CN111549357A - Anode steel claw head repairing method and application thereof - Google Patents
Anode steel claw head repairing method and application thereof Download PDFInfo
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- CN111549357A CN111549357A CN202010416875.5A CN202010416875A CN111549357A CN 111549357 A CN111549357 A CN 111549357A CN 202010416875 A CN202010416875 A CN 202010416875A CN 111549357 A CN111549357 A CN 111549357A
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- C25C3/00—Electrolytic production, recovery or refining of metals by electrolysis of melts
- C25C3/06—Electrolytic production, recovery or refining of metals by electrolysis of melts of aluminium
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- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract
The invention provides a method for repairing an anode steel claw head and application thereof, and relates to the technical field of electrolytic aluminum production, wherein the method for repairing the anode steel claw head comprises the following steps: and repairing the anode steel claw head to be repaired by using 3D printing. The repairing method is simple and efficient, can quickly recover the original radial dimension of the burnt anode steel claw, and has the advantages of high automation degree, high repairing efficiency and strong practicability.
Description
Technical Field
The invention relates to the technical field of electrolytic aluminum production, in particular to a method for repairing an anode steel claw head and application thereof.
Background
The anode steel claw is a device accessory which is used more in the electrolytic aluminum production process, and is very easy to corrode in a high-temperature and high-current operation environment due to the long-time contact with electrolytic aluminum liquid, so that the consumption is high, and the repair task is heavy. For a long time, domestic electrolytic aluminum enterprises adopt a manual electric arc welding method, namely a traditional girth welding method, for repairing the anode steel claw, but due to the limitations of weldment groove processing and welding processes, the welding method is low in efficiency, and the welding joint has the defects of small welding area, low joint strength, large resistivity, short service life and the like, so that the control of the electrolytic aluminum enterprises on the production cost is seriously influenced and limited.
In view of the defects of the conventional welding method, in recent years, related researchers developed some new repairing methods, and have already been put into use, such as fusion casting technology, surfacing welding, electroslag welding, automatic narrow gap arc welding, brazing and the like. The method overcomes the defects of low strength and large resistivity of the anode steel claw repaired by the girth welding method to a certain extent, but has limitations, such as large investment of casting technology equipment, large floor area and poor safety; the surfacing method, the electroslag welding and the automatic narrow-gap arc welding all need auxiliary round steel bars and connecting pieces, and the early preparation workload is large; the brazing method has high requirements on assembly precision and high requirements on the technical level of workers.
In view of the above, the present invention is particularly proposed.
Disclosure of Invention
The invention aims to provide a method for repairing an anode steel claw head, which is simple and efficient, can quickly recover the original radial dimension of a burning-out anode steel claw, and has the advantages of high automation degree, high repairing efficiency and strong practicability.
The invention provides a method for repairing an anode steel claw head, which comprises the following steps:
and repairing the anode steel claw head to be repaired by using 3D printing.
Further, comprising:
performing Boolean difference operation on the model of the regular anode steel claw head and the model of the anode steel claw head to be repaired to obtain a manufacturing model to be subjected to material increase;
and 3D printing is carried out on the anode steel claw head to be repaired by using the model to be additively manufactured, so that the repair of the anode steel claw head to be repaired is completed.
Further, the 3D printing the anode steel claw head to be repaired by using the model to be additively manufactured comprises:
dividing the model to be additively manufactured into a filling model and a cover model;
sequentially utilizing the filling model and the cover surface model to perform 3D printing on the anode steel claw head to be repaired;
preferably, after the filling model and the cover model are sliced, 3D printing is carried out on the anode steel claw head to be repaired;
preferably, the 3D printing comprises arc 3D printing.
Further, the ratio of the thickness of the cover surface model to the diameter of the anode steel claw head to be repaired is 1: 5-10.
Furthermore, the slice thickness of the filling model is 4-7 mm,
and/or the thickness of the section of the cover surface model is 3-5 mm.
