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- Volume 46, 2016
Annual Review of Materials Research - Volume 46, 2016
Volume 46, 2016
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Perspectives on Additive Manufacturing
Vol. 46 (2016), pp. 1–18More LessAdditive manufacturing (AM) has skyrocketed in visibility commercially and in the public sector. This article describes the development of this field from early layered manufacturing approaches of photosculpture, topography, and material deposition. Certain precursors to modern AM processes are also briefly described. The growth of the field over the last 30 years is presented. Included is the standard delineation of AM technologies into seven broad categories. The economics of AM part generation is considered, and the impacts of the economics on application sectors are described. On the basis of current trends, the future outlook will include a convergence of AM fabricators, mass-produced AM fabricators, enabling of topology optimization designs, and specialization in the AM legal arena. Long-term developments with huge impact are organ printing and volume-based printing.
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Ceramic Stereolithography: Additive Manufacturing for Ceramics by Photopolymerization
Vol. 46 (2016), pp. 19–40More LessCeramic stereolithography and related additive manufacturing methods involving photopolymerization of ceramic powder suspensions are reviewed in terms of the capabilities of current devices. The practical fundamentals of the cure depth, cure width, and cure profile are related to the optical properties of the monomer, ceramic, and photo-active components. Postpolymerization steps, including harvesting and cleaning the objects, binder burnout, and sintering, are discussed and compared with conventional methods. The prospects for practical manufacturing are discussed.
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Additive Manufacturing of Hybrid Circuits
Vol. 46 (2016), pp. 41–62More LessThere is a rising interest in developing functional electronics using additively manufactured components. Considerations in materials selection and pathways to forming hybrid circuits and devices must demonstrate useful electronic function; must enable integration; and must complement the complex shape, low cost, high volume, and high functionality of structural but generally electronically passive additively manufactured components. This article reviews several emerging technologies being used in industry and research/development to provide integration advantages of fabricating multilayer hybrid circuits or devices. First, we review a maskless, noncontact, direct write (DW) technology that excels in the deposition of metallic colloid inks for electrical interconnects. Second, we review a complementary technology, aerosol deposition (AD), which excels in the deposition of metallic and ceramic powder as consolidated, thick conformal coatings and is additionally patternable through masking. Finally, we show examples of hybrid circuits/devices integrated beyond 2-D planes, using combinations of DW or AD processes and conventional, established processes.
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Microstructural Control of Additively Manufactured Metallic Materials
Vol. 46 (2016), pp. 63–91More LessIn additively manufactured (AM) metallic materials, the fundamental interrelationships that exist between composition, processing, and microstructure govern these materials’ properties and potential improvements or reductions in performance. For example, by using AM, it is possible to achieve highly desirable microstructural features (e.g., highly refined precipitates) that could not otherwise be achieved by using conventional approaches. Simultaneously, opportunities exist to manage macro-level microstructural characteristics such as residual stress, porosity, and texture, the last of which might be desirable. To predictably realize optimal microstructures, it is necessary to establish a framework that integrates processing variables, alloy composition, and the resulting microstructure. Although such a framework is largely lacking for AM metallic materials, the basic scientific components of the framework exist in literature. This review considers these key components and presents them in a manner that highlights key interdependencies that would form an integrated framework to engineer microstructures using AM.
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Multiscale Modeling of Powder Bed–Based Additive Manufacturing
Vol. 46 (2016), pp. 93–123More LessPowder bed fusion processes are additive manufacturing technologies that are expected to induce the third industrial revolution. Components are built up layer by layer in a powder bed by selectively melting confined areas, according to sliced 3D model data. This technique allows for manufacturing of highly complex geometries hardly machinable with conventional technologies. However, the underlying physical phenomena are sparsely understood and difficult to observe during processing. Therefore, an intensive and expensive trial-and-error principle is applied to produce components with the desired dimensional accuracy, material characteristics, and mechanical properties. This review presents numerical modeling approaches on multiple length scales and timescales to describe different aspects of powder bed fusion processes. In combination with tailored experiments, the numerical results enlarge the process understanding of the underlying physical mechanisms and support the development of suitable process strategies and component topologies.
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Epitaxy and Microstructure Evolution in Metal Additive Manufacturing
Amrita Basak, and Suman DasVol. 46 (2016), pp. 125–149More LessMetal additive manufacturing (AM) works on the principle of incremental layer-by-layer material consolidation, facilitating the fabrication of objects of arbitrary complexity through the controlled melting and resolidification of feedstock materials by using high-power energy sources. The focus of metal AM is to produce complex-shaped components made of metals and alloys to meet demands from various industrial sectors such as defense, aerospace, automotive, and biomedicine. Metal AM involves a complex interplay between multiple modes of energy and mass transfer, fluid flow, phase change, and microstructural evolution. Understanding the fundamental physics of these phenomena is a key requirement for metal AM process development and optimization. The effects of material characteristics and processing conditions on the resulting epitaxy and microstructure are of critical interest in metal AM. This article reviews various metal AM processes in the context of fabricating metal and alloy parts through epitaxial solidification, with material systems ranging from pure-metal and prealloyed to multicomponent materials. The aim is to cover the relationships between various AM processes and the resulting microstructures in these material systems.
