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WO2024178456A1 - Revêtements de surface de dépôt électrolytique au plasma pour alliages de formation d'oxyde - Google Patents

Revêtements de surface de dépôt électrolytique au plasma pour alliages de formation d'oxyde Download PDF

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Publication number
WO2024178456A1
WO2024178456A1 PCT/AU2024/050061 AU2024050061W WO2024178456A1 WO 2024178456 A1 WO2024178456 A1 WO 2024178456A1 AU 2024050061 W AU2024050061 W AU 2024050061W WO 2024178456 A1 WO2024178456 A1 WO 2024178456A1
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Prior art keywords
electrolyte
electrolytic deposition
plasma electrolytic
electrolyte solution
composition
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Ceased
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PCT/AU2024/050061
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English (en)
Inventor
Milad LAGHAEI
Weiwei LEI
Ian Fordyce
Michael Fuller
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Conflux Technology Pty Ltd
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Conflux Technology Pty Ltd
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Priority claimed from AU2023900519A external-priority patent/AU2023900519A0/en
Application filed by Conflux Technology Pty Ltd filed Critical Conflux Technology Pty Ltd
Priority to AU2024228114A priority Critical patent/AU2024228114A1/en
Publication of WO2024178456A1 publication Critical patent/WO2024178456A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00Electrolytic coating by surface reaction, i.e. forming conversion layers
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02Anodisation
    • C25D11/024Anodisation under pulsed or modulated current or potential
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/005Apparatus specially adapted for electrolytic conversion coating
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02Anodisation
    • C25D11/04Anodisation of aluminium or alloys based thereon
    • C25D11/06Anodisation of aluminium or alloys based thereon characterised by the electrolytes used
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00Electroplating: Baths therefor
    • C25D3/02Electroplating: Baths therefor from solutions
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/18Electroplating using modulated, pulsed or reversing current
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00Electroplating characterised by the article coated
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D11/00Electrolytic coating by surface reaction, i.e. forming conversion layers
    • C25D11/02Anodisation
    • C25D11/30Anodisation of magnesium or alloys based thereon

