CN114473145B - Control method for forming welding seam of aluminum steel heterogeneous metal arc welding - Google Patents
Control method for forming welding seam of aluminum steel heterogeneous metal arc welding Download PDFInfo
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- CN114473145B CN114473145B CN202111563745.5A CN202111563745A CN114473145B CN 114473145 B CN114473145 B CN 114473145B CN 202111563745 A CN202111563745 A CN 202111563745A CN 114473145 B CN114473145 B CN 114473145B
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- 239000010959 steel Substances 0.000 title claims abstract description 50
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 49
- 238000000034 method Methods 0.000 title claims abstract description 42
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 19
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/16—Arc welding or cutting making use of shielding gas
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/23—Arc welding or cutting taking account of the properties of the materials to be welded
- B23K9/232—Arc welding or cutting taking account of the properties of the materials to be welded of different metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2103/00—Materials to be soldered, welded or cut
- B23K2103/18—Dissimilar materials
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- Engineering & Computer Science (AREA)
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- Arc Welding In General (AREA)
Abstract
The invention belongs to the technical field of welding methods, and discloses a control method for forming an aluminum steel heterogeneous metal arc welding seam. The improved CMT circulating droplet welding is adopted, so that the periodical control of droplet transition and the size control of welding spots can be realized, the lower and controllable heat input is realized, the high welding quality repetition rate and attractive scale pattern welding seams are realized, meanwhile, the entropy alloy powder is coated at the lap joint position, the generation of brittle intermediate phases is reduced, the wetting and spreading performance of the brazing filler metal is improved, and the weldability of heterogeneous materials is expected to be obviously improved.
Description
Technical Field
The invention belongs to the technical field of welding methods, and relates to a control method for forming an aluminum steel heterogeneous metal arc welding seam.
Background
With the rapid development of society, the life rhythm of human beings is continuously accelerated, and high efficiency is pursued. Therefore, the transportation industry is also coming into rapid development, such as automobiles, rail transit, aerospace and the like. The rapid development of the industries brings great challenges to the environment for human survival while bringing convenience to us. In the automobile structure, the weight of the automobile body is about 40% of that of the whole automobile, and for the whole automobile, the oil consumption can be reduced by 6% -8% when the weight of the automobile is reduced by 10%, so that the reduction of the weight of the whole automobile is an effective means for realizing energy conservation, emission reduction and energy utilization rate improvement of the automobile, particularly for the currently emerging new energy automobile market, the reduction of the weight of the automobile, the improvement of the endurance mileage and the improvement of the electric energy utilization rate.
The lightweight structural design of the vehicle body has become an important and research hotspot for the current automobile manufacturing industry for the automobile manufacturing industry. Compared with the traditional steel vehicle body, the design of the future vehicle body is changed from the single high-strength steel application dominant into the multi-material mixed application of high-strength steel and light alloy (aluminum and magnesium) so as to realize the purpose of light weight of the vehicle. Aluminum and aluminum alloy have the advantages of light specific gravity, good plasticity, excellent heat conductivity, good corrosion resistance and the like, and the adoption of an aluminum alloy-steel composite structure is particularly important for reducing the self-quality of automobiles, reducing energy consumption and environmental pollution and improving the economic benefit of the automobiles, but the weldability of aluminum and aluminum alloy is poor, the physical and chemical properties of the aluminum and aluminum alloy and steel are huge, solid solution is difficult to form between iron and aluminum, and Fe and Al are easy to form intermetallic compounds with hard and brittle textures at interfaces, so that the toughness and plasticity of welded joints can be weakened.
