a spray- coated layer on the region thereof against which a brake shoe is contacted in use.
  • the spray coated layer is a metal and/or ceramic layer and is provided for the purpose of mitigating the problem of loss of braking efficiency under wet conditions.
  • the coating layer is also said to be wear resistant. Examples of suitable metals for the coating layer are stated to be Al, Ti, Mo, Ta, Fe, Si, W, Co, Ni, Zn and Y, and alloys thereof.
  • suitable ceramics for the coating layer are stated to be the oxides, nitrides, carbides or borides of these metals, with Al 2 0 3 , gray alumina, Ti0 2 , Cr 2 0 3 , Si0 2 , Zr0 2 , Y 2 0 3 , MgO and CaO being specifically mentioned as suitable oxides. There is therefore no disclosure or recognition of the use of the coating layer for controlling the transmission of frictionally generated heat to the bulk of the wheel rim.
  • the present invention is concerned with friction members which are mainly intended for use in situations where the friction member may be required to handle a relatively high dissipation of frictionally generated heat in service, eg in brakes for heavy and relatively heavy vehicles, such as trains, aircraft, trucks, vans and motor cars.
  • An object of the present invention is to provide for proper thermal management of the brake disc whereby to achieve a controlled transfer of frictionally-generated heat to the bulk of the friction member in order to obviate or mitigate the above mentioned problem of thermal fatigue cracking.
  • a friction member having a ceramic surface layer defining a rubbing surface, characterized in that the ceramic surface layer is formed of at least 50% by weight ceramic oxide(s), and in that the ceramic surface layer is for use in spreading frictional heat generated when another friction member rubs against a part of said rubbing surface so that the heat transmitted to the bulk of the friction member under the surface layer is controlled to reduce thermal fatigue cracking of the bulk of the friction member.
  • the surface layer preferably has a combination of thermal conductivity and heat capacity properties at elevated temperatures such as to produce the required control of heat transfer to the bulk of the friction member so as to complement the properties of the bulk material at least under the most arduous conditions anticipated to be experienced by the friction member in service.
  • the surface layer has a thermal conductivity below 40 W ⁇ f K '1 .
  • the surface layer should be capable of maintaining the relevant properties at the elevated temperatures which are encountered in service. In the case of very heavy duty braking applications, the elevated temperatures may reach 1000°C, and even 1500°C.
  • the surface layer will normally have a melting temperature which is higher than that of the material forming the bulk of the friction member. However, depending upon the intended application, this is not necessarily an essential requirement.
  • the material forming the bulk of the friction member may have a relatively high melting temperature but still be prone to thermal fatigue cracking.
  • the surface layer it is possible for the surface layer to have the same or even a lower melting temperature than the bulk material, although of course it should have a sufficiently high melting temperature to be able to withstand the temperatures encountered in service.
  • the surface layer can have a thermal fatigue resistance which is higher than that of the bulk material. However, this is also not necessarily an essential requirement but depends upon the intended end use. It is possible for the surface layer to develop cracks in service provided that the cracks do not propagate to the bulk material and provided that, in spite of cracks appearing in the surface layer, no spalling of the latter takes place.
  • the thickness of the surface layer is chosen to suit the particular circumstances of use, but is generally 100 ⁇ m to 750 ⁇ m, preferably 100 ⁇ m to 500 ⁇ m. In the case where the surface layer is a plasma sprayed coating, the preferred coating thickness is about 150 to 300 ⁇ m and is most preferably about 200 to 250 ⁇ m.
  • the bonding layer is arranged to be compatible with the two materials with which it is in contact.
  • the bonding layer is formed of a nickel alloy, eg a nickel alloy containing about 95% nickel and about 5% aluminium.
  • a surface layer as in the present invention, it is possible to control the rate of flow of heat to the body material by spreading the heat laterally within the surface layer before it reaches the bulk material, thereby minimising the risk of localised overheating of the body material in service. It is therefore possible to reduce the thermal gradients which occur in the body material and this reduces the risk of thermal fatigue cracking.
  • ceramic oxide(s) includes one or more mixed oxide ceramics as well as simple oxide ceramics.
  • the preferred ceramic oxide(s) is/are metal oxide ceramics, the term “metal” in the context of light duty braking applications including silicon.
