CN114515818B - Manufacturing method and mold of aircraft engine combustion chamber swirler - Google Patents
Manufacturing method and mold of aircraft engine combustion chamber swirler Download PDFInfo
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- CN114515818B CN114515818B CN202011290672.2A CN202011290672A CN114515818B CN 114515818 B CN114515818 B CN 114515818B CN 202011290672 A CN202011290672 A CN 202011290672A CN 114515818 B CN114515818 B CN 114515818B
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- 238000004519 manufacturing process Methods 0.000 title claims description 17
- 238000002485 combustion reaction Methods 0.000 title claims description 14
- 238000005266 casting Methods 0.000 claims abstract description 22
- 238000003754 machining Methods 0.000 claims description 21
- 239000002184 metal Substances 0.000 claims description 18
- 210000005069 ears Anatomy 0.000 claims description 14
- 238000012545 processing Methods 0.000 claims description 14
- 239000007788 liquid Substances 0.000 claims description 11
- 238000000034 method Methods 0.000 claims description 9
- 238000010438 heat treatment Methods 0.000 claims description 5
- 239000012530 fluid Substances 0.000 claims description 4
- 238000004891 communication Methods 0.000 claims description 3
- 238000000926 separation method Methods 0.000 claims description 3
- 238000009826 distribution Methods 0.000 claims 3
- 230000000694 effects Effects 0.000 description 4
- 230000007547 defect Effects 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000009415 formwork Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 239000012528 membrane Substances 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000003801 milling Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000004018 waxing Methods 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
- B22C9/043—Removing the consumable pattern
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/20—Stack moulds, i.e. arrangement of multiple moulds or flasks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Abstract
The invention relates to a mold for casting a vortex device, wherein cavities of the mold comprise a first vortex device cavity to an nth vortex device cavity which are connected in series, n is more than or equal to 2, adjacent vortex device cavities are communicated end to end, and the serial connection direction of the vortex device cavities is parallel to the axis direction of the vortex device; the mold includes a top runner leading from one end of the mold to a first swirler cavity; the mold comprises side runners which are respectively communicated with the positions of the corresponding first side mounting lugs in each cavity of the vortex device.
Description
Technical Field
The invention relates to the field of material processing, in particular to a manufacturing method and a die of an aircraft engine combustion chamber swirler.
Background
The economy of the aero-engine is an important index, and is mainly reflected in high combustion efficiency of a combustion chamber and reduced oil consumption. In order to fully burn the fuel, the advanced aeroengine enables the fuel to be fully mixed with high-pressure air through the structural design of the nozzle. The swirler is a device for generating swirling air in a combustion chamber of an aeroengine, and aims to achieve the aim of better mixing fuel oil with air and achieving full combustion.
The swirler mainly comprises a vortex generating device and a mounting device. The swirler may be cast from a corrosion resistant superalloy and is formed by a combination of electrochemical machining and mechanical machining. The air flow path of the vortex generating device is formed by a circle of small blades which are not concentric.
In order to solve the size requirement of the vortex generating device, the air flow path is electrically machined. However, the square hole structure of the one-turn vortex generating device is electrically processed, and the working time is about 40 hours. And the positioning influences the positional relationship between the vortex generating device and the mounting device and influences the vortex forming effect due to repeated clamping.
The project aims at an aircraft engine swirler structure, and adopts the multiple-in-one processing idea. A method for machining a plurality of vortex devices by integrally casting the vortex devices and serially machining the vortex devices is disclosed.
Disclosure of Invention
In the traditional casting process of the vortex device, only one product can be cast per die at a time, the yield is low, and the waste of raw materials is serious. The method disclosed by the invention provides a novel die, and the die can be used for casting a plurality of serially connected casting combined blanks at one time, and the serially connected combined blanks are subjected to integral processing and then are separated, so that a plurality of products can be obtained. The die improves the yield of products, improves the utilization rate of raw materials and improves the processing efficiency.
Furthermore, the inventors found that, since the turbulators have a thick and thin abrupt annular structure, loose defects easily occur in castings when the series casting is performed. In order to solve the technical problem, the scheme of the disclosure further skillfully utilizes the specific self structure of the vortex device, besides the original top pouring channel of the die, side pouring channels are designed at the positions of mounting lugs of all the vortex devices, and loose production in castings can be avoided by co-pouring liquid from the top pouring channels and the side pouring channels.