Further, the material for 3D printing includes a metal wire;
preferably, the metal wire used for 3D printing on the anode steel claw head to be repaired by using the filling model comprises a low alloy steel welding wire;
preferably, the yield strength of the low alloy steel welding wire is 200-350 MPa;
preferably, the metal wire used for 3D printing on the anode steel claw head to be repaired by using the capping model includes at least one of a nickel-chromium welding wire, a nickel-chromium-molybdenum welding wire and a nickel-chromium-tungsten-molybdenum welding wire.
Further, a model of the anode steel claw head to be repaired is reconstructed by adopting a reverse engineering method, and/or
Building a model of the regular anode steel claw head by adopting three-dimensional software;
preferably, the reverse engineering software comprises at least one of Imageware, geogenic Studio, CopyCAD, and RapidForm;
preferably, the three-dimensional software comprises at least one of UG, pro, and SolidWorks.
Further, 3D printing is carried out on the anode steel claw head to be repaired by using the cover surface model to obtain a cover surface layer, and the cover surface layer is subjected to smoothing treatment;
preferably, the smoothing process comprises grinding.
Further, the anode steel claw head to be repaired is pretreated, wherein the pretreatment comprises cleaning treatment on the anode steel claw head to be repaired;
preferably, the cleaning treatment comprises a grit blasting treatment and/or a sanding treatment.
Use of a method of reconditioning as hereinbefore described in an electrolytic aluminium production process.
Compared with the prior art, the invention can at least obtain the following beneficial effects:
the anode steel claw repairing method is simple and efficient, can quickly recover the original radial dimension of the anode steel claw burning loss section, and is high in automation degree, repairing efficiency and feasibility; the repaired anode steel claw has high joint strength, low resistivity, long service life and greatly lowered comprehensive repairing cost.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
FIG. 1a is a schematic model view of an anode steel stud head to be repaired according to an embodiment of the present invention;
FIG. 1b is a schematic model view of an anode steel stud head to be repaired according to an embodiment of the present invention;
FIG. 2 is a schematic model of a regular anode steel jaw head according to an embodiment of the present invention;
FIG. 3 is a schematic view of a repaired anode steel stud head according to one embodiment of the present invention;
fig. 4 is a schematic view of a repaired anode steel stud head according to another embodiment of the present invention.
Detailed Description
Embodiments of the present invention will be described in detail below with reference to examples, but it will be understood by those skilled in the art that the following examples are only illustrative of the present invention and should not be construed as limiting the scope of the present invention. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.
In one aspect of the present invention, the present invention provides a method for repairing an anode steel stud head, the method comprising:
and repairing the anode steel claw head to be repaired by using 3D printing.
The anode steel claw repairing method is simple and efficient, can quickly recover the original radial dimension of the anode steel claw burning loss section, and is high in automation degree, repairing efficiency and feasibility; the repaired anode steel claw has high joint strength, low resistivity, long service life and greatly lowered comprehensive repairing cost.
It should be noted that the anode steel claw head may be corroded or burned during use, the anode steel claw head to be repaired refers to the corroded or burned anode steel claw head, and the anode steel claw head to be repaired may be a partially burned anode steel claw head or a fully burned anode steel claw head.
It can be understood that the repairing of the anode steel claw head to be repaired by using 3D printing is to complete the missing structure of the anode steel claw head to be repaired by using 3D printing.
In some embodiments of the present invention, the anode steel claw head to be repaired is subjected to a pretreatment, wherein the pretreatment comprises a cleaning treatment of the anode steel claw head to be repaired; preferably, the cleaning treatment comprises a grit blasting treatment and/or a sanding treatment. Therefore, the surface of the anode steel claw head after cleaning is smoother and cleaner, subsequent 3D printing is facilitated, materials printed on the surface of the anode steel claw head to be repaired are combined with the anode steel claw head to be repaired more closely, and the strength of the anode steel claw head after repairing is facilitated to be improved.