  • material forming the surface layer is selected from ceramic oxides based on the metals of Groups IIIA, IIIB, IVA, IVB, IIA, VB and VIB of the Periodic Table of Elements including oxide mixtures and mixed oxides based on any of such metals.
  • the oxides of the metals of Groups IIIA, IVA, IVB and VIB including oxide mixtures and mixed oxides based on any such metals.
  • Even more preferred are alumina, chromium sesquioxide, zirconia, zirconates, titanates, aluminates, silicates and mixtures thereof. Of these, alumina and chromium sesquioxide, with alumina being most preferred.
  • the surface layer is preferably composed of 100% ceramic oxide(s) .
  • thermal expansion coefficients over the temperature range encountered in service (and particularly at the upper end of such range) which are matched so as to act to minimise the stresses therebetween under the conditions where maximum stress would otherwise be expected to occur.
  • thermal expansion coefficients are matched to within almost 20%.
  • the surface layer can be applied to the body material, or to the bonding layer when provided, by any suitable means, eg by plasma spraying, flame spraying or other suitable thermal spraying techniques, or by a detonation gun process (eg the D-gun process - Union Carbide) .
  • the porosity of the surface layer is generally up to about 15% and preferably about 8 to 15%.
  • the precise choice of material for the coating layer will depend not only upon the desired performance of friction member concerned, but also upon, inter alia, the nature of the body material, the nature of the other friction element which the friction member is intended to cooperate in use, and the operating environment eg corrosion. Since the surface temperatures which exist on the friction member according to the'present invention are rather higher than those which exist with conventional friction members, it is necessary to take this into account when choosing the friction element with which the friction member intended to cooperate in use. For example, in the case where the friction member is a brake disc, the material of the friction pad (forming the friction element) is chosen to be suitably heat resistant and may even be coated with a surface layer which is the same as or at least compatible with that of the brake disc.
  • a cast iron brake disc having a thickness of 13mm was used.
  • the cast iron had a heat capacity C P of 500 JK " kg “1 , a thermal expansion coefficient of 11 x lO ' ", a thermal conductivity of 75 W ⁇ f'K “” , a Young's modulus of llOGPa, a density of 7.150Mg/m 3 as measured at room temperature, and a melting point of 1500K.
  • the brake disc was first degreased and then grit blasted with alumina grit.
  • the cleaned brake disc was then plasma sprayed with a bonding coat of a nickel aluminium alloy (95% nickel 5% aluminium-AM956 ex Plasma Teknik Ltd of Newport, Gwent) to a thickness of 100 ⁇ m.
  • a top coat of alumina (1003 grade-ex Plasma Teknik Ltd) was then plasma sprayed onto the bonding coat to a thickness of 300 ⁇ m and then diamond ground back to a thickness of 200 ⁇ m to produce an alumina coating having a porosity of approximately 10%.
  • the alumina coating had a melting point of 2300K and (as measured at room temperature) a heat capacity of 800 JK " kg -1 , a thermal expansion coefficient of 9 x 10 " K “ , a thermal conductivity of 29 Wm “ K “ , a Young's modulus of 345 GPa, a thickness of 250 ⁇ m, and a density of 3.32 Mg/m 3 .
  • the resultant coated disc was subjected to a test using a high temperature FERODO X406 material on a scale friction rig simulating a high speed train thermal input.
  • the treatment involved subjecting the disc to drag braking for 30 seconds followed by a cooling time of 3.5 minutes.
  • the power input to the disc was 6.283 kW.
  • Both the disc and the pad were weighed prior to the test starting and the disc was weighed at convenient intervals during the test. Each pad used was weighed before and after each part of the test to estimate the wear rate in terms of MJ/cc. Similarly, the disc wear rate is estimated in MJ/cc and then a comparison was made with known technology.
  • the weight of the pads and discs were related to wear by their respective densities.
  • the disc was found to complete 5000 test cycles with very little apparent damage and was thus able to complete substantially more test cycles before failure than conventional uncoated discs.
  • the pad had a maximum contact area during braking of about 30% of the disc face, the beneficial effects of the present invention can be applied to braking systems where full interface contact is intended.
  • the invention is applicable not only to friction members in the form of brake discs, but any friction members where a sufficient amount of frictionally generated heat is encountered to give rise to the previously mentioned cproblem of thermat fatigue cracking of the bulk of the friction member, eg heavy duty clutches etc.
  • the surface layer provided in accordance with the present invention can give a degree of corrosion resistance and can also improve the aesthetic appearance of the friction member.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Braking Arrangements (AREA)

