EP3507388A1 - Giessen eines metallmatrixverbundmaterials - Google Patents

Giessen eines metallmatrixverbundmaterials

Info

Publication number
EP3507388A1
EP3507388A1 EP17836105.1A EP17836105A EP3507388A1 EP 3507388 A1 EP3507388 A1 EP 3507388A1 EP 17836105 A EP17836105 A EP 17836105A EP 3507388 A1 EP3507388 A1 EP 3507388A1
Authority
EP
European Patent Office
Prior art keywords
casting
titanium
host
matrix
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP17836105.1A
Other languages
English (en)
French (fr)
Other versions
EP3507388A4 (de
Inventor
Kevin Francis Dolman
Xinhu TANG
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Weir Minerals Australia Ltd
Original Assignee
Weir Minerals Australia Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2016903066A external-priority patent/AU2016903066A0/en
Application filed by Weir Minerals Australia Ltd filed Critical Weir Minerals Australia Ltd
Publication of EP3507388A1 publication Critical patent/EP3507388A1/de
Publication of EP3507388A4 publication Critical patent/EP3507388A4/de
Pending legal-status Critical Current

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/04Making non-ferrous alloys by powder metallurgy
    • C22C1/045Alloys based on refractory metals
    • C22C1/0458Alloys based on titanium, zirconium or hafnium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/10Alloys containing non-metals
    • C22C1/1036Alloys containing non-metals starting from a melt
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/10Alloys containing non-metals
    • C22C1/1036Alloys containing non-metals starting from a melt
    • C22C1/1047Alloys containing non-metals starting from a melt by mixing and casting liquid metal matrix composites
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C14/00Alloys based on titanium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C16/00Alloys based on zirconium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C28/00Alloys based on a metal not provided for in groups C22C5/00 - C22C27/00
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C32/00Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0047Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10Processes characterised by the sequence of their steps
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy

Definitions

  • the present invention also relates to methods of casting metal matrix composite materials.
  • the metal matrix composite material castings of the present invention are particularly suitable for use as components that require a combination of severe corrosion resistance and wear resistance.
  • suitable components include, by way of example, components in High Pressure Acid Leaching (HPAL) plants that are exposed to highly corrosive and erosive mineral slurries transported in HPAL plants under high temperature and pressure conditions . These components include by way of example agitator blades.
  • HPAL High Pressure Acid Leaching
  • components also include by way of example the internal parts of valves , i.e. collectively referred to as valve trim, for conveying slurries typically at temperatures up to 200-250 °C at pressures up to 5 MPa and velocities as high as 340 m/s in HPAL plants.
  • the high temperatures and pressures in HPAL plants significantly increase the corrosiveness of the mineral slurries .
  • the entrained solids in the mineral slurries and the high velocities cause erosion of exposed surfaces of agitator blades, internal parts of valves and other components that are in contact with the mineral slurries .
  • the overall effect of these conditions is a high wear rate of exposed surfaces of internal parts of these components.
  • the agitator blades, internal parts of valves and other components in contact with the above- described mineral slurries in HPAL plants require thermal shock resistance, erosion resistance, and severe corrosion resistance .
  • HPAL plants are typically manufactured from (a) refractory materials selected from tungsten carbide, silicon carbide and partially stabilised zirconia (PSZ) , by sintering, (b) alloys including cobalt based alloys (such as Alloy 6) , and (c) hardfaced titanium alloys .
  • PSZ partially stabilised zirconia
  • alloys including cobalt based alloys such as Alloy 6
  • hardfaced titanium alloys hardfaced titanium alloys
  • the present invention provides a metal matrix composite material casting comprising particles of carbides and/or nitrides and/or borides of any one or more than one of the host metals titanium, zirconium, hafnium, and tantalum dispersed in a matrix of at least one of the host metals .
  • the present invention provides a metal matrix composite material casting comprising (a) one or more of the following host metals: titanium, zirconium, hafnium and tantalum, and (b) a dispersion of refractory particles comprising two or more carbides and/or nitrides and/or borides of at least one of the host metals.
  • refractory particles is understood herein to mean particles of a material with a melting point >
  • host metal used in the context of the matrix may include one of the host metals without the other host metals.
  • host metal used in the context of the matrix may also include an alloy of the metals titanium and/or zirconium and/or hafnium and/or tantalum.
  • the host metal (s) may also contain small
  • the host metal (s) may also contain small concentrations of any one or more than one of aluminium, vanadium, niobium, nickel, molybdenum, chromium, and cobalt for enhanced mechanical properties and palladium, ruthenium for better corrosion performance.
  • the casting does not contain platinum group elements in concentrations greater than 0.005 wt.%.
  • the casting may comprise carbides and/or nitrides and/or borides of one of the four host metals in a matrix of the same host metal.
  • the casting may comprise two or more of titanium carbides and/or nitrides and/or borides in a titanium matrix.
  • the refractory particles may comprise titanium carbides and titanium borides in the titanium matrix .
  • the refractory particles may comprise titanium carbides and titanium nitrides in the titanium matrix.
  • the refractory particles may comprise titanium borides and titanium nitrides in the titanium matrix.
  • the casting may comprise two or more carbides and/or nitrides and/or borides of one of the four host metals in a matrix of another one of the host metals.
  • the casting may comprise two or more of tantalum carbides and/or nitrides and/or borides in a titanium matrix.
  • the casting may comprise 5-60 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise 5-50 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise 5-40 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise greater than 10 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise greater than 15 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise less than 30 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise less than 25 volume % refractory particles dispersed in the matrix.
  • the casting may comprise less than 20 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise refractory particles in a range of 5 wt . % to 65 wt . % of the total weight of the casting .
  • the casting may comprise refractory particles in a range of 12 wt.% to 45 wt.% of the total weight of the casting .
  • the casting may comprise refractory particles in a range of 12 wt.% to 25 wt.% of the total weight of the casting .
  • the refractory particles may be less than 400 microns in a major dimension.
  • the refractory particles may be less than 200 microns in a major dimension.
  • the refractory particles may be less than 150 microns in a major dimension.
  • the refractory particles may be less than 100 microns in a major dimension.
  • the refractory particles may be less than 50 microns in a major dimension.
  • the refractory particles may be greater than 5 microns in a major dimension.
  • the concentrations of at least two of carbon, boron, and nitrogen may be up to 10 wt.% of the total weight of the casting.
  • the concentrations of at least two of carbon, boron, and nitrogen may be less than 8 wt.% of the total weight of the casting .
  • the concentrations of at least two of carbon, boron, and nitrogen may be less than 7 wt.% of the total weight of the casting .
  • the concentrations of at least two of carbon, boron, and nitrogen may be less than 6 wt.% of the total weight of the casting .
  • the host metal may be a pure metal .
  • the host metal may be a commercial grade metal, i.e. a metal that is not 100% pure metal but is substantially pure metal .
  • the host metal may be Grade 12 titanium.
  • Titanium Grade 12 is a titanium grade alloy with
  • Titanium Grade 12 has the following nominal chemistry, in wt.%: C: 0.08% max; H: 0.015% max; Fe: 0.3% max; Mo: 0.2-0.4%; Ni : 0.6-0.9%; N: 0.03% max; O: 0.25% max; and Ti : balance.
  • the casting may be any suitable component having a required shape .