Definitions

  • the present invention relates to surface coatings for oxide-forming alloys, together with processes and compositions and systems for creating such surface coatings.
  • Lightweight oxide-forming metal alloys are very useful and versatile materials that can be used to fabricate a wide variety of items. Such materials include alloys of aluminium, magnesium, titanium, brass and zinc, as well as other valve metals, including zirconium, niobium and tantalum. Depending on the item and its circumstances of use, oftentimes, it is desirable to provide the surface with a protective layer against corrosion and the like.
  • Electrochemical techniques use electrolytic reactions to generate a protective oxide surface layer from the substrate material itself, meaning that surface modifications can occur wherever the substrate material is in contact with the process electrolyte.
  • Electrochemical processes are particularly well suited for components with complex internal geometries, such as heat exchangers.
  • Electrochemical processes include anodising and plasma electrolytic deposition (PED). Both processes operate on the same principle: using the aluminium (or other oxide-forming alloys) component as an anode in an electrolyte bath with electrical current passing through the circuit via a cathode.
  • the processes differ in the electrolyte composition and concentration, as well as the electrical parameters, where PED processes tend to use a significantly higher voltage than anodising processes.
  • a key feature of the PED process that differs from anodising is the occurrence of plasma discharging at the metal-coating interface when employing high potentials.
  • the applied potential exceeds a certain critical breakdown point, a number of discrete short-lived microdischarges will appear and will move across the metal surface to form a surface film.
  • This process can be used to grow ceramic coatings on metal substrates. Because these surface coatings can provide high hardness and a continuous barrier, they can offer protection against wear, corrosion or heat, as well as electrical insulation.
  • the surface coating generated by plasma electrolytic deposition techniques is actually a chemical conversion of the substrate metal into its oxide (plasma electrolytic oxidation, or PEO).
  • PEO plasma electrolytic oxidation
  • the oxides grow both inwards and outwards from the original metal surface.
  • the coatings have strong adhesion to the substrate metal, compared to conventional deposited coatings.
  • the metal surface can be saturated by non- metallic elements such as O, C, N, B and a combination of these. These elements can form a vapour envelope along the metallic substrate surface and diffuse inward to the metal in a PED process.
  • the diffusing species are the chemicals that can be negatively ionised in the electrolyte.
  • the plasma will vaporise these species to form a vapour envelope.
  • the electric field applied by PED will accelerate across the voltage drop to bombard the substrate surface through interstitial and grain-boundary diffusion.
  • Modifying the PEO electrolyte to include a significant nitrogen source can result in a significant nitride surface coating.
  • a process is known as plasma electrolytic nitriding, or PEN.
  • PEN plasma electrolytic nitriding
  • the resulting nitride surface coating from the PEN process has higher density, lower porosity, improved mechanical properties, improved adhesion to sharp geometric features, better thermal conductivity and improved corrosion resistance properties similar to other coated layers.
  • Pain points of known electrolytic protective coating techniques include high costs due to multi-step process requirements and/or low-density coatings, resulting in less than optimised corrosion protection. Additionally, the coating of high-silicon aluminium alloys has not been widely reported. Moreover, known processes tend to use harmful electrolytes that are often toxic and/or corrosive, such as potassium hydroxide.
  • an electrolyte composition comprising an aqueous solution containing a charge carrier component together with an effective amount of carbamide, melamine, ammonium nitrate and/or similar nitrogen source for use in forming a protective coating on a metallic specimen by way of plasma electrolytic deposition.
  • the charge carrier component is preferably substantially pH neutral.
  • the charge carrier component comprises a sodium metaphosphate.
  • the charge carrier component may comprise sodium hexametaphosphate.
  • the electrolyte composition may include up to about 5 wt.% of sodium hexametaphosphate.
  • the electrolyte composition may include up to about 40 wt.% carbamide.
  • the electrolyte composition may include up to about 5 wt.% melamine.
  • the electrolyte composition may include up to about 20 wt.% glycerol, acting as an electrolyte conductivity modulator.
  • the electrolyte composition solution has a substantially neutral pH level.
  • One particular embodiment of the invention provides an electrolyte composition for plasma electrolytic deposition comprising an aqueous solution having about 1 wt.% sodium hexametaphosphate and about 30 wt.% carbamide.
  • One particular embodiment of the invention provides an electrolyte composition for plasma electrolytic deposition comprising an aqueous solution having about 1 wt.% sodium hexametaphosphate and about 3 wt.% melamine.
  • One particular embodiment of the invention provides an electrolyte composition for plasma electrolytic deposition comprising an aqueous solution having about 1 wt.% sodium hexametaphosphate, about 40 wt.% carbamide and about 20 wt.% glycerol.
  • the present invention also provides a method for forming a protective coating on a metallic object, comprising: immersing the object in an electrolyte solution according to a composition defined above; electrically coupling the object as the anode in a power supply circuit that also includes a cathode in contact with the electrolyte solution; controlling the power supply circuit to apply, for a predetermined period of time, a pulsed DC voltage of selected frequency and power characteristics sufficient to generate plasma electrolytic deposition on the surface of the object.
  • the method may include inducing relative movement between the object and the electrolyte solution during immersion to ensure that all surfaces of the object to be coated are in contact with the electrolyte solution during the plasma electrolytic deposition operation.
