CN102639950A - 盛装熔融金属的容器及其制造方法 - Google Patents
盛装熔融金属的容器及其制造方法 Download PDFInfo
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Abstract
本发明的示例性实施例提供了用于盛装或输送在其中的熔融金属的容器。该容器的外表面的至少一部分合并嵌入在该表面中的金属线的网,线相互覆盖,在其间形成有开口。耐火材料渗透到这些开口中。该网可以包括织造金属线或非织造金属线或两者。该网赋予抗裂性(或一旦形成裂纹,遏制裂纹)和/或如果裂纹发展则抑制熔融金属泄漏。本发明还提供了包含这样的容器的金属盛装结构及其制造方法。
Description
技术领域
本发明涉及包括用于输送、处理和/或容纳熔融金属的耐火容器或陶瓷容器的熔融金属盛装结构。更具体地,本发明涉及这样的容器及其段。
背景技术
在铸造作业等期间常常需要诸如流槽、流道等的金属盛装结构以将熔融金属从一个位置例如金属熔化炉输送到另一位置例如铸模或浇铸台。在其它作业中,金属盛装结构用于诸如金属过滤、金属除气、金属运输、或金属容纳之类的金属处理。在这样的结构中所使用的诸如槽、罐、桶等的金属接触容器一般由耐火材料并且尤其是陶瓷材料制成,其耐高温并且抑制它们暴露到的熔融金属所致的。退化。有时,这样的结构设置有热源以确保:熔融金属在其盛装在容器内或通过容器输送时,不会过度冷却或固化。该热源可以是电加热元件,该电加热元件定位成相邻于容器或外壳,所述容器或外壳沿着容器的内表面或外表面输送热流体(例如燃烧气体)。
当熔融金属被输送时、或当应用额外加热时、或当容器段闲置或被允许冷却时,在这样的结构中所使用的耐火容器遭受热循环即温度的显著变化。热循环能够促使裂纹形成在制造容器或容器段的耐火材料中。裂纹随时间扩展并且最终可能变得大而深以致熔融金属从容器泄漏。当这种情况发生时,必须对因此受影响的容器进行修理或更换,并且往往这样的组件的使用寿命很短。因此,存在对如下方式的需要:延长熔融金属接触容器及容器段的有效使用寿命;以及防止或最少化裂纹形成和熔融金属从这样的容器泄漏。
1942年11月3日授予Lewis
T.Welshans的美国专利2,301,101公开了一种用于具有金属网嵌入其壁中的铸模的耐火保温帽,但是该专利中不存在关于槽段中这样的用途的公开内容。
1996年4月9日授予Charles
W.Connors的美国专利5,505,893公开了一种在模制槽的耐火炉衬中所使用的开放网筛。然而,在槽已经完成之后,筛被拆下或溶解掉。
尽管存在这些公开,但仍然存在对改进的容器段及制造其的改进方法的需要。
发明内容
示例性实施例提供了用于盛装熔融金属的容器,该容器包括耐火材料的主体,该主体具有:腔,该腔用于盛装或输送熔融金属;以及外表面,该外表面具有嵌入在其中的金属线的网。该网的线相互覆盖,在金属线之间形成有开口,耐火材料渗透到这些开口中。
另一示例性实施例提供了熔融金属盛装结构,该熔融金属盛装结构包括:如上所定义的容器;以及金属壳,该金属壳至少部分地围绕该容器。
根据又一示例性实施例,提供了制造加强耐火容器或容器段的方法。该方法涉及:提供具有容器或容器段的预期形状的模具;配制能够形成铸造耐火本体的耐火材料的浆料;用金属线的网给该模具的至少一个内表面装衬里,这些线覆盖,在线之间形成有开口;在使得浆料渗透开口的同时,将浆料引入到模具中;让浆料凝固以形成在其外表面处合并所述网的容器或容器段;以及从模具拆下该容器或容器段。在浆料凝固或变硬之前可以使模具振动和/或对其加压以促进浆料渗透到网的开口。
另一示例性实施例提供了制造加强耐火容器的替代方法。该替代方法涉及:提供容器,该容器由耐火材料制成并且具有外表面;以及将网粘附到该外表面,其中该网包括金属线,具有在其间的开口,并且其中该网借助于耐火粘合剂粘附到所述外表面,该耐火粘合剂通过所述开口渗入到所述网中。