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Metal Additive Manufacturing: A Review of Mechanical Properties
Vol. 46 (2016), pp. 151–186More LessThis article reviews published data on the mechanical properties of additively manufactured metallic materials. The additive manufacturing techniques utilized to generate samples covered in this review include powder bed fusion (e.g., EBM, SLM, DMLS) and directed energy deposition (e.g., LENS, EBF3). Although only a limited number of metallic alloy systems are currently available for additive manufacturing (e.g., Ti-6Al-4V, TiAl, stainless steel, Inconel 625/718, and Al-Si-10Mg), the bulk of the published mechanical properties information has been generated on Ti-6Al-4V. However, summary tables for published mechanical properties and/or key figures are included for each of the alloys listed above, grouped by the additive technique used to generate the data. Published values for mechanical properties obtained from hardness, tension/compression, fracture toughness, fatigue crack growth, and high cycle fatigue are included for as-built, heat-treated, and/or HIP conditions, when available. The effects of test orientation/build direction on properties, when available, are also provided, along with discussion of the potential source(s) (e.g., texture, microstructure changes, defects) of anisotropy in properties. Recommendations for additional work are also provided.
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Architected Cellular Materials
Vol. 46 (2016), pp. 187–210More LessAdditive manufacturing enables fabrication of materials with intricate cellular architecture, whereby progress in 3D printing techniques is increasing the possible configurations of voids and solids ad infinitum. Examples are microlattices with graded porosity and truss structures optimized for specific loading conditions. The cellular architecture determines the mechanical properties and density of these materials and can influence a wide range of other properties, e.g., acoustic, thermal, and biological properties. By combining optimized cellular architectures with high-performance metals and ceramics, several lightweight materials that exhibit strength and stiffness previously unachievable at low densities were recently demonstrated. This review introduces the field of architected materials; summarizes the most common fabrication methods, with an emphasis on additive manufacturing; and discusses recent progress in the development of architected materials. The review also discusses important applications, including lightweight structures, energy absorption, metamaterials, thermal management, and bioscaffolds.
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Topology Optimization for Architected Materials Design
Vol. 46 (2016), pp. 211–233More LessAdvanced manufacturing processes provide a tremendous opportunity to fabricate materials with precisely defined architectures. To fully leverage these capabilities, however, materials architectures must be optimally designed according to the target application, base material used, and specifics of the fabrication process. Computational topology optimization offers a systematic, mathematically driven framework for navigating this new design challenge. The design problem is posed and solved formally as an optimization problem with unit cell and upscaling mechanics embedded within this formulation. This article briefly reviews the key requirements to apply topology optimization to materials architecture design and discusses several fundamental findings related to optimization of elastic, thermal, and fluidic properties in periodic materials. Emerging areas related to topology optimization for manufacturability and manufacturing variations, nonlinear mechanics, and multiscale design are also discussed.
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The Chemistry and Applications of π-Gels
Vol. 46 (2016), pp. 235–262More Lessπ-Gels are a promising class of functional soft materials formed out of short π-conjugated molecules. By utilizing the chemistry of noncovalent interactions, researchers have created a wide range of π-gels that are composed of supramolecular polymers. During the last two decades, supramolecular gel chemistry has been pursued with the hope of developing new materials for applications in, for example, organic electronics, energy harvesting, sensing, and imaging. The high expectations for π-gels were centered mainly around their electronic properties, such as tunable emission, energy transfer, electron transfer, charge transport, and electrical conductivity; such properties are amenable to modulation through size and shape control of molecular assemblies. Although a large number of exciting publications have appeared, a major technological breakthrough is yet to be realized. In this review, we analyze the recent advancements in the area of functional π-gels and their scope in future applications.
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Dealloying and Dealloyed Materials
Vol. 46 (2016), pp. 263–286More LessA successful working model for nanoporosity evolution during dealloying was introduced 15 years ago. Since that time, the field has rapidly expanded, with research groups from across the world studying dealloying and dealloyed materials. Dealloying has grown into a rich field, with some groups focusing on fundamentals and mechanisms of dealloying, other groups creating new porous metals and alloys, and even more groups studying their properties. Dealloying was originally considered only in the context of corrosion, but now it is considered a facile self-organization technique to fabricate high-surface-area, bicontinuous nanoporous materials. Owing to their high interfacial area and the versatility of metallic materials, nanoporous metals have found application in catalysis, sensing, actuation, electrolytic and ultracapacitor materials, high-temperature templates/scaffolds, battery anodes, and radiation damage–tolerant materials. In this review, we discuss the fundamental materials principles underlying the formation of dealloyed materials and then look at two major applications: catalysis and nanomechanics.