Abstract

Un élément à frottement, tel qu'un disque de frein, comporte une couche superficielle pulvérisée au plasma, composée d'un matériau céramique dont au moins 50 % en poids est composé d'oxyde de céramique, en particulier de l'alumine. La couche superficielle, qui peut être fixée au matériau composant le corps de l'élément à frottement au moyen d'une couche de liaison sert à répandre la chaleur de friction produite lorsqu'un autre élément à frottement se frotte contre une partie de ladite surface de frottement, de sorte que la chaleur transmise à la masse de l'élément à frottement sous la couche de surface est contrôlée afin de réduire les fissures dues à la fatigue thermique du corps du matériau de frottement.
PCT/GB1991/001992 1990-11-14 1991-11-13 Elements a frottement WO1992008909A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9024702.4 1990-11-14
GB909024702A GB9024702D0 (en) 1990-11-14 1990-11-14 Friction members

Publications (1)

Publication Number Publication Date
WO1992008909A1 true WO1992008909A1 (fr) 1992-05-29

Family

ID=10685325

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1991/001992 WO1992008909A1 (fr) 1990-11-14 1991-11-13 Elements a frottement

Country Status (3)

Country Link
AU (1) AU8867591A (fr)
GB (1) GB9024702D0 (fr)
WO (1) WO1992008909A1 (fr)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0527434A3 (en) * 1991-08-09 1993-08-04 Centro Sviluppo Materiali S.P.A. Thermal barrier made from ceramic materials for braking devices
US5330036A (en) * 1991-10-31 1994-07-19 Elephant Chain Block Company Limited Mechanical brake for a hoist and traction machine
GB2282821A (en) * 1993-09-10 1995-04-19 Sab Wabco Friction pads comprising ceramic material for use in disc brakes
EP0674114A1 (fr) * 1994-03-25 1995-09-27 Gec Alsthom Transport Sa Disque multimatériaux pour freinage à haute énergie
WO1995027859A1 (fr) * 1994-04-12 1995-10-19 Lanxide Technology Company, L.P. Rotors de frein, plateaux d'embrayage ou analogue et leurs procedes de fabrication
US5770323A (en) * 1991-02-20 1998-06-23 T & N Technology Limited Bearings
WO2000047911A1 (fr) * 1999-02-09 2000-08-17 Martin John Michael Murphy Surface d'un composant de frein a coefficient de friction controle
WO2003104513A1 (fr) * 2002-06-11 2003-12-18 Scania Cv Ab (Publ) Composant de vehicule recouvert d'un revetement resistant a l'usure
FR2886486A1 (fr) * 2005-05-31 2006-12-01 Sagem Defense Securite Perfectionnement aux materiaux de friction
WO2007043961A1 (fr) * 2005-10-13 2007-04-19 Scania Cv Ab (Publ) Composant de véhicule revêtu résistant à l'usure et véhicule
WO2008138458A3 (fr) * 2007-05-15 2009-08-06 Sew Eurodrive Gmbh & Co Support de garniture, frein, embrayage ou moteur électrique