In some aspects, the present disclosure provides a mold for casting an aircraft engine combustion chamber swirler, wherein the swirler comprises: an annular body and a pair of mounting ears; the pair of mounting ears extend radially from opposite sides of the annular body, the pair of mounting ears including a first side mounting ear and a second side mounting ear;
The cavities of the mold comprise a first swirler cavity to an nth swirler cavity which are connected in series, n is more than or equal to 2, adjacent swirler cavities are communicated end to end, and the serial connection direction of the swirler cavities is parallel to the axis direction of the swirler;
the mold includes a top runner leading from one end of the mold to a first swirler cavity;
The mold comprises side runners, the side runners are located on one side of each swirler cavity, each side runner comprises a plurality of branches, and each branch is communicated to the position of the corresponding first side mounting lug in each swirler cavity.
In some embodiments, the annular body comprises an annular vortex generator.
In some embodiments, the annular body further comprises an annular deflector extending axially from one side of the annular vortex generator.
In some embodiments, a pair of mounting ears extend radially from opposite sides of the annular vortex generator or annular deflector.
In some embodiments, the first swirler cavity and the nth swirler cavity are respectively the swirler cavities closest to the two ends of the mold.
In some embodiments, the mold further comprises a main runner in fluid communication with the top runner and the side runner, respectively, and a flow divider for adjusting the ratio of the metal liquid from the main runner to the top runner and the side runner.
In some embodiments, the projections of the respective swirler cavities in the serial direction coincide with each other.
In some embodiments, a wax drain structure is provided within each swirler cavity at a location corresponding to the second side mounting ear.
In some aspects, the present disclosure provides a method of making a mold as described in any one of the above, comprising the steps of:
1) Providing a wax core of a preset shape;
2) Wrapping the surface of the wax core with a mould shell;
3) An upper opening of a wax removing structure on the mould shell is provided, and the wax core is melted by heating and is discharged from the mould shell;
4) Plugging the wax removing structure to obtain the die.
In some aspects, the present disclosure provides a method of making a swirler comprising the steps of:
1) A swirler assembly comprising a plurality of swirler blanks in series is cast using a mold according to any one of the above.
In some embodiments, in step 1), the molten metal from the top runner and the side runner is brought together in each swirler cavity at a location other than the corresponding mounting ear by adjusting the amount of feed to the top runner and the side runner.
In some embodiments, the molten metal from the top runner and side runner is brought together at the juncture of adjacent two swirler cavities by adjusting the amount of feed to the top runner and side runner.
In some embodiments, the method of making a swirler further comprises the following steps.
2) Machining and/or electrically machining the swirler assembly blank;
3) The plurality of swirlers obtained by the processing are separated from each other.
In some embodiments, in step 2), the swirler assembly is machined using an electro-machining apparatus having a plurality of electrodes, one swirler blank for each electrode during machining;
In some embodiments, in step 2), the plurality of swirler blanks are maintained from separation during processing.
Description of the terminology:
If the following terms are used in the present invention, they may have the following meanings:
Various relative terms such as "front," "rear," "top" and "bottom," "upper," "lower," "above," "below," and the like may be used to facilitate description of the various embodiments. Relative terms are defined with respect to a conventional orientation of the structure and do not necessarily refer to the actual orientation of the structure as manufactured or in use. The following detailed description is, therefore, not to be taken in a limiting sense. As used in the description and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.
Electric discharge machining (electric discharge machining) refers to a method of machining a workpiece using the principle of electric discharge.
Machining refers to a method of using a tool to perform a craftsman on a workpiece, including, for example: turning, milling, planing, drilling, boring and grinding.
Advantageous effects
One or more technical solutions of the present disclosure have one or more of the following beneficial effects:
(1) The product yield is high. Conventional turbulators are cast, one piece at a time. The method can collect multiple castings by one die, can improve the yield of one casting die product, and further improves the utilization rate of raw materials.