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Material Evaluation by Infrared Thermography
Vol. 46 (2016), pp. 287–303More LessInfrared thermography uses the temperature-imaging capability of modern thermal cameras to characterize materials and detect flaws. An energy source—whether a pulse of light from a laser or flash lamp, an induction coil, or some other source—induces heat flow in a material, and the resulting temperature patterns are imaged with the thermal camera. In flash thermography, the most widely used form of quantitative thermography, a pulse of light is used as the energy source, and then the surface cooldown is imaged with the thermal camera. Calculations based on an elementary theory of 1D heat conduction can determine thickness (or, equivalently, thermal diffusivity), and nonuniformity in the cooldown will identify defects. This article reviews the methods, approaches, and models of thermography. It focuses on illustrating and identifying the materials, thicknesses, and flaw conditions under which thermography is an effective material characterization technique.
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Physics of Ultrathin Films and Heterostructures of Rare-Earth Nickelates
Vol. 46 (2016), pp. 305–334More LessThe electronic structure of transition metal oxides featuring correlated electrons can be rationalized within the Zaanen-Sawatzky-Allen framework. Following a brief description of the present paradigms of electronic behavior, we focus on the physics of rare-earth nickelates as an archetype of complexity emerging within the charge transfer regime. The intriguing prospect of realizing the physics of high-Tc cuprates through heterostructuring resulted in a massive endeavor to epitaxially stabilize these materials in ultrathin form. A plethora of new phenomena unfolded in such artificial structures due to the effect of epitaxial strain, quantum confinement, and interfacial charge transfer. Here we review the present status of artificial rare-earth nickelates in an effort to uncover the interconnection between the electronic and magnetic behavior and the underlying crystal structure. We conclude by discussing future directions to disentangle the puzzle regarding the origin of the metal-insulator transition, the role of oxygen holes, and the true nature of the antiferromagnetic spin configuration in the ultrathin limit.
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Polymer-Derived Ceramic Fibers
Vol. 46 (2016), pp. 335–356More LessSiC-based ceramic fibers are derived from polycarbosilane or polymetallocarbosilane precursors and are classified into three groups according to their chemical composition, oxygen content, and C/Si atomic ratio. The first-generation fibers are Si-C-O (Nicalon) fibers and Si-Ti-C-O (Tyranno Lox M) fibers. Both fibers contain more than 10-wt% oxygen owing to oxidation during curing and lead to degradation in strength at temperatures exceeding 1,300°C. The maximum use temperature is 1,100°C. The second-generation fibers are SiC (Hi-Nicalon) fibers and Si-Zr-C-O (Tyranno ZMI) fibers. The oxygen content of these fibers is reduced to less than 1 wt% by electron beam irradiation curing in He. The thermal stability of these fibers is improved (they are stable up to 1,500°C), but their creep resistance is limited to a maximum of 1,150°C because their C/Si atomic ratio results in excess carbon. The third-generation fibers are stoichiometric SiC fibers, i.e., Hi-Nicalon Type S (hereafter Type S), Tyranno SA, and Sylramic™ fibers. They exhibit improved thermal stability and creep resistance up to 1,400°C. Stoichiometric SiC fibers meet many of the requirements for the use of ceramic matrix composites for high-temperature structural application. SiBN3C fibers derived from polyborosilazane also show promise for structural applications, remain in the amorphous state up to 1,800°C, and have good high-temperature creep resistance.
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Raman Studies of Carbon Nanostructures
Vol. 46 (2016), pp. 357–382More LessThis article reviews recent advances on the use of Raman spectroscopy to study and characterize carbon nanostructures. It starts with a brief survey of Raman spectroscopy of graphene and carbon nanotubes, followed by recent developments in the field. Various novel topics, including Stokes–anti-Stokes correlation, tip-enhanced Raman spectroscopy in two dimensions, phonon coherence, and high-pressure and shielding effects, are presented. Some consequences for other fields—quantum optics, near-field electromagnetism, archeology, materials and soil sciences—are discussed. The review ends with a discussion of new perspectives on Raman spectroscopy of carbon nanostructures, including how this technique can contribute to the development of biotechnological applications and nanotoxicology.
