CN109175364B - Laser additive manufacturing device and additive manufacturing method thereof - Google Patents
Laser additive manufacturing device and additive manufacturing method thereof Download PDFInfo
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- CN109175364B CN109175364B CN201811140619.7A CN201811140619A CN109175364B CN 109175364 B CN109175364 B CN 109175364B CN 201811140619 A CN201811140619 A CN 201811140619A CN 109175364 B CN109175364 B CN 109175364B
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- B22F12/40—Radiation means
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- B22F12/00—Apparatus or devices specially adapted for additive manufacturing; Auxiliary means for additive manufacturing; Combinations of additive manufacturing apparatus or devices with other processing apparatus or devices
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Abstract
The invention provides a laser material increase device, which comprises a rotary beam laser system, a high-frequency short pulse laser system and an auxiliary current system, wherein the rotary beam laser system is connected with the high-frequency short pulse laser system; the rotating beam laser system outputs rotating continuous laser which is used for melting and depositing the wire on the surface of the base material; the high-frequency short pulse laser system outputs high-frequency short pulse laser which is used for inputting pulse laser beams into a molten pool; the auxiliary current system is used for enabling the wire and the molten pool to form a current loop and enabling the interior of the molten pool to directly generate strong electromagnetic force. The rotary beam laser system comprises a continuous laser generator, a first high-precision mechanical arm and a continuous laser head; the high-frequency short pulse laser system comprises a high-frequency short pulse laser generator, a high-frequency short pulse laser head and a second high-precision mechanical arm. The invention can solve the defects of easy element segregation, gas exhaust failure, uneven structure, thermal stress concentration and the like in the molten pool.
Description
Technical Field
The invention relates to the technical field of laser additive manufacturing, in particular to a laser additive manufacturing device and an additive manufacturing method thereof.
Background
Additive manufacturing technology, also known as 3D printing technology, has attracted a great deal of attention of many scholars in recent years, and is called the "third industrial revolution". Among many additive manufacturing methods, Laser Additive Manufacturing (LAM) is an advanced manufacturing method for preparing net-shaped metal members with excellent performance, and is widely applied to the fields of automobiles, aerospace, military equipment, medical treatment and the like. At present, a plurality of scholars at home and abroad make great progress in the field of laser additive manufacturing technology research, and alloy components made of materials such as nickel-based alloy, titanium alloy, stainless steel and the like with good performance are successfully prepared by utilizing the technology.
However, in the laser additive manufacturing process of the component, some common problems are usually faced, such as incomplete melting, air hole inclusions, pores, cracks, coarse grain structures and other metallurgical defects can occur in the additive component; due to the characteristics of 'quick cooling and quick heating', large residual tensile stress, element segregation and the like can be generated in the member; therefore, with the development of laser composite processing technology, many researchers improve the comprehensive performance of the additive component by the method of using the external energy field to assist laser additive manufacturing. According to the existing research and report at home and abroad, the purpose of refining the microstructure is achieved by applying an external crossed magnetic field in a molten pool; however, the magnetic field is in a static form, the energy of the magnetic field is kept unchanged in the operation process, the real-time regulation and control cannot be realized, and the magnetic field and a molten pool are influenced in a non-contact manner and have limited effect on the inside of the molten pool; at present, the light beam that laser vibration material disk used is the laser beam of penetrating directly, and the inside energy distribution of sharp laser beam is uneven, can lead to that the melt channel boundary is unclear, irregular, and the sedimentary deposit roughness is poor, and bonding strength between the layer is low, and then seriously influences the mechanical properties of component.
Laser processing technological parameters and laser equipment are important factors influencing the performance of the additive component, and in order to obtain a laser additive component with excellent comprehensive performance, after numerous technological parameters are tried, the prepared additive component is subjected to later detection and comparison, and the best one is selected. The laser material increase cost is higher, and through a large amount of sample detections, the time and labor are wasted and the production cost is greatly increased.
By searching domestic and foreign documents, a plurality of researchers mainly focus on regulating and controlling the microstructure performance of the component by an external electric field or magnetic field method at present.
Disclosure of Invention
Aiming at the defects in the prior art, the invention provides a laser additive manufacturing device and a method thereof, which can overcome the defects that element segregation is easy to occur in a molten pool, gas cannot be discharged, the structure is not uniform, the thermal stress is concentrated and the like.