It should be noted that, the cleaning of the anode steel claw head to be repaired means that the cleaning of the whole structure of the anode steel claw head to be repaired can be performed, and the cleaning of only the corroded or burnt part of the anode steel claw head can also be performed.
In some embodiments of the invention, the pre-treatment comprises the steps of:
and (3) carrying out sand blasting treatment on the burning section of the anode steel claw head to be repaired, removing rust, aluminum slag and residual graphite on the surface of the burning section, then polishing the burning section by using an angle grinder to ensure that the surface of the burning section is in a metallic luster, scrubbing by using alcohol, and drying for later use.
In some embodiments of the present invention, referring to fig. 1a, 1b and 2, the method for repairing an anode steel stud head comprises:
performing Boolean difference operation on the model 2 of the regular anode steel claw head and the model 1 of the anode steel claw head to be repaired to obtain a manufacturing model to be subjected to material increase;
and 3D printing is carried out on the anode steel claw head to be repaired by using the model to be additively manufactured, so that the repair of the anode steel claw head to be repaired is completed (the repaired anode steel claw head can refer to fig. 3 and 4).
Therefore, the structure of the difference between the regular anode steel claw head and the anode steel claw head to be repaired can be accurately obtained, and the anode steel claw head to be repaired can be accurately repaired by performing 3D printing on the anode steel claw head to be repaired by using the model of the structure.
It is understood that the model of the regular anode steel jaw head and the model of the anode steel jaw head to be repaired refer to software models with process parameters.
It should be noted that the regular anode steel claw head refers to an anode steel claw head without any burning loss or defect; and in the process of performing 3D printing on the anode steel claw head to be repaired by using the model to be additively manufactured, putting the anode steel claw head to be repaired into a 3D printer, and directly performing 3D printing on the surface of the anode steel claw head to be repaired so as to restore the anode steel claw head to be repaired to the structure of a regular anode steel claw head.
In some embodiments of the invention, the model of the anode steel claw head to be repaired is reconstructed by a reverse engineering method, and/or the model of the regular anode steel claw head is constructed by three-dimensional software.
Therefore, the model of the anode steel claw head to be repaired and the model of the regular anode steel claw head can be accurately obtained.
In some embodiments of the present invention, when the anode steel stud model to be repaired is reconstructed by using a reverse engineering method, a 3D scanner is first used to perform 3D scanning on the anode steel stud to be repaired, scanning point cloud data is obtained, then the scanning point cloud is processed and optimized by using reverse engineering software to generate a regular result point cloud, a NURBS curved surface is constructed according to the regular result point cloud and is input to 3D CAD software, and the anode steel stud model to be repaired is formed.
In some embodiments of the invention, the reverse engineered software comprises at least one of Imageware, GeomagicStudio, CopyCAD, and RapidForm; the three-dimensional software comprises at least one of UG, PROE and SolidWorks. Therefore, the model of the anode steel claw head to be repaired and the model of the regular anode steel claw head can be obtained more accurately.
In some embodiments of the invention, referring to fig. 3 and 4, the 3D printing of the anode steel claw head to be repaired using the model to be additively manufactured comprises:
dividing the model to be additively manufactured into a filling model 21 and a facing model 22;
and 3D printing is carried out on the anode steel claw head to be repaired by sequentially utilizing the filling model 21 and the cover surface model 22.
Therefore, the filling model is firstly used for conducting 3D printing on the anode steel claw head to be repaired to fill the vacancy of the anode steel claw head to be repaired, and then the cover model is used for conducting 3D printing on the anode steel claw head to be repaired to restore the diameter of the anode steel claw head to be repaired to the diameter of the regular anode steel claw head (the repaired anode steel claw head can refer to fig. 3 and 4).