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Recent Advances in Superhard Materials
Zhisheng Zhao, Bo Xu, and Yongjun TianVol. 46 (2016), pp. 383–406More LessIn superhard materials research, two topics are of central focus. One is to understand hardness microscopically and to establish hardness models with atomic parameters, which can be used to guide the design or prediction of novel superhard crystals. The other is to synthesize superhard materials with enhanced comprehensive performance (i.e., hardness, fracture toughness, and thermal stability), with the ambition of achieving materials harder than natural diamond. In this review, we present recent developments in both areas. The microscopic hardness models of covalent single crystals are introduced and further generalized to polycrystalline materials. Current research progress in novel superhard materials and nanostructuring approaches for high-performance superhard materials are discussed. We also clarify a long-standing controversy about the criterion for performing a reliable indentation hardness measurement.
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Synthetic Micro/Nanomotors and Pumps: Fabrication and Applications
Vol. 46 (2016), pp. 407–432More LessSynthetic active systems capable of autonomous motion or driving fluid flow are of great current interest owing to their potential applications in nanomachinery, cargo capture and delivery, reversible assemblies, and chemical/biochemical sensing. Designing self-powered micro/nanomotors and understanding their propulsion mechanisms and ensemble behavior are now areas of great interest in low-Reynolds-number mechanics. In this article, we classify prototypes of existing small-scale motors on the basis of the materials used in synthesis and fabrication, with the aim of understanding the importance of material selection in designing functional motors for futuristic applications.
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Thermal Boundary Conductance: A Materials Science Perspective
Vol. 46 (2016), pp. 433–463More LessThe thermal boundary conductance (TBC) of materials pairs in atomically intimate contact is reviewed as a practical guide for materials scientists. First, analytical and computational models of TBC are reviewed. Five measurement methods are then compared in terms of their sensitivity to TBC: the 3ω method, frequency- and time-domain thermoreflectance, the cut-bar method, and a composite effective thermal conductivity method. The heart of the review surveys 30 years of TBC measurements around room temperature, highlighting the materials science factors experimentally proven to influence TBC. These factors include the bulk dispersion relations, acoustic contrast, and interfacial chemistry and bonding. The measured TBCs are compared across a wide range of materials systems by using the maximum transmission limit, which with an attenuated transmission coefficient proves to be a good guideline for most clean, strongly bonded interfaces. Finally, opportunities for future research are discussed.
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Ultraincompressible, Superhard Materials
Vol. 46 (2016), pp. 465–485More LessThe search for new ultraincompressible, superhard materials has been performed largely through trial and error. Despite the difficulties in synthesizing such materials, interest in this field has blossomed with recent experimental and theoretical results. Such progress has led to the development of superhard metal borides, ultraincompressible nitrides, and strong carbides. Our previous parameters of high electron density and high covalent bond density had served us well in synthesizing ultraincompressible, superhard metals, but after a decade of research, a more detailed understanding is needed. By studying the origin of strength from previously discovered incompressible, hard materials, we hope to gain new insight into this rapidly growing field. In particular, we propose a focus on bonding and structure to understand why some materials are ultraincompressible and superhard.
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Previous Volumes
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Volume 54 (2024)
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Volume 53 (2023)
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Volume 52 (2022)
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Volume 51 (2021)
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Volume 50 (2020)
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Volume 49 (2019)
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Volume 48 (2018)
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Volume 47 (2017)
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Volume 46 (2016)
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Volume 45 (2015)
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Volume 44 (2014)
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Volume 43 (2013)
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Volume 42 (2012)
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Volume 41 (2011)
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Volume 40 (2010)
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Volume 39 (2009)
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Volume 38 (2008)
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Volume 37 (2007)
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Volume 36 (2006)
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Volume 35 (2005)
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Volume 34 (2004)
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Volume 33 (2003)
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Volume 32 (2002)
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Volume 31 (2001)
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Volume 30 (2000)
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Volume 29 (1999)
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Volume 28 (1998)
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Volume 27 (1997)
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Volume 26 (1996)
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Volume 25 (1995)
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Volume 24 (1994)
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Volume 23 (1993)
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Volume 22 (1992)
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Volume 21 (1991)
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Volume 20 (1990)
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Volume 19 (1989)
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Volume 18 (1988)
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Volume 17 (1987)
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Volume 16 (1986)
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Volume 15 (1985)
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Volume 14 (1984)
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Volume 13 (1983)
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Volume 12 (1982)
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Volume 11 (1981)
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Volume 10 (1980)
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Volume 9 (1979)
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Volume 8 (1978)
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Volume 7 (1977)
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Volume 6 (1976)
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Volume 5 (1975)
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Volume 4 (1974)
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Volume 3 (1973)
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Volume 2 (1972)
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Volume 1 (1971)
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Volume 0 (1932)