优选地,该容器的形状和尺寸适于用作选自如下结构的物件:具有形成在其中的通道的细长金属输送槽、用于熔融金属过滤器的容器、用于熔融金属脱气器的容器、坩埚等。
该示例性实施例的容器由耐火材料制成。此处用来涉及金属盛装容器的术语“耐火材料”旨在包括所有如下材料:其相对地耐熔融金属的腐蚀并且在针对在对于容器的在正常使用期间所预期的高温下能够保持它们的强度,所述高温例如熔融金属的温度。这样的材料包括但不限于陶瓷材料(无机非金属固体和耐热玻璃)和非金属。适当材料的非限制性列举包括如下材料:下述的氧化物:铝(氧化铝)、硅(二氧化硅,尤其是熔凝硅石)、镁(氧化镁)、钙(石灰)、锆(氧化锆)、硼(氧化硼);金属碳化物、硼化物、氮化物、诸如碳化硅、硅化物粘合的碳化硅(SiC/Si3N4)的硅化物、碳化硼、氮化硼;硅酸铝,例如硅酸钙铝;复合材料(例如氧化物和非氧化物的合成物);玻璃,包括可机加工的玻璃;纤维的矿物棉或其混合物;碳或石墨;等等。
该示例性实施例的容器通常旨在用于盛装熔融铝和铝合金,但是可用于盛装其它熔融金属,尤其是那些具有与铝类似的熔点的金属,例如(具有比铝低的熔点的)镁、铅、锡、锌以及(具有比铝高的熔点的)铜和金。优选地,为了与预期将被盛装或输送的特定熔融金属一起使用,所挑选的用于金属线网的线的金属应与该特定熔融金属不起反应,或至少是充分不活泼的以致于与该熔融金属有限的接触不会引起对该网的过度腐蚀、分解或吸收。钛是用于与熔融铝和铝合金一起使用的良好选择,但是具有高成本的缺点。较便宜的备选方案包括但不限于Ni-Cr合金(例如Inconel®)和不锈钢。
该容器可以形成具有外部金属壳的金属盛装结构的一部分,并且该结构可以设置有用于熔融金属的加热器。在2005年12月13日授予Tingey等人的美国专利No.6,973,955中,或2008年7月10日公开的公开号为no.2008/0163999的Hymas等人的待审美国专利申请序列号No.12/002,989中描述了这种受热结构(这些专利和专利申请的公开内容特别地通过该引用并入此处)。
附图说明
下面参考附图描述示例性实施例,其中:
图1是根据一个示例性实施例的槽段的透视图;
图2是在图1的线II-II上截取的图1的槽段的横向剖面;
图3是用在图1和图2的槽段中的加强网的侧视图;
图4是图3的加强网的平面图;
图5是形成图3和图4的加强网的一部分的织物层的平面图;
图6是形成图3和图4的加强网的另一部分的非织物层的平面图;
图7是靠近其侧壁的金属输送槽段的一部分的放大横截面,示出了根据图3至图6的加强网的位置;
图8是合并了如图1和图2中所示的槽段的用于输送熔融金属的金属盛装结构的端视图;以及
图9是类似于图2的槽段的槽段的竖向横截面图,但是示出了另外的示例性实施例。
具体实施方式
图1和图2示出根据一个示例性实施例的以金属传送槽或槽段10的形式的金属盛装容器。该容器在下文中将被称为槽段,因为金属输送槽通常由两个或更多个放置成首尾相连的这样的段组成,但是功能槽可以由仅一个这样的段组成。通常地,(多个)槽段将被保持在熔融金属盛装结构的外部金属壳内(稍后将结合图8描述的实施例),以对该(多个)槽段提供物理保护,并且以在存在多于一个槽段时保持这些槽段相互对齐。当通过该(多个)槽段输送熔融金属时,也可以提供加热装置(未示出)来帮助保持熔融金属在适当的温度下。