In the welding of aluminum-steel dissimilar materials, friction welding, laser welding and electron beam welding can realize good connection of aluminum-steel, and a welded joint with good plastic toughness is obtained. However, friction welding and electron beam welding are subject to the shape and size of the material, while laser welding has high assembly accuracy for the components, and the above method is not suitable for wide popularization and application in industry. In addition, the welding heat input is reduced or different metal material intermediate layers are added in the welding process, so that the thickness of intermetallic compounds can be reduced, and high-quality welding of aluminum-steel dissimilar materials can be realized. The conventional fusion welding method such as MIG, TIG and the like is adopted, and the performance of the aluminum-steel heterojunction is deteriorated due to the problems of difficult control of intermetallic compound thickness, large defects and the like caused by excessive heat input. In order to solve the problem of effective control of heat input in the aluminum-steel welding process, a CMT (Cold METAL TRANSFER) Cold metal transition technology proposed by Fronius company can realize no splashing, small heat transfer, good bridging capability and high tolerance to assembly gaps compared with the common MIG welding, and is particularly suitable for automatic welding of aluminum-steel lap joints; however, the weld formability and the aesthetic properties are required to be further improved.
Disclosure of Invention
The invention provides a control method for forming an aluminum steel heterogeneous metal arc welding seam, which adopts improved CMT circulating droplet welding, can realize periodical control of droplet transition and size control of welding spots, has lower and controllable heat input, extremely high welding quality repetition rate and attractive scale pattern welding seam, simultaneously lays intermediate entropy alloy powder at a lap joint position, reduces the generation of brittle intermediate phase, improves the wetting spreading performance of brazing filler metal, and is expected to obviously improve the weldability of heterogeneous materials.
In order to achieve the above purpose, the present invention provides the following technical solutions:
A control method for forming welding seam of aluminum steel heterogeneous metal arc welding comprises the steps of fixing two workpieces to be welded on a welding workbench in a lap joint mode, paving a layer of entropy alloy powder on the surface of the lap joint, and welding the two workpieces by adopting a CMT circulating liquid drop method to form a smooth scale-shaped welding seam.
Further, the two workpieces are respectively arranged as an aluminum alloy workpiece and a galvanized steel workpiece, the two workpieces are fixedly arranged on a welding workbench by adopting a welding fixture in a lap joint mode under aluminum upper steel, then a layer of entropy alloy powder is coated on the surface of the galvanized steel workpiece of the lap joint, when the CMT circulating liquid drop method is adopted for welding, the cycle liquid drop period is set to be 2-10, and the cycle liquid drop interruption time is set to be 0.06-0.16s.
Further, the method comprises the following steps:
step one, preprocessing two workpieces to be welded
Firstly polishing by using coarse sand paper, then polishing by using fine sand paper to remove surface impurities, cleaning the surface of a galvanized steel workpiece by using absorbent cotton balls, then placing an aluminum alloy workpiece and the galvanized steel workpiece into alcohol for ultrasonic cleaning, and finally washing and drying;
Secondly, fixedly arranging two workpieces on a welding workbench in a lap joint mode under aluminum upper steel, and then coating a layer of entropy alloy powder on the surface of a galvanized steel workpiece at a lap joint;
thirdly, welding two workpieces by adopting a CMT circulating liquid drop method
During welding, the welding wire is biased towards the galvanized steel workpiece side, the offset from the aluminum alloy workpiece is set to be 0.5-1.5mm, the dry extension of the welding wire is set to be 10-12mm, the welding speed is set to be 0.39-0.55m/min, the wire feeding speed is set to be 4-6.5m/min, the welding gun pushing angle is set to be 95-120 degrees, and the side inclination angle is set to be 60-90 degrees.
Further, the thickness of the medium entropy alloy powder is set to be 200-600 mu m, and the mass ratio of the component formula is 20-50% of Cr, 20-50% of Co and 20-50% of Ni.
Further, the shielding gas is set to argon Ar, nitrogen N2 or a mixed gas of the argon Ar and the nitrogen N2, and the gas flow is set to 15L/min.