  • Relative movement between the object and the electrolyte solution may be provided by mechanical agitation of the electrolyte solution or specimen, or both.
  • the method may include inducing flow of the electrolyte solution to ensure that the electrolyte sufficiently wets all surfaces of the object, and all surfaces are continually replenished with electrolyte during the plasma electrolytic deposition operation.
  • the method may include determining a surface area of the object and controlling characteristics of the power supply circuit according to the determined surface area.
  • the predetermined period of time is selected according to a desired plasma electrolytic deposition layer thickness.
  • the present invention also provides a system for forming a protective coating on a metallic object, comprising: an electrolyte bath containing an electrolyte solution according to a composition defined above; a cathode that is in contact with the electrolyte solution, in use; a controllable power supply adapted to apply, for a predetermined period of time, a pulsed DC voltage of selected frequency and power characteristics sufficient to generate plasma electrolytic deposition on the surface of the object while the object is, in use, coupled to the power supply as the anode and immersed in the electrolyte solution.
  • the present invention also encompasses a metallic object formed with a protective coating according to the method as defined above and/or utilising the system as defined above.
  • Coatings formed using the novel electrolyte composition and electrical operating parameters as disclosed herein have a number of advantages. For instance, embodiments of the present invention provide an ability to grow nitride coatings on high-silicon aluminium alloys. A greater range of alloys to apply coatings to means greater material choices for design engineers. Moreover, PEN coatings formed according to embodiments of the invention exhibit:
  • our developed PEN-coated parts by using the novel electrolyte and operating parameters could create low-porosity surface coatings on oxide-forming alloys that improve corrosion resistance while maintaining sufficient thermal conductivity for heat transfer applications.
  • electrolytes disclosed herein are vastly more environmentally friendly and non-toxic since a sodium polymetaphosphate is used as a charge carrier. It is also close to neutral, with ⁇ 6.5 pH, meaning it is not acidic or basic, and thus, not corrosive.
  • Figure 1 is a flow-chart diagram outlining a process according to embodiments of the invention for applying a protective surface coating to a specimen;
  • Figure 2 is a schematic diagram of a system for creating a PEN coating on specimen according to embodiments of the invention
  • Figure 3 is an image of a PEN coated specimen
  • Figure 4 is a cross-sectional microscopy image showing coating density and thickness (3-4um) and attachment to metallic substrate;
  • Figure 5 is a schematic diagram of material phases present through coating thickness
  • Figure 6 illustrates the thermal diffusivity of AISiWMg specimens coated with three variations of PEN coating processes according to embodiments of the invention, versus an uncoated specimen
  • Figure 7 illustrates Vickers hardness of AISiWMg specimens coated with three variations of PEN coating processes according to embodiments of the invention, versus an uncoated specimen
  • Figure 8 illustrates flat-cell corrosion results (corrosion current density versus corrosion potential) of three coated AISiWMg specimens versus the uncoated specimen.
  • Figure 9 illustrates a representative composition-depth profile of a PEN surface coating according to an embodiment of the invention.
  • compositions, processes, apparatus and techniques for applying protective coatings to metal components can be applied to oxideforming alloy components that are manufactured by forming, forging, casting, fabricating, machining and/or additive manufacturing (3D-printing).
  • Such components may include simple geometries such as brackets or housings, complex parts such as heat exchangers or other parts featuring highly complex geometric features such as lattice structures, honeycombs, gyroids, etc.
  • Coated components can be put into service in corrosive environments where their service life would be severely reduced without protective coatings.
  • Such environments may be in marine, energy sector, outdoor plant equipment, industrial processing, etc.
  • Corrosion resistance is increased as the nitride layers generated by the PEN process disclosed herein greatly reduces the formation of pitting under the influence of the negative potential and presence of aggressive species such as chloride ions present in corrosive solutions of the prior art. Erosion resistance is also improved as the fabricated ceramic layer can increase surface hardness, improving mechanical protection.
  • a process 100 for applying a protective surface coating according to embodiments of the invention is illustrated in the form of a flowchart diagram in Figure 1 , beginning at operation 102.
  • the process can be performed using a system 10 for applying a PEN coating such as that shown schematically in Figure 2.
  • the system 10 comprises an electrolyte bath in the form of an electrolyte solution 20 in a container 15 suitable for holding the specimen 50 to be coated.
  • a hanger 25 or other suitable means may be provided to support the specimen while submerged in the electrolyte bath.
  • the specimen 50 is electrically connected to the positive polarity output of a controllable electrical power supply 40, while a cathode member 30 is connected to the negative polarity output.
  • the cathode 30 is formed from a suitable corrosion-resistant conductive metal material and, in use, is submerged in the electrolyte solution along with the specimen 50 which comprises the anode.
  • the cathode may comprise a 316L-Grade stainless steel mesh.
  • controllable electrical power supply 40 comprises a direct current (DC) plasma generator with the following capabilities and characteristics:
  • operation 104 involves determining the surface area of the specimen 50. This information can be extracted from CAD model data, for example, or may be calculated manually for simpler components.
  • Operation 106 entails preparing the electrolyte solution for the electrolyte bath.
  • an electrolyte composition having a source of nitrogen is used. Table 1 below provides a guide to the functional components of an electrolyte composition according to embodiments of the present invention.