(2) The side pouring channel is creatively designed by utilizing the special structure of the vortex device, and is designed at the position of the mounting lug; through the common liquid injection of the top pouring gate and the side pouring gate of each vortex device cavity, loose production in castings can be avoided;
(3) The mold is provided with a flow dividing device, and the flow of the top pouring channel and the side pouring channel is adjusted to ensure that the liquid surfaces of the side pouring channel and the top pouring channel are intersected at positions except the mounting lugs, so that the service life of the vortex device is prolonged;
(4) The special structure of the vortex device is creatively utilized to design the pouring channel, and the mounting lug position is utilized to design the wax removing structure. Because the swirler is a thick and thin abrupt annular structure, when a plurality of castings are serially assembled, the swirler is easy to expand by heating at a locally thicker position. In the process of removing the wax, the volume of the wax liquid is larger than the solid volume of the wax, and the expansion of the wax liquid can lead to the deformation of the die cavity. According to the scheme, the wax removing structure is designed at the position of the mounting lug on one side of each vortex device cavity, the position of the wax removing structure is opened before dewaxing, so that molten wax can be discharged from the top pouring channel and the wax removing structure, and the expansion and the size out-of-tolerance of the membrane shell caused by the melting expansion of the wax are reduced. After the removal of the wax is completed, the openings at the wax removal structure are resealed.
Drawings
Fig. 1 shows a top view of an aircraft engine combustion chamber swirler
FIG. 2 shows a B-B cross-sectional view of the swirler of FIG. 1
Fig. 3 shows a mold for casting a combustion chamber swirler.
Fig. 4 shows a schematic view of the processing of a swirler assembly blank.
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 for illustrating the present invention and should not be construed as limiting the scope of the present invention. The specific conditions are not noted in the examples and are carried out according to conventional conditions or conditions recommended by the manufacturer. The reagents or apparatus used were conventional products commercially available without the manufacturer's attention.
Fig. 1 shows a top view of an aircraft engine combustion chamber swirler and fig. 2 shows a B-B section of the swirler of fig. 1. As shown in fig. 1-2, the swirler includes an annular body 15 and a pair of mounting ears 13; a pair of mounting ears 13 extend radially from opposite sides of the annular body 15, the pair of mounting ears 13 including a first side mounting ear 131 and a second side mounting ear 132. The annular vortex generator 11 and the annular deflector 12 have a common axis of symmetry 10.
In some embodiments, the annular body 15 includes an annular vortex generator 11.
In some embodiments, the annular body 15 further comprises an annular deflector 12 axially protruding from one side of the annular vortex generator 11.
In some embodiments, a pair of mounting ears 13 extend radially from opposite sides of the annular deflector 12.
In some embodiments, a plurality of swirl vanes are circumferentially disposed on the annular swirl generator 11.
In some embodiments, the mounting ears 13 are used to connect with mounting structures within the combustion chamber.
Fig. 3 shows a mold for casting a combustion chamber swirler. The mold cavity comprises a first swirler cavity 21, a second swirler cavity 22 and an nth swirler cavity 23 which are connected in series, wherein n=6, adjacent swirler cavities (21, 22) are communicated end to end, and the serial direction of the swirler cavities (namely, the connecting line passing through the center of each swirler) is parallel to the axis 10 direction of each swirler; the mold also includes a top runner 31, the top runner 31 leading from one end of the mold (e.g., the top end of the mold) to a location of the first swirler cavity 21 (i.e., from where the opening into the cavity is made); the mould comprises a side runner 32, the side runner 32 being located on one side of each swirler cavity, the side runner 32 comprising a plurality of branches, each branch leading to a respective location in each swirler cavity corresponding to the first side mounting lug 131 (i.e. opening into the cavity from that location).
As shown in fig. 3, the side runner 31 is located beside the swirler cavities, and the side runner 31 includes a main flow path extending in series along the swirler cavities and a plurality of branch flow paths extending from the main flow path and communicating with positions of the corresponding first side mounting lugs 131 in each of the swirler cavities.
The above embodiment has the following advantageous effects: firstly, a plurality of swirlers are cast in series, so that the efficiency can be effectively improved; and secondly, through the common liquid injection of the top pouring gate and the side pouring gate of each vortex device cavity, loose production in the casting can be avoided.