The beneficial technical effects of the invention are as follows:
Compared with the existing aluminum-steel fusion brazing process, the invention uses the CMT circulating liquid drop technology to carry out aluminum-steel fusion brazing, adopts ER4043 welding wires and coats a layer of entropy alloy powder on the surface of steel, and the aluminum-steel welding joint with excellent performance is obtained by adjusting welding process parameters, controlling welding heat input and reducing the thickness of interfacial intermetallic compounds. Under proper technological parameters, on one hand, the melted intermediate entropy alloy powder reacts with interface Fe atoms to generate Fe-Ni solid solution, so that the weld joint and interface structure can be alloyed, the diffusion of Al and Fe to generate brittle intermetallic compounds is prevented, the brittleness of the weld joint is reduced, the formed welding joint with attractive appearance, no cracks, few air holes and good plasticity is obtained, and meanwhile, liquid drops can be regulated and controlled to obtain the completely consistent scale pattern weld joint. The CMT circulating liquid drop fusion brazing method also greatly reduces the influence of a large amount of brittle and hard intermetallic compounds, deformation and the like on the quality of the joint due to large physical and chemical property difference of two materials, and simultaneously has the advantages of flexible and convenient operation, very low cost, high efficiency, high degree of automation and the like, and is easy to popularize and apply in industrial production.
Drawings
FIG. 1 is a schematic illustration of a CMT circulating droplet mode aluminum-steel braze welding of the present invention;
FIG. 2 is a side view of a schematic diagram of a welding process of the present invention;
FIG. 3 (a) is a macroscopic aluminum-steel weld obtained in the conventional CMT mode in example 1 of the present invention; FIG. 3 (b) is a macroscopic aluminum-steel weld obtained after the cyclic droplet cycle welding in example 2; FIG. 3 (c) is a macroscopic aluminum-steel weld obtained after welding with varying cycle droplet break-up time in example 2 of the present invention;
FIG. 4 shows an aluminum-steel macroscopic weld joint obtained after welding with the addition of a medium entropy alloy in example 3 of the present invention;
FIG. 5 (a) is a metallographic micrograph of an aluminum-steel welded joint prepared in the conventional CMT mode at a welding speed of 0.40m/min and a wire feed speed of 6.6m/min according to example 1 of the present invention; FIG. 5 (b) is a metallographic microscope image of the aluminum-steel welded joint prepared in example 2 of the present invention; FIG. 5 (c) is a metallographic microscope image of an aluminum-steel welded joint prepared by adding a medium entropy alloy in embodiment 3 of the present invention;
FIG. 6 (a-b) is an enlarged view of the reaction interface of an aluminum-steel welded joint prepared in the conventional CMT mode at a welding speed of 0.40m/min and a wire feed speed of 6.6m/min in example 1 of the present invention; FIG. 6 (c-d) is an enlarged view of the interface of the reaction layer of the aluminum-steel welded joint according to example 2 of the present invention; FIG. 6 (e-f) is an enlarged view of the interface of the reaction layer of the aluminum-steel welded joint after adding the medium entropy alloy according to an embodiment 3 of the present invention;
FIG. 7 (a) is a standard size schematic of the tensile test of the present invention; FIG. 7 (b) is a schematic diagram showing the fracture form of the tensile joint in example 2 of the present invention; FIGS. 7 (c) and (d) are schematic views showing the fracture form of the tensile joint in example 2 of the present invention; FIG. 7 (e) is a schematic diagram showing the fracture form of the tensile joint in example 3 of the present invention;
The welding fixture comprises a 1-galvanized steel sheet, a 2-aluminum alloy plate, a 3-welding wire, a 4-welding gun, a 5-backing plate, a 6-fixture table, a 7-lap length, an 8-medium entropy alloy powder layer, an alpha-welding gun inclination angle and a beta-side inclination angle.
Detailed Description
The following detailed description of the invention refers to the accompanying drawings and preferred embodiments.