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB944578A (en) * 1960-06-28 1963-12-18 Bendix Corp Thermal shock resistant refractory structure
GB2003935A (en) * 1977-09-07 1979-03-21 Alusuisse Wear resistant coating for disc brakes
FR2631044A1 (fr) * 1988-05-06 1989-11-10 Hautes Technologies Indles Surface de friction de frein, procede et dispositif pour sa fabrication
EP0467518A1 (fr) * 1990-07-20 1992-01-22 Borg-Warner Automotive Transmission And Engine Components Corporation Disques d'embrayage en céramique

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB944578A (en) * 1960-06-28 1963-12-18 Bendix Corp Thermal shock resistant refractory structure
GB2003935A (en) * 1977-09-07 1979-03-21 Alusuisse Wear resistant coating for disc brakes
FR2631044A1 (fr) * 1988-05-06 1989-11-10 Hautes Technologies Indles Surface de friction de frein, procede et dispositif pour sa fabrication
EP0467518A1 (fr) * 1990-07-20 1992-01-22 Borg-Warner Automotive Transmission And Engine Components Corporation Disques d'embrayage en céramique

Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5770323A (en) * 1991-02-20 1998-06-23 T & N Technology Limited Bearings
EP0527434A3 (en) * 1991-08-09 1993-08-04 Centro Sviluppo Materiali S.P.A. Thermal barrier made from ceramic materials for braking devices
US5330036A (en) * 1991-10-31 1994-07-19 Elephant Chain Block Company Limited Mechanical brake for a hoist and traction machine
GB2282821A (en) * 1993-09-10 1995-04-19 Sab Wabco Friction pads comprising ceramic material for use in disc brakes
GB2282821B (en) * 1993-09-10 1997-10-08 Sab Wabco Friction pad comprising a ceramic for use in disc brakes
US5725077A (en) * 1993-09-10 1998-03-10 Sab Wabco (Bromborough) Limited Friction pads for use in disc brakes
EP0674114A1 (fr) * 1994-03-25 1995-09-27 Gec Alsthom Transport Sa Disque multimatériaux pour freinage à haute énergie
FR2717874A1 (fr) * 1994-03-25 1995-09-29 Gec Alsthom Transport Sa Disque multimatériaux pour freinage à haute énergie.
US5612110A (en) * 1994-03-25 1997-03-18 Gec Alsthom Transport Sa Multimaterial disk for high-energy braking comprising an assembly of various flanges
US5629101A (en) * 1994-03-25 1997-05-13 Gec Alsthom Transport Sa Multimaterial disk for high-energy braking
WO1995027859A1 (fr) * 1994-04-12 1995-10-19 Lanxide Technology Company, L.P. Rotors de frein, plateaux d'embrayage ou analogue et leurs procedes de fabrication
WO2000047911A1 (fr) * 1999-02-09 2000-08-17 Martin John Michael Murphy Surface d'un composant de frein a coefficient de friction controle
WO2003104513A1 (fr) * 2002-06-11 2003-12-18 Scania Cv Ab (Publ) Composant de vehicule recouvert d'un revetement resistant a l'usure
FR2886486A1 (fr) * 2005-05-31 2006-12-01 Sagem Defense Securite Perfectionnement aux materiaux de friction
EP1729353A1 (fr) * 2005-05-31 2006-12-06 Sagem Defense Securite Perfectionnement aux materiaux de friction
US7501742B2 (en) 2005-05-31 2009-03-10 Sagem Defense Securite Mechanical actuator comprising an active linear piston
WO2007043961A1 (fr) * 2005-10-13 2007-04-19 Scania Cv Ab (Publ) Composant de véhicule revêtu résistant à l'usure et véhicule
EP1945828B1 (fr) * 2005-10-13 2013-07-10 Scania CV AB Composant de véhicule revêtu résistant à l'usure et véhicule
WO2008138458A3 (fr) * 2007-05-15 2009-08-06 Sew Eurodrive Gmbh & Co Support de garniture, frein, embrayage ou moteur électrique
DE102008020513B4 (de) 2007-05-15 2022-06-23 Sew-Eurodrive Gmbh & Co Kg Bremse, Kupplung oder Elektromotor

Also Published As

Publication number Publication date
GB9024702D0 (en) 1991-01-02
AU8867591A (en) 1992-06-11

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