It should be noted that, the step of performing 3D printing on the anode steel claw head to be repaired by using the filling model and the capping model is to set process parameters of the filling model and the capping model in a computer according to the filling model and the capping model, and perform 3D printing according to the process parameters.
In some embodiments of the invention, the ratio of the thickness of the capping model to the diameter of the anode steel claw head to be repaired is 1:5 (5: 10), and may be, for example, 1:5, 1:6, 1:7, 1:8, 1:9, or 1: 10. Compared with the diameter ratio range, when the ratio of the thickness of the cover surface model to the diameter of the anode steel claw head to be repaired is larger than 1:10, the thickness of the cover surface layer is larger, and the thickness of the filling layer is smaller, because the cover surface layer adopts a nickel-chromium welding wire, a nickel-chromium-molybdenum welding wire and a nickel-chromium-tungsten-molybdenum welding wire, the thicker cover surface layer generates larger stress, cracks and other defects, the conductivity of the repaired anode steel claw head is not favorably improved, in addition, the prices of Ni, Cr and Mo are expensive, and the cost is increased; when the ratio of the thickness of the cover surface model to the diameter of the anode steel claw head to be repaired is less than 1:5, the cover surface layer is thin, and electric arc cladding adopts small heat input, so that the fusion depth is reduced, and the 3D printing efficiency is reduced.
In some embodiments of the invention, the filling model and the capping model are sliced and then 3D printed on the anode steel claw head to be repaired. Thereby, the slicing operation facilitates the subsequent 3D printing.
In some embodiments of the present invention, the filling mold has a slice thickness of 4 to 7mm (e.g., 4mm, 5mm, 6mm, or 7mm, etc.), and/or the cover mold has a slice thickness of 3 to 5mm (e.g., 3mm, 4mm, or 5mm, etc.). Compared with the thickness range, when the slice thickness of the filling model is too thick, the fusion depth of arc cladding is larger, so that the heat input is larger, the residual stress of cladding metal of the filling layer is increased, the width of a heat affected zone is increased, and the performance of the heat affected zone is reduced; when the section thickness of capping model was too thick, then increased the quantity of nickel-chromium welding wire, nickel-chromium molybdenum welding wire or nickel-chromium tungsten molybdenum welding wire, Ni, Cr, Mo are expensive, increase cost, thicker capping layer produces great stress simultaneously, forms defects such as crackle, is unfavorable for improving the electric conductivity of restoreing back positive pole steel claw head, when the section thickness of capping model was too thin, then arc cladding adopted less heat input, reduced the penetration, reduced 3D printing efficiency.
In some embodiments of the invention, the 3D printing comprises arc 3D printing.
In some embodiments of the invention, the material from which the 3D printing is performed comprises a metal wire. Therefore, the anode steel claw head which is printed and repaired by using the metal wire has higher strength.
In some embodiments of the invention, the metal wire used for 3D printing on the anode steel claw to be repaired by using the filling model comprises a low alloy steel welding wire; the yield strength of the low alloy steel welding wire is 200-350 MPa. Therefore, the repaired anode steel claw head has higher strength.
In some embodiments of the invention, the metal wire used for 3D printing on the anode steel claw head to be repaired by using the capping model comprises at least one of a nickel-chromium welding wire, a nickel-chromium-molybdenum welding wire and a nickel-chromium-tungsten-molybdenum welding wire. Therefore, the material source is wide, the material is high-temperature resistant and high in strength, and the repaired anode steel claw head is good in performance.
In some embodiments of the present invention, a cover layer is obtained after 3D printing is performed on the anode steel claw head to be repaired by using the cover model, and the cover layer is smoothed. Therefore, after the smoothing treatment, the surface layer and the non-burning part can be in smooth transition, and the integrity is stronger.
In some embodiments of the invention, the smoothing process comprises sanding.
In another aspect of the invention, the invention provides the use of a method of reconditioning as hereinbefore described in an electrolytic aluminium production process.