The present invention achieves the above-described object by the following technical means.
A laser additive device comprises a rotating beam laser device and a high-frequency short pulse laser device;
the rotating beam laser device outputs rotating continuous laser which is used for melting and depositing the wire on the surface of the base material;
the high-frequency short pulse laser device outputs high-frequency short pulse laser which is used for inputting pulse laser beams into a molten pool.
Further, the auxiliary current device is also included; the auxiliary current device is used for enabling the wire and the molten pool to form a current loop and enabling the interior of the molten pool to directly generate strong electromagnetic force.
Further, the rotating beam laser device comprises a continuous laser generator, a first high-precision mechanical arm and a continuous laser head; the continuous laser generator is connected with the continuous laser head; the continuous laser head is arranged on the first high-precision mechanical arm; and the wire feeder is used for conveying wires into the continuous laser head.
Furthermore, an optical rotation module is arranged in the continuous laser head and used for generating a rotating light beam.
Further, the high-frequency short pulse laser device comprises a high-frequency short pulse laser generator, a high-frequency short pulse laser head and a second high-precision mechanical arm; the high-frequency short pulse laser generator is connected with the high-frequency short pulse laser head; the high-frequency short-pulse laser head is arranged on the second high-precision mechanical arm; the high-frequency short pulse laser head is positioned beside the continuous laser head and is aligned to a quasi-molten pool on the surface of the substrate, and the high-frequency short pulse laser head is used for continuously providing a pulse laser beam to the molten pool.
Further, the auxiliary current device comprises a power supply device and an additional rolling electrode; one end of the power supply device is connected with the wire, the other end of the power supply device is connected with the additional rolling electrode, and the additional rolling electrode is located on the rear side of the molten pool and is in contact with the surface of the settled layer to form a current loop.
Further, the system also comprises an information acquisition system; the information acquisition system comprises a high-speed camera, an illuminating device, a spectrometer probe, a spectrometer and a synchronous signal generator; the high-speed camera is positioned near the molten pool, the spectrometer probe is used for measuring plasma/metal vapor generated in the molten pool, and the spectrometer is used for collecting data measured by the spectrometer probe; the high-speed camera, the illuminating device and the spectrometer are connected with the synchronous signal generator, so that when the high-speed camera collects images, the illuminating device is in an illuminating state, and the high-speed camera and the spectrometer are ensured to collect data simultaneously.
Further, a high-frequency induction heating system is also included; the high-frequency induction heating system comprises a high-frequency induction heating coil and a high-frequency induction heating power supply, wherein the high-frequency induction heating coil is positioned at the bottom of the base material, and the high-frequency induction heating power supply is connected with the high-frequency induction heating coil and used for heating the base material.
A method of using a laser additive device for additive manufacturing, comprising:
outputting rotary continuous laser by a rotary beam laser device to melt and deposit the filament on the surface of the base material;
inputting high-frequency short pulse laser into a molten pool through a high-frequency short pulse laser device;
further, the method also comprises the following steps:
electromagnetic waves are generated inside the molten pool: forming a current loop by the wire and the molten pool, so that strong electromagnetic force is directly generated in the molten pool;
preheating a base material: preheating the substrate by a high-frequency induction heating system;
online monitoring of the quality of a deposited layer: and detecting plasma/metal vapor generated in the molten pool in real time through an information acquisition system, judging the quality of a deposited layer, and dynamically adjusting parameters of the rotary beam laser device, the high-frequency short pulse laser device and the auxiliary current device according to the judgment result by a control computer.
The invention has the beneficial effects that:
1. according to the laser additive manufacturing device, the optical rotation module is arranged in the continuous laser head, light beams rotate in the additive manufacturing process, the uniform distribution of the energy and temperature fields in a single molten pool is ensured, and the problems that the melting channel boundary is not clear and irregular, the flatness of a deposited layer is poor, the interlayer bonding strength is low and the like due to the uneven energy distribution of linear light beams are solved.
2. The laser material increasing device can ensure that the energy and temperature fields in a single molten pool are uniformly distributed by the continuous light beam rotation, is beneficial to generating a uniform electromagnetic field in the molten pool by current, and realizes the full and uniform stirring in the molten pool by the metal liquid in the molten pool rotating along with the rotation of the focus.