The CMT circulating liquid drop process is improved from the traditional CMT process, not only has all the advantages of no splashing, low heat input, good welding quality and the like of the CMT technology, but also has the special advantages that: the method has the advantages of extremely high welding quality repetition rate, fully repeatable welding spot size, controllable heat input, perfect scale pattern welding seams and the like, and has particular advantages in aluminum-steel metal welding. According to the invention, aluminum-steel fusion brazing is performed based on a CMT circulating liquid drop technology, and the aluminum-steel dissimilar metal welding joint with attractive weld formation, thinner interface intermetallic compound and good weld repeatability is obtained by adding the medium entropy alloy powder in the welding process and optimizing the process parameters such as the process circulation times, the circulation interval time and the like in a set single period. The method comprises the following steps:
as shown in fig. 1 and 2, the invention provides a control method for forming an aluminum steel heterogeneous metal arc welding seam, which comprises the following steps:
step one, preprocessing two workpieces to be welded
Before welding, processing aluminum alloy and galvanized steel into flat samples by utilizing wire cutting, firstly polishing by using coarse sand paper, then polishing by using fine sand paper to remove impurities such as surface oxide films, cleaning the surfaces of galvanized steel workpieces by using absorbent cotton balls, then placing the aluminum alloy workpieces and the galvanized steel workpieces into alcohol for ultrasonic cleaning to remove impurities such as surface greasy dirt and particles, and finally washing and drying;
And secondly, fixedly arranging two workpieces on a welding workbench in a lap joint mode of aluminum upper steel and lower steel, wherein the lap joint length is about 5-15mm, and then paving a layer of medium entropy alloy powder on the surface of the galvanized steel workpiece of the lap joint, wherein the thickness of the medium entropy alloy powder is set to be 200-600 mu m, the mass ratio of the component formula is 20-50% of Cr, 20-50% of Co and 20-50% of Ni and Ni, and the medium powder layer can inhibit the formation and growth of brittle intermetallic compounds of an interface and promote the solid solution metallurgical effect of the interface.
And thirdly, welding the two workpieces by adopting a CMT circulating liquid drop method to form a flat scale-shaped welding seam.
The welding wire is ER4043 welding wire, is suitable for welding aluminum-steel or steel plates with galvanized layers, and comprises the following components in percentage by mass: 4.5% -6.0% of Si, 0.8% of Fe, 0.3% of Cu, 0.4% of other elements and the balance of Al, wherein the other elements are other components which are allowed to appear in the Al-Si alloy welding wire meeting the standard, the welding reaction of the main components Al and Si is not influenced, and the diameter of the welding wire is 1.2mm.
During welding, the welding wire is biased to the galvanized steel workpiece side, the offset from the aluminum alloy workpiece is set to be 0.5-1.5mm, the dry extension of the welding wire is set to be 10-12mm, the pushing angle of a welding gun is set to be 95-120 degrees, the side inclination angle is set to be 60-90 degrees, and the parameters of the CMT circulating liquid drop welding process are as follows: the welding speed is set to be 0.39-0.55m/min, the wire feeding speed is set to be 4-6.5m/min, the cycle liquid drop period is set to be 2-10, and the cycle liquid drop interruption time is set to be 0.06-0.16s.
To verify the feasibility of the welding method of the present invention, we performed the following experiments:
Example 1
S1, preparing a welding material:
Galvanized steel work piece: the dimensions are 120mm by 50mm, and the thickness is 1.3mm.
Aluminum alloy workpiece: the dimensions are 120mm by 50mm, and the thickness is 2.0mm.
The welding wire is an aluminum-steel AlSi5 series welding wire suitable for welding, and the diameter of the welding wire is 1.2mm. The Al-Si alloy welding wire comprises the following components in percentage by mass: 4.5% -6.0% of Si, 0.8% of Fe, 0.3% of Cu, 0.4% of other elements, and the balance of Al, wherein the other elements are other components which are allowed to appear in the ER4043 Al-Si alloy welding wire meeting the standard, and the welding reaction of the main components Al and Si is not influenced.