  • Glycerol 0 - 20 conductivity to avoid forming troublesome sparks
  • aqueous solutions may be mixed to provide transparent conductive solutions with the following compositions:
  • Sodium hexametaphosphate is a form of sodium metaphosphate, in particular a sodium polymetaphosphate, that is a benign substance which has applications in a wide variety of industries, including as a food additive.
  • the sodium hexametaphosphate acts as charge carrier, facilitating conduction of electrons into the specimens being coated.
  • Sodium metasilicate has also been used forthis function in testing, but results indicate the production of a lower quality coating (higher porosity) as compared to SHMP. Testing also indicates that, to some degree, it is possible to reduce the current density required by increasing sodium hexametaphosphate concentration.
  • Ammonium nitrate and other similar nitrogen sources can be added to the electrolyte as well.
  • Other nitrogen sources are also possible, but qualities of the coating may vary due to different number of anions and cations in solution due to different chemistry. A different porosity may result as the coating would develop at different applied voltage.
  • glycerol in the electrolyte can reduce the incidence of hot-spots (a.k.a. “troublesome sparks”) on the surface of the specimen during coating, by controlling electrolyte conductivity.
  • glycerol addition is increased control of surface porosity via desired small, consistent sparks at the surface.
  • An electrolyte with a composition as described above is mixed to provide a transparent conductive solution. Once prepared, the electrolyte solution 20 is added to process container 15.
  • the particular electrolyte composition can affect characteristics of the resulting coating such as thermal diffusivity, corrosion resistance and hardness, which is discussed hereinbelow with reference to Figures 6, 7 and 8.
  • the power supply is connected to cathode 30 and the specimen 50 (operation 108), both of which are submerged in the electrolyte solution (operation 1 10).
  • the electrolyte solution For components with complex geometries, including voids, closely packed features and/or internal passages such as those of a heat exchanger, relative movement between the electrolyte and coating specimen may be required to achieve optimal coating. This movement may be provided by mechanical agitation of the electrolyte solution or specimen or by way of a flow-inducing system to ensure that the electrolyte sufficiently wets all surfaces of the specimen, and all surfaces are continually replenished with electrolyte during the coating operation.
  • Plasma DC generator controller Electrical operating parameters are entered into plasma DC generator controller at operation 120, for example:
  • the coating operation 112 involves applying the selected electrical operating parameters to the power supply so that the plasma DC generator 40 controls current flow through electrolyte bath and specimen for a specified duration. Increased duration results in increased coating thickness. In trials, duration in the range of about 3 - 15 minutes has proved successful. However, the coating time can vary based on the type of electrolyte, parameters and customer requirements. Coating time is not dependent on surface area.
  • the coating operation is stopped and the specimen is removed from the bath (operation 114).
  • the specimen is ultrasonically cleaned in deionised water to remove residual electrolyte (operation 116).
  • the coating process is complete (operation 118).
  • an aqueous solution of PM containing 0-3.2 wt.% melamine (C3H6N6) and 0-5 wt.% sodium hexametaphosphate (NaPO 3 )6 with the neutral pH, was mixed.
  • the treatment time was selected to be 6 min to provide a desired coating thickness, using cooling and circulating in which the electrolyte temperature is maintained below 30 °C during the process. After the process, the specimen was washed with distilled water and dried. The finished coated samples showed improved corrosion resistance in comparison to the reference alloy.
  • Figure 3 is an image showing a specimen 51 which has undergone an electrolytic coating process according to an embodiment of the present invention using the electrolyte composition designated as 'P20' (see above).
  • Figure 4 is a cross-sectional microscopy image showing density, thickness and attachment of the coating to the aluminium substrate. The coating duration for the specimen in this image was 6 minutes, and the protective coating as shown has a thickness of about 3-4pm.
  • Figure 5 is a schematic diagram of material phases present though the coating thickness.
  • the coating comprises a dense interface layer that integrates with the metal alloy, a thick and solidified oxide layer, and a porous outer layer.
  • a representative composition-depth profile for such a coating is illustrated in Figure 9, which indicates the relative amounts of significant chemical components in the coating according to depth from the coating surface. As can be seen, at the coating surface the composition is dominated by the presence of nitrogen and oxygen with a relatively small amount of aluminium.
  • Figures 6, 7 and 8 are charts illustrating some performance parameters for specimens of aluminium alloy coated using the three electrolyte compositions disclosed above, compared with an uncoated sample.
  • Figure 6 shows good thermal diffusivity for the coated samples ( ⁇ 58 - 63 mm 2 /S), although somewhat lower than the uncoated sample ( ⁇ 75 mm 2 /S) as expected.
  • Figure 7 charts a measure of hardness, which shows two of the three coated specimens (P20, PW) exhibiting significantly increased hardness as compared to the uncoated sample.
  • Figure 8 illustrates a measure of corrosion resistance, which shows that the coated specimens all substantially outperform the uncoated sample.
  • Embodiments of the invention have been described herein by way of example, with reference to various possible components, compositions, operations and control characteristics. Such embodiments are intended to be illustrative rather than restrictive. It should be understood that embodiments include various combinations and sub- combinations of features described herein, even if such features are not explicitly described in such a combination or sub-combination.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Sampling And Sample Adjustment (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)