3. According to the laser material increase device, the auxiliary current is provided for the molten pool through the additional electrode, strong electromagnetic force is directly generated inside the molten pool, the current is not easy to lose through a base material, and the liquid metal inside the molten pool is promoted to rapidly and controllably flow so as to achieve the purpose of heat balance distribution.
4. The laser material increasing device provided by the invention directly acts in a molten pool through a high-frequency short pulse laser beam to generate cavitation and crushing effects in the molten pool, and the three components are coupled to uniformly and fully stir the molten pool in cooperation with the action of electromagnetic force and rotating light beams on the molten pool, so that the aims of eliminating or inhibiting various metallurgical defects in a component and releasing thermal stress are fulfilled.
5. The laser material increase method provided by the invention is used for judging whether the quality of a deposition layer is good or not by taking the state of plasma/metal steam in a molten pool as a criterion. The plasma/metal vapor information in the molten pool is collected by using a high-speed camera and a spectrometer, the collected information is transmitted to a control computer, the internal condition of the molten pool is known according to the plasma/metal vapor information, the quality performance of a deposition layer is judged, high-frequency short-pulse laser parameters, continuous laser parameters, auxiliary power supply parameters and light beam rotation parameters are regulated and controlled in real time according to a judgment result, and the whole device forms a closed-loop system, so that the systematization, automation and intellectualization are realized, the preparation time and cost are saved, and the efficiency and the quality are improved.
6. The laser material adding device provided by the invention has the advantages that the high-frequency short pulse laser and the high-density current are used for cooperating with the rotating laser beam to simultaneously stir the molten pool, the plasma/metal vapor information in the molten pool is collected through the high-speed camera and the spectrometer, the collected information is transmitted to the control computer, the internal condition of the molten pool is known according to the plasma/metal vapor information, the quality performance of a deposition layer is judged, the high-frequency short pulse laser parameter, the continuous laser parameter, the auxiliary power supply parameter and the light beam rotating parameter are regulated and controlled in real time according to the judgment result, and the aims of inhibiting metallurgical defects, optimizing microstructure and improving mechanical property of a material adding component are fulfilled.
Drawings
Fig. 1 is a schematic view of a laser additive manufacturing apparatus according to the present invention.
Fig. 2 is a partial top view of a laser additive apparatus according to the present invention.
Fig. 3 is a graph comparing residual stress of additive components prepared by different methods.
Fig. 4 is a graph comparing tensile strength of additive components prepared by different methods.
FIG. 5 shows the microstructure of a titanium alloy component prepared by the laser additive manufacturing method in the prior art.
FIG. 6 shows the microstructure of the titanium alloy member prepared by the present invention.
In the figure:
1-a continuous laser generator; 2-a first high precision mechanical arm; 3-high frequency short pulse laser generator; 4-high frequency short pulse laser head; 5-a second high-precision mechanical arm; 6-wire feeder; 7-a power supply device; 8-additional rolling electrodes; 9-continuous laser head; 10-a molten pool; 11-a high frequency induction heating coil; 12-a deposition layer; 13-a substrate; 14-high frequency induction heating power supply; 15-control computer; 16-a high-speed camera; 17-a synchronization signal generator; 18-a spectrometer; 19-plasma/metal vapor; 20-a lighting device; 21-spectrometer probe.
Detailed Description
The invention will be further described with reference to the following figures and specific examples, but the scope of the invention is not limited thereto.
As shown in fig. 1 and fig. 2, the laser additive manufacturing apparatus according to the present invention includes a rotating beam laser device, a high-frequency short pulse laser device, an auxiliary current device, an information acquisition system, a high-frequency induction heating system, and a control computer 15.