所示的槽段10具有由耐火材料制成的主体11,该耐火材料耐高温并且耐由通过该槽段被输送的熔融金属的腐蚀。可用于主体11的特别优选的材料的例子包括陶瓷,诸如氧化铝、碳化硅(例如氮化物粘合的碳化硅)、硅酸铝、熔凝硅石、或这些材料的组合。当然,例如先前所描述的那些中的任一种的其它耐火材料也可用于该主体。主体11具有外表面18,该外表面延伸遍及相对的侧壁12、底壁13、相对的纵端14和上壁15。细长U形金属输送通道16从上壁15向下伸进主体11中并且从该主体的一个纵端14延伸到另一纵端。如图2中所示,该槽段在使用中盛装熔融金属达如点线所示的由水平水准17表示的深度,并且将该熔融金属从该槽段的一端输送至另一端。水准17表示一高度,高于所述高度,通过该槽段所输送的熔融金属的上表面在该槽段的正常使用期间不上升。
侧壁12和底壁13示出为平面,但若需要,可以具有波状形状,和/或在侧壁的情况下,相对于竖直面具有倾斜度。这些壁设置有嵌入在其外表面中的金属线的网20。在附图的图3至图6中更详细地示出了孤立于主体11的耐火材料的该网。将从图3的侧视图中看到的是,该示例性实施例的网20由两个不同的部分构成,即织造金属基质21和非织造缠结(毡状)金属基质22。这两部分(例如通过烧结或焊接)牢固地粘附到一起,因此它们充当单个统一的多孔网20。(图5中孤立地示出的)织造基质21由交错编织在一起的隔开的经纱纤维和隔开的纬纱纤维形成,以在这些纤维之间留下开口,这些开口的平均尺寸(每侧上的宽度或直径)优选在0.5mm至10mm,更优选1mm至10mm,甚至更优选1mm至5mm范围内。如果这些开口留得太小,则一些耐火材料可能不会完全渗入到这些开口中,并且织物层21可能不合期望地产生宽阔的剪切面,耐火材料可抵靠该剪切面自由移动。如果这些开口尺寸比约10mm大得多,则在一些实施例中,可能没有足够的线密度来有效地保持耐火材料在适当的位置。然而,应注意,具有在所述范围之外的宽度的开口可能对于一些耐火材料以及对于用于线的一些金属是有效的,因此,可以利用简单的测试来为用于该槽段的主体11的任何特定耐火材料建立最佳尺寸范围。耐火材料渗透织造基质的开口以与金属网20形成单一结构。这提供了具有有效加强的槽段从而防止裂纹形成或一旦裂纹形成在该槽中限制裂纹的扩展或变宽。优选如所示的单层织造基质21,但是可替代地,可以使用多个织物层,尤其是在这样的层例如通过烧结或焊接牢固地粘附在一起的情况下。用于一个特定实施例的适当的织造基质的实例是#2网筛,该网筛具有宽度约7mm的开口和直径约14mm的线。该织造基质可以单独地使用,但是优选地,将其结合如下所述的非织造基质22利用。
(图6中孤立地示出的)非织造基质22由以随机方式相互覆盖的线股组成,并且在股之间形成有开口。在股之间的开口在尺寸上可以类似于织造基质的线之间的那些开口,但是优选更小。这些开口的尺寸范围优选地从约50µm至10mm,但是更优选最大尺寸是5mm、1mm、500µm、450µm、 400µm、350µm、300µm、250µm、200µm 和150µm。最优选地,平均开口尺寸在50μm至150μm范围内,并且通常为约100μm(±25%),但是在特定实施例中更小或更大的开口尺寸会是有效的。非织造基质22的开口尺寸优选地大足以允许用于形成槽段的主体的耐火材料有效地渗透,但是优选地小足以:如果裂纹在相邻的槽段中发展,则熔融金属不会容易地透过该基质。非织造基质22优选由许多相互覆盖并且压缩在一起的金属线构成以形成相对较厚的层,使得如果熔融金属开始渗透该层,则它必须遵从曲折或旋绕路径以完全透过该金属基质,这再次使完全渗透不可能。在一些实施例中,如果裂纹在槽段中发展,则非织造基质22可以单独地用来提供对金属渗透的抵抗,但是优选将其与如所示和上述的织造基质21结合使用,使得能够获得加强以及对金属渗透的抵抗的组合。当织造基质的开口尺寸大于非织造基质的开口尺寸时,可以获得良好的加强和对金属渗透的抵抗的组合。虽然织造基质通常优选用于加强物,并且非织造基质优选用于提供对金属渗透的抵抗,但是若需要,可通过对非织造基质提供比织造基质大的开口来颠倒这些角色。