It will be appreciated that damage to the anode steel stud head inevitably occurs during the electrolytic aluminium production process and the damaged anode steel stud head can be repaired using the method described hereinbefore.
Some embodiments of the present invention will be described in detail below with reference to specific embodiments. The embodiments described below and the features of the embodiments can be combined with each other without conflict.
Examples
Example 1
The anode steel claw head repairing method comprises the following steps:
step one, early preparation: carrying out sand blasting treatment on a burning section of the anode steel claw head to be repaired, removing rust, aluminum slag and residual graphite on the surface of the burning section, then polishing the burning section by an angle grinder to enable the surface of the burning section to be in metal luster, scrubbing by adopting alcohol, and drying for later use;
step two, three-dimensional modeling: constructing the anode steel claw head model to be repaired, which is processed in the first step, by adopting a reverse engineering method, constructing a regular anode steel claw head model by adopting three-dimensional software (UG), performing Boolean difference operation on the regular anode steel claw head model and the anode steel claw head model to be repaired to obtain a manufacturing model to be additively manufactured,
when the anode steel claw head model to be repaired is reconstructed by adopting a reverse engineering method, a 3D scanner is adopted to carry out 3D scanning on an anode steel claw burning loss section to obtain scanning point cloud data, then reverse engineering software (Imageware) is adopted to process and optimize the scanning point cloud to generate regular result point cloud, a NURBS curved surface is constructed according to the regular result point cloud and is input into 3D CAD software, and the anode steel claw head model to be repaired is formed;
thirdly, the to-be-repaired additive manufacturing model is divided into a filling model and a cover model, and the ratio of the thickness of the cover model to the diameter of the to-be-repaired anode steel claw head is 1: 8;
step four, slicing the model: selecting metal wire electric arc material increase 3D printing equipment, and slicing the filling model and the cover model by adopting slicing software of the 3D printing equipment, wherein the slice thickness of the filling model is 4mm, and the slice thickness of the cover model is 3 mm;
step five, additive repair: setting 3D printing technological parameters of the filling layer, and printing a filling model by adopting a low alloy steel welding wire with the yield strength of 300 Mpa; setting the 3D printing technological parameters of the cover surface layer, and printing the cover surface model by adopting a nickel-chromium welding wire;
step six, post-processing: and after printing, polishing the 3D printing covering layer to enable the covering layer to be in smooth transition with the part without burning loss of the steel claw head, and finishing the repair of the anode steel claw head.
Example 2
The repairing method of the anode steel claw head is the same as that in the embodiment 1, except that the slice thickness of the filling model is 7mm, and the slice thickness of the cover model is 5 mm.
Example 3
The repairing method of the anode steel claw head is the same as that in the embodiment 1, except that the slice thickness of the filling model is 6mm, and the slice thickness of the cover model is 6 mm.
Example 4
The repairing method of the anode steel claw head is the same as that in the embodiment 1, except that the slice thickness of the filling model is 2mm, and the slice thickness of the cover model is 2 mm.
Example 5
The repairing method of the anode steel claw head is the same as that of the embodiment 1, except that the slice thickness of the filling model is 9mm, and the slice thickness of the cover model is 7 mm.
Comparative example 1
The anode steel claw head repairing method comprises the following steps:
firstly, completely cutting off a burning loss section of an anode steel claw head to be repaired, and repairing a cutting surface into a plane; selecting a section of round steel bar with the same material and diameter as the anode steel claw head according to the design size of the steel claw head, and turning the end face of the round steel bar into a plane;
secondly, selecting an auxiliary connecting rod which is the same as or similar to the material of the anode steel claw head to be repaired, has the length of 15-35 mm and the diameter of 4-10 mm, and performing girth welding on the auxiliary connecting rod between the cutting surface of the anode steel claw head and the end surface of the round steel rod to ensure that the anode steel claw head, the auxiliary connecting rod and the round steel rod are coaxial, and forming an annular surfacing space between the anode steel claw head and the round steel rod; when the diameter of the auxiliary connecting rod is larger than or equal to 6mm, the two ends of the auxiliary connecting rod are in a truncated cone structure, the taper of the auxiliary connecting rod is 90 degrees, and the diameter of the truncated cone at the end part is 2 mm; when the diameter of the auxiliary connecting rod is less than 6mm, the auxiliary connecting rod is a cylinder;
and thirdly, adopting gas metal arc welding (the welding wire is a flux-cored wire) to weld the whole annular overlaying space to be solid, namely completing the welding repair of the anode steel claw head.