The arc welding power supply system used is TPS 600i welding power supply, and common CMT mode is selected for aluminum-steel welding.
Step S2, preparing work before welding:
1. And removing surface burrs of the wire-cut aluminum alloy and galvanized steel workpiece sample by using an angle grinder.
2. Polishing the surface of the processed aluminum alloy sample sequentially with 400# coarse sand paper and 1500# fine sand paper until the surface is shiny, removing impurities such as oxide films on the surface, repeatedly wiping and cleaning the surface of galvanized steel with alcohol-dipped absorbent cotton balls, putting the aluminum alloy and the galvanized steel into alcohol for ultrasonic cleaning for 3-5 minutes, removing impurities such as oil stains and particles on the surface, washing with alcohol, and blow-drying with electric hair drier cold air to keep dry.
3. The aluminum alloy and galvanized steel workpieces are flatly and tightly placed on a welding fixture, and a lap joint mode of aluminum upper steel and lower steel is adopted, wherein the lap joint length is 10mm.
4. After confirming the overlap length and the close fitting degree of the two samples, the two samples are clamped by a clamp.
S3, welding:
1. The welding gun is moved above the assembled aluminum alloy and galvanized steel sheet, a robot teaching programming is used, a welding path and a welding gun angle are adjusted, the dry extension of the welding wire is 10mm, the pushing angle of the welding gun is alpha=105°, the side inclination angle is beta=85°, and the welding offset is 0.5mm. The common CMT mode is selected for welding, and the welding technological parameters are set as follows: the welding speed was 0.40m/min, and the wire feed speeds were 7.0, 6.8, 6.6, 6.4, 6.2m/min.
2. The welding shielding gas is argon (Ar), and the flow of the inspection gas is 15L/min.
3. And after the joint is naturally cooled, the clamp is disassembled, cleaned and dried, and the welding sample is shown in fig. 3 (a).
S4, observing and detecting performance after welding:
1. Preparing a metallographic specimen by cutting a rectangle with the size of 6mm multiplied by 18mm on a vertical welding line, polishing the metallographic specimen after step by using No. 600, no. 800, no. 1000, no. 1500 and No. 2000, and observing the appearance of the whole welding line under a metallographic microscope as shown in fig. 5 (a); the metallographic high magnification view of the weld interface is shown in fig. 6 (a-d).
2. Standard tensile specimens were taken as in fig. 7 (a), and the tensile strength of the aluminum-steel welded joint was tested with a universal tensile tester as in fig. 7 (b) for the tensile breaking position, with all the specimens broken at the interface. In this example, the resulting joint strength was about 1417.+ -. 167N maximum.
Example 2
S1, preparing a welding material: the same as in example 1.
Step S2, preparing work before welding:
1. sample preparation was the same as in example 1.
2. The surface treatment of the processed sample was the same as in example 1.
3. The welding lap joint was the same as in example 1.
4. The overlap length at the time of welding was the same as in example 1.
S3, welding:
1. The welding process was the same as that of example 1, except that only one set of the preferred parameters of example 1 was used and the CMT circulating droplet process test was performed, i.e. the welding speed was 0.40m/min and the wire feed speed was 6.6m/min. Selecting a CMT circulating liquid drop mode for welding, and setting welding process parameters as follows: (a) The cycle liquid drop period is 2, 3, 4, 5 and 6 respectively, and the cycle liquid drop interruption time is 0.1s; (b) The cycle droplet period was 4 and the cmt cycle droplet break-up time was 0.06s, 0.08s, 0.1s, 0.12s, 0.14s, as shown in fig. 3 (b) and (c) for the weld samples.
S4, observing and detecting performance after welding:
The post-weld observation and performance test methods were the same as in example 1. As shown in FIGS. 7 (c) and (d), the tensile fracture sites were shown, and the specimens were almost broken at the interface. In this example, the maximum strength of the joint obtained is about 1914.+ -.110N.
Example 3
S1, preparing a welding material: the same as in example 1.