The rotary beam laser device comprises a continuous laser generator 1, a first high-precision mechanical arm 2, a wire feeder 6 and a continuous laser head 9; the continuous laser generator 1 is connected with the continuous laser head 9 and provides a continuous laser light source for the continuous laser generator; an optical rotation module is arranged in the continuous laser head 9, and a laser beam generates a rotating light beam in the emission process; the continuous laser head 9 is arranged on the first high-precision mechanical arm 2; the wire feeder 6 conveys the wire to the center of the rotating continuous laser beam until the wire is deposited on the surface of the base material, and the wire feeder is used for feeding wires coaxially in the light; through the built-in optical rotation module in the continuous laser head 9, the light beam rotates in the material increase manufacturing process, the distribution of the internal energy and the temperature field of a single molten pool 10 is ensured to be uniform, and the problems that the energy distribution of a straight line light beam is not uniform, the boundary of a molten channel is not clear and irregular, the flatness of a deposited layer is poor, the bonding strength between layers is low and the like are solved.
The high-frequency short pulse laser device comprises a high-frequency short pulse laser generator 3, a high-frequency short pulse laser head 4 and a second high-precision mechanical arm 5, wherein the high-frequency short pulse laser generator 3 is connected with the high-frequency short pulse laser head 4 and provides a pulse laser light source for the high-frequency short pulse laser head 4, and the high-frequency short pulse laser head 4 is installed on the second high-precision mechanical arm 5; the high-frequency short pulse laser head 4 is positioned beside the continuous laser head 9, is aligned to the molten pool 10 and continuously provides a pulse laser beam into the molten pool 10; the high-frequency short pulse laser beam directly acts inside the molten pool 10 to generate cavitation and crushing effects inside the molten pool 10, and the three parts are coupled to uniformly and fully stir the molten pool in cooperation with the action of electromagnetic force and rotating light beams on the molten pool, so that the aims of eliminating or inhibiting various metallurgical defects inside components and releasing thermal stress are fulfilled.
Said auxiliary current means comprise power supply means 7 and an additional rolling electrode 8. One output stage of the power supply device 7 is connected with the wire, the other output stage is connected with an additional rolling electrode 8 which is positioned at the rear side of the molten pool 10 and is contacted with the surface of the deposition layer, and current passes through the molten pool to form a current loop. The additional rolling electrode 8 is fixed at the side of the continuous laser head 9 and does not interfere with the high-frequency short pulse laser head 4; the auxiliary current is provided for the molten pool through the additional electrode, strong electromagnetic force is directly generated in the molten pool, the current is not easy to lose through a base material, and the liquid metal in the molten pool is promoted to rapidly and controllably flow so as to achieve the purpose of heat balance distribution.
The information acquisition system includes a high speed camera 16, an illumination device 20, a spectrometer probe 21, a spectrometer 18 and a synchronization signal generator 17 located alongside the molten bath 10. A spectrometer probe 21 arranged near the molten pool 10 is aligned with the plasma/metal vapor 19, a spectrometer 18 is connected with the spectrometer probe 21, and data measured by the spectrometer probe 21 are collected; the high-speed camera 16, the illumination device 20 and the spectrometer 18 are connected to the synchronization signal generator 17, so that the illumination device 20 is in an illumination state when the high-speed camera 16 collects images, and the high-speed camera 16 and the spectrometer 18 are ensured to collect data at the same time. The condition of the quality of the deposition layer is judged by taking the state of the plasma/metal vapor 19 in the molten pool 10 as a criterion. The method comprises the steps of collecting plasma/metal vapor 19 information in a molten pool 10 by using a high-speed camera 16 and a spectrometer 18, transmitting the collected information to a control computer 15, knowing the internal condition of the molten pool 10 according to the plasma/metal vapor 19 information, judging the quality performance of a deposition layer 12, and regulating and controlling high-frequency short pulse laser parameters, continuous laser parameters, auxiliary power supply parameters and light beam rotation parameters in real time according to a judgment result, wherein the whole device forms a closed-loop system, thereby realizing systematization, automation and intellectualization, saving preparation time and cost, and improving efficiency and quality. The shooting speed of a high-speed camera 16 of the information acquisition system reaches 40000 frames per second at most, and the dynamic range reaches 160 dB; the spectrometer 18 can measure the wavelength range of 200-1100nm, and the highest resolution is 0.04 nm.
The high-frequency induction heating system includes a high-frequency induction heating coil 11 and a high-frequency induction heating power supply 14. The high-frequency induction heating power supply 14 is connected with the high-frequency induction heating coil 11 to provide electric energy for the high-frequency induction heating coil to heat the base material 13 placed on the high-precision two-dimensional moving platform; the high-precision two-dimensional moving platform can move in the X, Y direction or be linked in the X and Y directions in the horizontal plane.