The anode steel claw heads repaired by the repair methods of examples 1 to 5 and comparative example 1, and new steel claw heads (i.e., the anode steel claw heads that were not used) were sampled and tested for their pressure drop, and the test results are shown in table 1 below:
TABLE 1
The voltage drop test method is to test the voltage drop of the sample by using a voltage drop tester.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. A method for repairing an anode steel claw head is characterized by comprising the following steps:
and repairing the anode steel claw head to be repaired by using 3D printing.
2. The repair method according to claim 1, comprising:
performing Boolean difference operation on the model of the regular anode steel claw head and the model of the anode steel claw head to be repaired to obtain a manufacturing model to be subjected to material increase;
and 3D printing is carried out on the anode steel claw head to be repaired by using the model to be additively manufactured, so that the repair of the anode steel claw head to be repaired is completed.
3. The repair method according to claim 2, wherein the 3D printing of the anode steel claw head to be repaired using the model to be additively manufactured comprises:
dividing the model to be additively manufactured into a filling model and a cover model;
sequentially utilizing the filling model and the cover surface model to perform 3D printing on the anode steel claw head to be repaired;
preferably, after the filling model and the cover model are sliced, 3D printing is carried out on the anode steel claw head to be repaired;
preferably, the 3D printing comprises arc 3D printing.
4. The method for repairing according to claim 3, wherein the ratio of the thickness of the cover surface model to the diameter of the anode steel claw to be repaired is 1:10 (5-10).
5. The repair method according to claim 3, wherein the filling pattern has a slice thickness of 4 to 7mm,
and/or the thickness of the section of the cover surface model is 3-5 mm.
6. The repair method according to claim 3, wherein the material subjected to 3D printing comprises a metal wire;
preferably, the metal wire used for 3D printing on the anode steel claw head to be repaired by using the filling model comprises a low alloy steel welding wire;
preferably, the yield strength of the low alloy steel welding wire is 200-350 MPa;
preferably, the metal wire used for 3D printing on the anode steel claw head to be repaired by using the capping model includes at least one of a nickel-chromium welding wire, a nickel-chromium-molybdenum welding wire and a nickel-chromium-tungsten-molybdenum welding wire.
7. Repair method according to any one of claims 2 to 6, characterized in that the model of the anode steel claw head to be repaired is reconstructed by means of reverse engineering and/or
Building a model of the regular anode steel claw head by adopting three-dimensional software;
preferably, the reverse engineering software comprises at least one of Imageware, geogenic Studio, CopyCAD, and RapidForm;
preferably, the three-dimensional software comprises at least one of UG, pro, and SolidWorks.
8. The repairing method according to claim 7, characterized in that the cover surface model is used for performing 3D printing on the anode steel claw head to be repaired to obtain a cover surface layer, and the cover surface layer is subjected to smoothing treatment;
preferably, the smoothing process comprises grinding.
9. The method for repairing according to any one of claims 1 to 6 and 8, wherein the anode steel claw head to be repaired is subjected to a pretreatment comprising a cleaning treatment of the anode steel claw head to be repaired;
preferably, the cleaning treatment comprises a grit blasting treatment and/or a sanding treatment.
10. Use of a method of remediation according to any one of claims 1 to 9 in an electrolytic aluminium production process.
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