网20的一个部分并且优选地两个部分由如下金属制成,即该金属抑制对由通过所述槽待被输送的熔融金属的腐蚀,并且不易被所述熔融金属浸湿。这使得:如果裂纹发展,则熔融金属渗透该金属网变得不太可能。适当的金属包括但不限于钛、Ni-Cr合金(例如Inconel®)、不锈钢、不容易被待输送的熔融金属的溶解的钛和其它金属或合金。然而,对于网20,已经发现使用由美国FL32713,Debary,230 Springview Commerce Dr., Suite 100的Micron
Fiber-Tech以商标名G-mat®出售的双层材料最有利。该产品具有如图3至图6中所示的结构并且能够抵抗高热量,并且由特别的Fe-Cr-Al-M合金制成(其中M表示专有成分)。
用于每个网基质21和22的线的金属通常相同,但是若需要可以使用不同的金属,例如为一个基质提供对金属渗透更高的抵抗性以及为另一个提供用于加强耐火材料的更高的强度。
用于不同基质21和22的线的粗度可以相同,但是优选它们不同,较粗的线用于织造基质21(用于更大强度),并且较细的线用于非织造基质22(以提供用于渗透熔融金属的更旋绕的路径)。线粗度的例子是对于非织造基质22为0.0002英寸至0.0003英寸并且对于织造基质21的线为0.006英寸至0.007英寸(直径)。然而,这些粗度仅仅只是例子并且不应被视为对于所形成金属网的适当有效性是必要的。
如果槽段用在受热的熔融金属分配结构中,则网20应优选具有高热传导性以允许热渗透。然而,用于该网的几乎任何适当的金属将具有适当的热传导性以促进热从加热装置传输到该槽段的通道内的熔融金属。
图7是同一实施例的槽段的一部分的放大横截面,示出了相邻于在侧壁12处的外侧表面18的主体11的结构。将看到的是,主体11的耐火材料已经渗透过这两个网段并且形成该槽段的外壁12的一部分。在该实施例中,非织造基质22定位成最靠近外侧表面18,并且织造基质21更深地埋在主体11的耐火材料中。如果裂纹发展,则非织造基质22抵抗熔融金属到槽段的外表面18的渗透,并且织物基质21提供结构加强并且使得这样的裂纹的形成和变宽不太可能。非织造基质22的金属线中的一些在外表面18上是可见的,但是该部分优选具有嵌入其中的槽主体11的耐火材料。虽然优选将织造基质21定位成比非织造基质22离表面18更远,如所示,但是若需要这个布置可以颠倒,即,交织基体21可定位成比非织造基质22更靠近表面18。
优选将网20精确地定位在耐火材料的外表面18(紧挨下方)处,如所示。耐火材料的主体11内的更深位置将促使网20将主体11的壁划分成在该网的每侧上的两个无加强(仅仅耐火的)区,这会降低壁的强度和抗裂性。因此,将网精确地定位在表面处并且保持槽段的壁的仅耐火的部分尽可能厚被视为是较好的。此外,代替如所示的实施例中的仅一个,将网20埋得更深产生两个可能的剪切面,耐火材料可以沿着该剪切面从该网脱离。
网20优选合并到槽段的外表面18的在水平水准17(参见图2)的下方的所有部分中,该水平水准对应于通道16内的金属的最大预期表面高度,但是该网更优选合并到侧壁12和底壁13的所有部分中,如所示。裂纹趋向于在槽段中形成在顶部处,因此与顶部相邻的加强是期望的。然而,通常不需要将基质合并到槽段的顶壁15中。
上述种类的槽段以各种尺寸出现。一个实例具有665mm的长度、204mm的宽度、以及365mm的高度。任何尺寸的槽段可以设置有根据本发明的示例性实施例的嵌入网20。
如先前所提及的,作为用于盛装或输送熔融金属的容器的实例,槽段10可被包括在诸如金属输送流槽的例如如图8中所示的金属盛装结构中。在该示例性实施例中,槽段10被保持在用于支撑和保护的金属壳30内。该壳的内部可以设置有加热装置(未示出)和/或热绝缘。