In some embodiments, as shown in fig. 3, the mold further includes a sprue 41 and a diverter 42, the sprue 41 being in fluid communication with the top runner 31 and side runners 32, respectively, via the diverter 42. The diversion device 42 can adjust the proportion of the metal liquid that the total runner 41 is diverted to the top runner 31 and the side runner 32.
The above embodiment has the following advantageous effects: by adjusting the ratio of the molten metal in the top runner 31 and the side runner 32, the converging position of the molten metal in the top runner 31 and the side runner 32 into the cavity of the swirler can be adjusted. Preferably, a technician can use ProCAST software in advance to build a molten metal flow model during casting, and adjust the molten metal flows of the top runner 31 and the side runner 32 so that the two meet at a position other than the mounting ears 13. Because microscopic defects may exist at the molten metal intersection position, the bearing parts on the vortex device of the mounting lug 13 are avoided, and the service life of the vortex device can be prolonged.
In some embodiments, the projections of the respective swirler cavities in the serial direction coincide with each other.
In some embodiments, the pitch of the respective swirler cavities is equal and oriented the same.
Based on this, since the arrangement of the respective swirlers is regular, when the cast product is subsequently integrally processed, the cast product can be integrally processed using the processing apparatus having a plurality of electrodes/cutters without separating the respective swirlers. And the processing efficiency is improved.
In some embodiments, as shown in fig. 3, a wax drain structure 33 is provided within each swirler cavity at a location corresponding to the second side mounting ear 132.
In some embodiments, there is provided a method of making a mold of any of the above, comprising the steps of:
(1) Providing a wax core of a preset shape;
(2) Wrapping the surface of the wax core with a mould shell;
(3) An upper opening of a wax removing structure on the mould shell is provided, and the wax core is melted by heating and is discharged from the mould shell;
(4) Plugging the wax removing structure to obtain the die.
In some embodiments, the formwork is a sand type formwork.
In some embodiments, as shown in fig. 3, a wax drain structure 33 is provided within each swirler cavity at a location corresponding to the second side mounting ear 132. The wax removing structure 33 is arranged at the position corresponding to the second side mounting lug 132 in each cavity of the vortex device, and after the mould shell is dried and hardened, the wax removing structure is opened at the position, and the wax core is melted by heating and is discharged from the mould shell. This embodiment has the following beneficial effects: because the swirler is of a thick and thin abrupt annular structure, when a plurality of castings are connected in series to form a group of trees, the local thicker position is easy to be heated and expanded; during dewaxing of the production mold, wax melts and flows out of the de-waxing structure 33 in addition to the top runner 31, which reduces expansion of the wax melt causing expansion of the membrane shell and resulting in oversized shell.
Fig. 4 shows a schematic view of the processing of a swirler assembly blank.
In some embodiments, a method of making a swirler is provided comprising the steps of:
(1) The above mold casting is used to prepare a swirler assembly 50 comprising a plurality of swirler blanks (41, 42, 43, 44) in series.
In some embodiments, in step (1), by setting the feed rates of the top runner 31 and the side runner 32, the metal liquid from the top runner and the side runner is brought together at a position other than the corresponding mounting lug 13 in each swirler cavity. The positions other than the mounting lugs 13 are non-bearing positions, so that molten metal is converged at the positions, and even if fine defects exist at the re-converged positions, the service life of the product is not basically reduced.
In some embodiments, a technician may use fluid analysis software (e.g., proCAST software) to create a molten metal flow model during casting in advance, by adjusting the molten metal flows of the top runner 31 and the side runners 32 to meet at a location other than the mounting ears 13.
In some embodiments, the molten metal from the top runner 31 and side runner 32 is brought together at the juncture of adjacent two swirler cavities by adjusting the amount of feed to the top runner and side runner. The junction between two adjacent swirler cavities is removed in the subsequent machining process, so that the position where the molten metal meets is not basically existed in the swirler body.
In some embodiments, the method of making a swirler further comprises the steps of:
(2) Machining a vortex combination blank;
(3) The plurality of swirlers obtained by the processing are separated from each other.