The rotary beam laser device, the high-frequency short pulse laser device, the auxiliary current device, the information acquisition system, the high-frequency induction heating system and the high-precision two-dimensional moving platform are all connected with the control computer 15. The information acquisition system feeds back the acquired information to the control computer 15, and the control computer 15 adjusts the technological parameters of the rotary beam laser device, the high-frequency short pulse laser device, the wire feeding system and the auxiliary current device in real time to complete material deposition.
In the following, taking laser additive manufacturing of titanium alloy as an example, a laser additive manufacturing method according to the present invention is used, and a schematic diagram of the apparatus is shown in fig. 1. The method comprises the following specific steps:
A. establishing a three-dimensional model of the additive component in the control computer 15, slicing the model by using built-in software, acquiring profile information of the component, and compiling a continuous laser beam scanning path in the control computer 15 according to the shape information;
B. initializing a high-precision two-dimensional mobile platform, a continuous laser generator 1 and a high-frequency short pulse laser generator 3;
C. turning on a high-frequency induction heating power supply 14, setting a temperature value of a high-frequency induction heating coil 11, and preheating the base material to enable the temperature of the base material to reach 300 ℃;
D. after the base material is preheated to the designated temperature, the high-speed camera 16, the lighting device 20, the spectrometer probe 21, the spectrometer 18 and the synchronous signal generator 17 are turned on;
E. opening the continuous laser generator 1, the high-frequency short pulse laser generator 3, the wire feeder 6 and the power supply device 7 to realize the high-frequency short pulse laser-current coupling auxiliary rotating beam laser additive manufacturing processing; initial continuous laser generator parameters are set as: the laser power is 1500W, the diameter of a light spot is 2mm, the lap joint rate is 50 percent, and the powder feeding rate is 25 g/min; the optical rotation module is arranged as follows: the rotation rating is 1500min-1The beam deflection angle is 3 degrees, and the radius of the rotating beam path is 1.5 mm; the parameters of the initial high-frequency short pulse laser generator are set as follows: the center wavelength is 1030nm, the maximum output power is 80W, the pulse output energy is 80 muJ, and the pulse width is 100 fs. The initial wire feeding speed is 900 mm/min; the initial power supply means current is set to 100A.
F. In the additive manufacturing process, the quality of the deposition layer 12 is judged according to the plasma/metal steam 19 information obtained by the high-speed camera 16 and the spectrometer probe 21, and the process parameters of the continuous laser generator 1, the high-frequency short-pulse laser generator 3, the wire feeder 6 and the power supply device 7 are adjusted in real time.
G. And closing all the devices after the additive manufacturing process is finished.
The measurement conditions of the residual stress and the tensile strength of the blocky titanium alloy sample prepared by the common laser additive manufacturing method, the electromagnetic auxiliary laser additive manufacturing method and the method are respectively shown in fig. 3 and 4, and the titanium alloy prepared by the device and the method has the lowest residual stress and the maximum tensile strength; observation of the microstructure showed. In fig. 3 and 4, the right-most drawing shows a titanium alloy sample produced by the method according to the present invention.
As shown in fig. 5, the titanium alloy prepared by the common laser additive manufacturing method has coarse grains, uneven distribution of the grain structure, anisotropy, obvious defects such as pores, cracks and the like; as shown in fig. 6, the titanium alloy prepared by the laser additive manufacturing method of the present invention combines the high-frequency short pulse laser, the high-density current, and the rotating laser beam in cooperation, and the three are coupled to assist the laser additive manufacturing, has a compact and uniform structure, fine crystal grains, no defects such as pores and cracks, and can significantly improve the comprehensive mechanical properties of the titanium alloy.
The present invention is not limited to the above-described embodiments, and any obvious improvements, substitutions or modifications can be made by those skilled in the art without departing from the spirit of the present invention.
Claims (10)
1. A laser additive device is characterized by comprising a rotating beam laser device and a high-frequency short pulse laser device;
the rotating beam laser device outputs rotating continuous laser which is used for melting and depositing the wire on the surface of the base material (13);
the high-frequency short pulse laser device outputs high-frequency short pulse laser, the high-frequency short pulse laser is used for inputting pulse laser beams into a molten pool (10) of liquid metal, the output energy of the pulse laser beams is 80 muJ, and the output pulse width of the pulse laser beams is 100 fs.