图9示出容器的另一实施例,在该容器中,槽段10具有完全封闭的通道16,该通道从一个纵端延伸到另一个。该通道可以是如所示的管状(在横截面上是圆形),但是可替代地,可以具有任何横截面形状,例如椭圆形、不对称的圆形或多边形。网20沿着槽的底壁13延伸并且延伸到侧壁12处的高于水平水准17的高度,该水平水准17即通过通道输送的熔融金属的预期最大高度。然而,若需要,则网20可以延伸环绕槽段的外表面18。
以上种类和其它耐火容器的槽段及其具有嵌入的金属网的部分可以通过如下方式制成:在具有期望形状的模具中铸造耐火颗粒的浆料,让一层金属网20保持抵靠该模具的将形成侧壁或底壁表面的一个或多个侧面。浆料可以由液体(例如水或硅胶)和耐火泥(范围从细粉到大颗粒)形成。浆料优选被配制用以提供最佳的充模和到网20的开口中的渗透,以及具有短干燥时间。在其凝固以形成槽段的固体本体之前,浆料渗透金属网。期望地,为了方便浆料渗透到金属加强物层中并且透过这些层,在引入浆料时并且在浆料凝固之前,使模具振动和/或对其加压(例如通过在压力下引入浆料)。然后将槽段从模具拆下、烘干、并且通常烧结以形成坚硬的耐火固体本体,并且金属线网20仍然在适当的位置并且嵌入在耐火表面中。
替代形成方法涉及用耐火粘合剂将网20粘附到预先成形的完全由耐火材料制造的容器或容器段的外表面。耐火粘合剂渗透金属线网,并且一旦被固化,在该表面处具有与上述实施例相同的结构。然而,存在如下增加的可能性:在裂纹形成期间或在热循环时,网将开始从耐火材料的剩余部分脱离,因此该方法与以上所讨论的方法相比是次优选的,但仍然是修改预先形成的槽段以改进它们性能诸如抑制金属泄漏的有用方式。
在以上实施例中,容器已被示出为在熔融金属分配系统中所使用类型的细长熔融槽或槽段,所述熔融金属分配系统用于将熔融金属从一个位置(例如金属熔化炉)输送至另一位置(例如铸模或浇铸台)。然而,根据其它示例性实施例,可以利用其它种类的金属盛装和分配容器,例如被设计作为内嵌陶瓷过滤器(例如陶瓷泡沫过滤器)的那些容器,该内嵌陶瓷过滤器用于当熔融金属流例如从金属熔化炉流动至浇铸台时,从熔融金属流中滤出微粒。在这种情况下,容器包括用于输送熔融金属的通道,过滤器定位在该通道中。在1997年10月7日授予Aubrey等人的美国专利No.5,673,902和2006年10月26日公布的PCT公开号WO2006/110974 A1中公开了这样的容器和熔融金属盛装系统的实例。特别地,上述美国专利和PCT公布的公开内容通过该引用并入此处。
在另一示例性实施例中,容器充当在其中对熔融金属脱气的罐子,例如1995年8月10日公布的PCT专利公开WO95/21273中所公开的所谓的“Alcan compact metal degasser”(其公开内容通过引用并入此处)。当熔融金属流从炉行进至浇铸台时,脱气操作从其除去氢和其它杂质。这样的容器包括用于熔融金属盛装的内体积,可旋转脱气器叶轮从上方伸入到该内体积中。容器可用于批处理,或它可以是附连到金属输送容器的金属分配系统的一部分。一般而言,容器可以是定位在金属壳内的任何耐火金属盛装容器。容器也可被设计为用于盛装用于从一个位置运输到另一个位置的大量熔融金属的耐火陶瓷坩埚。所有这样的替代容器可与本发明的示例性实施例一起使用。
实例
已经在具有G-mat®网合并到所述表面中的耐火材料测试件上执行了试验。将该测试件经历热循环以确定它是否会分离成层,然后经历破坏试验以了解该网是否会将耐火材料的破裂件保持在一起。结果显示,该测试件不分离成层,并且破裂件的确被保持在一起。
Claims (26)
1.一种用于熔融金属的容器,所述容器包括:耐火材料的主体,所述主体具有用于盛装或输送熔融金属的腔;以及外表面,所述外表面具有嵌入其中的金属线的网,所述线相互覆盖,在所述线之间形成有开口,所述耐火材料渗透进所述开口。
2.根据权利要求1所述的容器,其中所述主体具有水平水准,盛装在所述腔中或通过所述腔输送的熔融金属的上表面在所述容器的正常使用期间不延伸高于所述水平水准,并且其中所述加强物在所述水平水准处和低于所述水平水准嵌入在所述外表面的至少所有部分中。