In some embodiments, in step (2), the swirler assembly blank is machined with a tool.
In some embodiments, in step (2), the swirler assembly blank 50 is machined using an electro-machining apparatus having a plurality of electrodes 62, one swirler blank (41, 42, 43, 44) for each electrode 62 during machining.
In some embodiments, the plurality of swirler blanks are maintained from separation during processing. Thus, a plurality of swirlers can be processed at one time, and the processing efficiency is improved.
In some embodiments, the tool 61 is used to machine the inner and outer cavities of the part, then the electrode 62 is used to form the circumferential square groove structure, then the tool 61 is used to machine the deflector, and finally the individual swirler parts in the composite blank 50 are cut out sequentially.
Although specific embodiments of the invention have been described in detail, those skilled in the art will appreciate that: many modifications and variations of details may be made to the disclosed embodiments in light of the overall teachings of the invention and remain within its scope. The full scope of the invention is given by the appended claims and any equivalents thereof.
Claims (13)
1. A mold for casting an aircraft engine combustion chamber swirler, wherein the swirler comprises: an annular body (15) and a pair of mounting ears (13), the pair of mounting ears (13) extending radially from opposite sides of the annular body (15), the pair of mounting ears (13) including a first side mounting ear (131) and a second side mounting ear (132);
The mold cavity of the mold comprises a first swirler cavity (21) to an nth swirler cavity (23) which are connected in series, n is more than or equal to 2, adjacent swirler cavities are communicated end to end, and the serial connection direction of the swirler cavities is parallel to the axis direction of the swirler;
the mould comprises a top runner (31), the top runner (31) leading from one end of the mould to a first swirler cavity (21);
the mold comprises side runners (32), the side runners (32) are positioned on one side of each swirler cavity, the side runners (32) comprise a plurality of branches, and each branch is communicated with a position corresponding to a first side mounting lug (131) in each swirler cavity.
2. A mould according to claim 1, the annular body (15) comprising an annular vortex generator (11).
3. A mould according to claim 2, the annular body (15) further comprising annular flow guiding means (12) axially projecting from one side of the annular vortex generator (11).
4. The mould according to claim 1, further comprising a main runner (41) and a distribution device (42), the main runner (41) being in fluid communication with the top runner (31) and the side runner (32) respectively via the distribution device (42), the distribution device (42) being adapted to adjust the proportion of molten metal that the main runner (41) distributes to the top runner (31) and the side runner (32).
5. The mold of claim 1, projections of the respective swirler cavities in the tandem direction coinciding with each other.
6. The mold of claim 1, wherein a wax removal structure (33) is provided in each swirler cavity at a location corresponding to the second side mounting lug (132).
7. A method of making the mold of any one of claims 1-6, comprising the steps of:
(1) Providing a wax core of a preset shape;
(2) Wrapping the surface of the wax core with a mould shell;
(3) An upper opening of a wax removing structure on the mould shell is provided, and the wax core is melted by heating and is discharged from the mould shell;
(4) Plugging the wax removing structure to obtain the die.
8. A method of making a swirler comprising the steps of:
(1) A swirler assembly produced by casting using the mold according to any one of claims 1 to 6, the swirler assembly comprising a plurality of swirler blanks connected in series.
9. The production method according to claim 8, wherein in the step (1), the molten metal from the top runner (31) and the side runner (32) is caused to meet at a position other than the corresponding mounting lug (13) in each cavity of the swirler by providing the amounts of the liquid feeds from the top runner and the side runner.
10. The production method according to claim 9, wherein the molten metal from the top runner (31) and the side runner (32) is caused to meet at the junction between the adjacent two swirler cavities by adjusting the amounts of the liquid feeds from the top runner and the side runner.
11. The method of claim 8, further comprising the step of:
(2) Machining and/or electrically machining the swirler assembly blank;
(3) The plurality of swirlers obtained by the processing are separated from each other.
12. The method of claim 11, wherein in step (2), the swirler assembly blank (50) is electrically machined using an electrical machining apparatus having a plurality of electrodes (62), each electrode (62) corresponding to a respective swirler blank during machining.
13. The method of claim 12, wherein the plurality of swirler blanks are maintained from separation during the machining.
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