2. The laser additive device of claim 1, further comprising an auxiliary current device; the auxiliary current device is used for enabling the wire and the molten pool (10) to form a current loop and enabling the interior of the molten pool (10) to directly generate strong electromagnetic force.
3. The laser additive device according to claim 1, wherein the rotating beam laser device comprises a continuum laser generator (1), a first high precision robotic arm (2), and a continuum laser head (9); the continuous laser generator (1) is connected with a continuous laser head (9); the continuous laser head (9) is arranged on the first high-precision mechanical arm (2); the wire feeder (6) is used for feeding wires into the continuous laser head (9).
4. Laser additive device according to claim 3, characterized in that an optical rotation module is built in the continuous laser head (9) for generating a rotating beam.
5. The laser additive apparatus according to claim 1, wherein the high-frequency short pulse laser apparatus comprises a high-frequency short pulse laser generator (3), a high-frequency short pulse laser head (4), and a second high-precision robot arm (5); the high-frequency short pulse laser generator (3) is connected with the high-frequency short pulse laser head (4); the high-frequency short-pulse laser head (4) is arranged on a second high-precision mechanical arm (5); the high-frequency short pulse laser head (4) is located beside the continuous laser head (9), and the high-frequency short pulse laser head (4) is aligned to a molten pool (10) on the surface of the substrate (13) and is used for continuously providing a pulse laser beam into the molten pool (10).
6. Laser additive device according to claim 2, wherein said auxiliary current device comprises a power supply device (7) and an additional rolling electrode (8); one end of the power supply device (7) is connected with the wire, the other end of the power supply device (7) is connected with the additional rolling electrode (8), and the additional rolling electrode (8) is located on the rear side of the molten pool (10) and is in surface contact with the deposition layer (12) to form a current loop.
7. The laser additive device of any one of claims 1-6, further comprising an information acquisition system; the information acquisition system comprises a high-speed camera (16), an illuminating device (20), a spectrometer probe (21), a spectrometer (18) and a synchronous signal generator (17); the high-speed camera (16) is positioned near the molten bath (10), the spectrometer probe (21) is used for measuring plasma/metal vapor (19) generated in the molten bath (10), and the spectrometer (18) is used for collecting data measured by the spectrometer probe (21); the high-speed camera (16), the lighting device (20) and the spectrometer (18) are connected with the synchronous signal generator (17), so that when the high-speed camera (16) collects images, the lighting device (20) is in a lighting state, and the high-speed camera (16) and the spectrometer (18) are ensured to collect data simultaneously.
8. The laser additive apparatus of any one of claims 1-6, further comprising a high frequency induction heating system; the high-frequency induction heating system comprises a high-frequency induction heating coil (11) and a high-frequency induction heating power supply (14), wherein the high-frequency induction heating coil (11) is positioned at the bottom of a base material (13), and the high-frequency induction heating power supply (14) is connected with the high-frequency induction heating coil (11) and used for heating the base material (13).
9. A method of laser additive manufacturing according to claim 1, comprising the steps of:
outputting rotating continuous laser through a rotating beam laser device to melt and deposit the filament on the surface of the base material (13);
inputting high-frequency short pulse laser into a molten pool (10) through a high-frequency short pulse laser device; the output energy of the pulse laser beam is 80 muJ, and the output pulse width of the pulse laser beam is 100 fs.
10. The method for laser additive manufacturing of claim 9, further comprising the steps of:
electromagnetic waves are generated inside the molten pool (10): forming a current loop by the wire and the molten pool (10) to directly generate strong electromagnetic force in the molten pool (10);
preheating base material (13): preheating the substrate (13) by means of a high-frequency induction heating system;
on-line monitoring of the quality of the deposit (12): and detecting plasma/metal steam (19) generated in the molten pool (10) in real time through an information acquisition system, judging the quality of the deposition layer (12), and dynamically adjusting parameters of a rotating beam laser device, a high-frequency short-pulse laser device and an auxiliary current device by a control computer (15) according to the judgment result.
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