Step S2, preparing work before welding:
1. sample preparation was the same as in example 1.
2. The surface treatment of the processed sample was the same as in example 1.
3. The welding lap joint was the same as in example 1.
4. The overlap length at the time of welding was the same as in example 1, the only difference being that: before lapping, a layer of 400-500 mu m medium entropy alloy powder is coated on the surface of steel.
S3, welding:
1. The welding method and process, welding speed and wire feed speed were the same as in example 2, except that the additive mid-entropy alloy powder test was performed using only one set of the preferred parameters of example 2. The CMT circulation drop period was 5 and the CMT circulation drop break-up time was 0.1s. Fig. 5 (c) shows a welding sample.
S4, observing and detecting performance after welding:
the post-weld observation and performance test methods were the same as in example 1. As shown in fig. 7 (e) which shows the tensile fracture site, all the specimens were fractured in the heat affected zone. In this example, the resulting joint maximum strength is about 2536.+ -. 160N.
In conclusion, the process is adopted to weld the aluminum alloy and the galvanized steel, and the weld joint is formed and the section of the weld joint is observed; measuring residual height, penetration, width and the like; carrying out a tensile test and a microhardness test to test mechanical properties; and carrying out detection analysis on intermetallic compounds by SEM, EDS and XRD on metallographic structures. The results show that: the continuous and uniform fish scale-shaped weld joint has good wettability, high weld joint repeatability, no undercut and other macroscopic defects, good mechanical property of the joint, satisfactory hardness and thinner thickness of the interface intermetallic compound. After the medium entropy alloy powder is added, the wetting length of the welding line is increased, the interfacial compound layer is reduced, the fracture position is changed from interfacial fracture to fracture of a heat affected zone, the formability of the aluminum-steel welding joint is improved, and the mechanical property of the joint is improved.
While particular embodiments of the present invention have been described above, it will be understood by those skilled in the art that these are by way of example only and that various changes or modifications may be made to these embodiments without departing from the principles and spirit of the invention.
Claims (1)
1. A control method for forming an aluminum steel heterogeneous metal arc welding seam is characterized by comprising the following steps:
step one, preprocessing two workpieces to be welded
Firstly polishing by using coarse sand paper, then polishing by using fine sand paper to remove surface impurities, cleaning the surface of a galvanized steel workpiece by using absorbent cotton balls, then placing an aluminum alloy workpiece and the galvanized steel workpiece into alcohol for ultrasonic cleaning, and finally washing and drying;
Step two, the two workpieces are respectively arranged as an aluminum alloy workpiece and a galvanized steel workpiece, the two workpieces are fixedly arranged on a welding workbench in a lap joint mode under aluminum upper steel, and then a layer of entropy alloy powder is coated on the surface of the galvanized steel workpiece at the lap joint;
The thickness of the medium-entropy alloy powder is set to be 200-600 mu m, and the mass ratio of the component formula is 20-50% of Cr, 20-50% of Co and 20-50% of Ni and Ni;
Thirdly, welding the two workpieces by adopting a CMT circulating liquid drop method to form a flat scale-shaped welding seam;
When the CMT circulating liquid drop method is adopted for welding, the period of the circulating liquid drop is set to be 2-10, and the interruption time of the circulating liquid drop is set to be 0.06-0.16s;
During welding, the welding wire is biased to the galvanized steel workpiece side, the offset from the aluminum alloy workpiece is set to be 0.5-1.5mm, ER4043 welding wire is adopted, the dry extension of the welding wire is set to be 10-12mm, the welding speed is set to be 0.39-0.55m/min, the wire feeding speed is set to be 4-6.5m/min, the welding gun pushing angle is set to be 95-120 degrees, and the side inclination angle is set to be 60-90 degrees;
the welding uses shielding gas which is argon Ar, nitrogen N2 or a mixed gas of the argon Ar and the nitrogen N2, and the gas flow is set to be 15L/min.
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