3.根据权利要求1或权利要求2所述的容器,其中所述金属线的网包括所述金属线的织造基质。
4.根据权利要求1或权利要求2所述的容器,其中所述金属线的网包括所述金属线的非织造基质。
5.根据权利要求1或权利要求2所述的容器,其中所述金属线的网包括连接到彼此的至少两个覆盖的网段。
6.根据权利要求5所述的容器,其中所述覆盖的网段之一包括所述金属线的织造基质,并且所述网段中的另一个包括所述金属线的非织造基质。
7.根据权利要求6所述的容器,其中所述非织造基质定位成比所述织造基质更靠近所述表面。
8.根据权利要求6所述的容器,其中所述织造基质定位成比所述非织造基质更靠近所述表面。
9.根据权利要求6、权利要求7或权利要求8所述的容器,其中所述金属线的织造基质具有平均宽度比所述非织造基质中开口的平均宽度更大的开口。
10.根据权利要求9所述的容器,其中所述织造基质中的所述开口的平均宽度在0.5mm至10mm范围内。
11.根据权利要求9所述的容器,其中所述织造基质中的所述开口的平均宽度在1mm至10mm范围内。
12.根据权利要求9所述的容器,其中所述非织造基质中的所述开口的平均宽度在50µm至10mm范围内。
13.根据权利要求9所述的容器,其中所述非织造基质中的所述开口的平均宽度在50µm至150µm范围内。
14.根据权利要求9所述的容器,其中所述非织造基质中所述开口的平均宽度为约100µm。
15.根据权利要求1至14中任一项所述的容器,其中所述金属线由如下金属制成:所述金属抵抗通过槽段所输送的熔融金属的腐蚀。
16.根据权利要求1至15中任一项所述的容器,其中所述金属线由从由不锈钢、钛、Ni-Cr基合金、和Fe-Cr-Al基合金组成的组中选择的金属制成。
17.根据权利要求1至16中任一项所述的容器,其中所述容器是细长槽或槽段,并且所述腔形成从所述主体的一个纵向端延伸到其另一端的通道。
18.根据权利要求17所述的容器,其中所述主体具有上表面,并且所述通道在所述主体的上表面处是开放的。
19.根据权利要求17所述的容器,其中所述容器的所述主体除在所述纵端处之外完全包围所述通道。
20.根据权利要求1至16中任一项所述的容器,其中所述容器是从由细长金属输送槽、用于熔融金属过滤器的容器、用于熔融金属脱气器的容器、或坩锅组成的组中选择的物件。
21.一种熔融金属盛装结构,包括:根据权利要求1至20中任一项所述的容器;以及至少部分地围绕所述容器的金属壳。
22.一种制造加强的耐火容器或容器段的方法,包括:
提供具有所述容器或容器段的预期形状的模具;
产生能够形成铸造耐火本体的可铸耐火材料的浆料;
用金属线的网给所述模具的至少一个内表面装衬里,所述线被形成在其间的开口覆盖;
在使得所述浆料渗透所述开口的同时,将所述浆料引入到所述模具;
让所述浆料凝固以形成在其外表面处整合所述网的容器或容器段;以及
将所述容器或容器段从所述模具拆下。
23.根据权利要求22所述的方法,其中在所述浆料凝固之前,使所述模具振动以方便浆料渗透到所述网的所述开口中。
24.根据权利要求22所述的方法,其中在所述浆料凝固之前,对所述模具加压以方便浆料渗透到所述网的所述开口中。
25.根据权利要求22所述的方法,其中在所述浆料凝固之前,使所述模具振动并且对其加压以促进浆料渗透到所述网的所述开口中。
26.一种制造加强的耐火容器的方法,包括:
提供容器,所述容器由耐火材料制成并且具有外表面,并且将网粘附到所述外表面,其中所述网包括金属线,具有在其间的开口,并且其中所述网借助于耐火粘合剂粘附到所述外表面,所述耐火粘合剂通过所述开口渗入到所述网中。
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