Abstract

La divulgation concerne une composition d'électrolyte destinée à être utilisée dans la formation d'un revêtement protecteur sur un échantillon métallique au moyen d'un dépôt électrolytique au plasma, comprenant une solution aqueuse contenant un composant de support de charge conjointement avec une quantité efficace de carbamide, de mélamine, de nitrate d'ammonium et/ou de source d'azote similaire. Un système et un procédé d'application d'un revêtement protecteur sur un échantillon métallique utilisent une alimentation électrique pouvant être commandée conçue pour appliquer, pendant une période de temps prédéterminée, une tension CC pulsée ayant des caractéristiques de fréquence et de puissance sélectionnées suffisantes pour générer un dépôt électrolytique au plasma sur la surface de l'objet pendant que l'objet est, lors de l'utilisation, couplé à l'alimentation électrique en tant qu'anode et immergé dans la solution électrolytique. De manière avantageuse, un métaphosphate de sodium, tel que l'hexamétaphosphate de sodium, peut être utilisé en tant que composant de support de charge, la solution d'électrolyte ayant un pH sensiblement neutre.
PCT/AU2024/050061 2023-02-28 2024-02-01 Revêtements de surface de dépôt électrolytique au plasma pour alliages de formation d'oxyde Ceased WO2024178456A1 (fr)

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AU2023900519A AU2023900519A0 (en) 2023-02-28 Surface coatings for metal objects

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Citations (4)

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Publication number Priority date Publication date Assignee Title
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TW201413063A (zh) * 2012-09-28 2014-04-01 Univ Nat Pingtung Sci & Tech 鋁基板直接形成氮化鋁層之方法
CN111118570A (zh) * 2018-10-31 2020-05-08 华孚精密科技(马鞍山)有限公司 压铸铝合金微弧氧化电解液、方法及其产品
RU2725492C1 (ru) * 2019-09-18 2020-07-02 Федеральное государственное бюджетное образовательное учреждение высшего образования "Московский государственный технологический университет "СТАНКИН" (ФГБОУ ВО "МГТУ "СТАНКИН") Электролит для анодного плазменно-электролитного модифицирования

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TW201413063A (zh) * 2012-09-28 2014-04-01 Univ Nat Pingtung Sci & Tech 鋁基板直接形成氮化鋁層之方法
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RU2725492C1 (ru) * 2019-09-18 2020-07-02 Федеральное государственное бюджетное образовательное учреждение высшего образования "Московский государственный технологический университет "СТАНКИН" (ФГБОУ ВО "МГТУ "СТАНКИН") Электролит для анодного плазменно-электролитного модифицирования

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