  • the component may be used as a stand-alone component or as part of a more complex component.
  • the component may be any component that is used in
  • HPAL plants that are exposed to mineral slurries at high temperatures and pressures that require thermal shock resistance, erosion resistance, and corrosion resistance. These components include by way of example agitator blades and internal parts of valves .
  • the present invention also provides a metal matrix composite material comprising particles of carbides and/or nitrides and/or borides of any one or more than one of the host metals titanium, zirconium, hafnium, and tantalum dispersed in a matrix of at least one of the host metals.
  • the present invention also provides a metal matrix composite material comprising particles of two or more carbides and/or nitrides and/or borides of any one or more than one of the host metals titanium, zirconium, hafnium, and tantalum dispersed in a matrix of at least one of the host metals .
  • the present invention also provides a method of forming a metal matrix composite material casting
  • the applicant has found in laboratory experimental work that it is possible to form liquid titanium melts at significantly lower temperatures when titanium is melted with at least two of carbon, boron, and nitrogen than when titanium is melted with one only of carbon, boron, and nitrogen. Specifically, the applicant found that furnace temperatures significantly higher than 2000°C were required to melt 75 wt.% Grade 12 titanium and 25 wt.% titanium carbide feed materials in an electroslag remelting furnace and that operating at these temperatures caused damage to the furnace.
  • furnace temperatures of less 2000°C could melt (a) titanium, boron and carbon feed materials, (b) titanium, boron and nitrogen feed materials, (c) titanium, nitrogen and carbon feed materials, and (d) titanium, boron, carbon, and nitrogen feed materials, without any furnace damage.
  • operating with two or more than two of boron, carbon, and nitrogen feed materials significantly lowered the melting temperature for the materials.
  • the applicant also found that the resultant castings formed from these feed materials had excellent corrosion resistance, hardness and other mechanical properties.
  • the method may include forming the liquid melt of one of the host metals and at least two of carbon, boron, and nitrogen at furnace temperatures of less than 2000°C.
  • the furnace temperatures may be less than 1900°C, typically less than 1800°C.
  • the microstrueture of the casting may comprise titanium carbides and titanium borides dispersed in a titanium matrix, with the carbides and the borides precipitating from the liquid melt during solidification .
  • the method may comprise mixing feed materials containing at least one of the host metals and at least two of carbon, boron, and nitrogen.
  • the method may include forming a uniform mixture of the feed materials .
  • the feed materials may be in a sponge form.
  • ponge form is understood herein to mean that the feed materials are in a porous form.
  • the feed materials may be in the form of powders.
  • powders is understood herein to mean a dry, bulk solid composed of a large number of fine particles that may flow freely when shaken or tilted.
  • the feed materials may be in the form of powders of the host metal.
  • the feed materials may be in the form of powders of the host metal and one or more of carbon, boron and nitrogen.
  • the feed materials may be titanium boride powders .
  • the feed materials may be in the form of powders of two or more of carbon, boron and nitrogen.
  • the feed material may be a boron-carbon- containing powder or a boron-carbon-nitrogen-containing powder .
  • the feed materials may comprise up to 10 wt.% of at least two of carbon, boron, and nitrogen.
  • the feed materials may comprise up to 10 wt.% of at least two of carbon, boron, and nitrogen.
  • the feed materials may comprise less than 8 wt.% of at least two of carbon, boron, and nitrogen.
  • the feed materials may comprise less than 7 wt.% of at least two of carbon, boron, and nitrogen.
  • the feed materials may comprise less than 6 wt.% of at least two of carbon, boron, and nitrogen.
  • the host metal may be a pure metal .
  • the host metal may be a commercial grade metal, i.e. a metal that is not 100% pure metal but is substantially pure metal .
  • the titanium when the host metal is titanium, the titanium may be Grade 12 titanium.
  • the host metal may be an alloy of the host metal and another metal .
  • the method may comprise pressing the mixture of the feed material and forming pellets, compacts, or other pressed shapes .
  • the method may comprise forming the liquid melt of one of the host metals and at least two of carbon, boron, and nitrogen by melting the feed material in any suitable furnace under inert atmosphere conditions.
  • the furnace may be an electroslag re-melting furnace.
  • the furnace may be a vacuum melting furnace.
  • the method may include any suitable option for casting the liquid melt into the component.
  • the method may comprise centrifugal casting the liquid melt into the component.
  • the casting may comprise 5-60 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise 5-50 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise 5-40 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise greater than 10 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise greater than 15 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise less than 30 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise less than 25 volume % refractory particles dispersed in the matrix.
  • the casting may comprise less than 20 volume % refractory particles dispersed in the host metal matrix.
  • the casting may comprise refractory particles in a range of 5 wt . % to 65 wt . % of the total weight of the material .
  • the casting may comprise refractory particles in a range of 12 wt.% to 25 wt.% of the total weight of the material .
  • the refractory particles may be less than 400 microns in a major dimension.
  • the refractory particles may be less than 200 microns in a major dimension.
  • the refractory particles may be less than 150 microns in a major dimension.
  • the refractory particles may be less than 100 microns in a major dimension.
  • the refractory particles may be less than 50 microns in a major dimension.
  • the refractory particles may be greater than 5 microns in a major dimension.
  • the casting may comprise a uniform dispersion of the refractory particles in the host metal matrix.
  • the casting may comprise a non-uniform dispersion of the refractory particles in the host metal matrix.
  • Figure 1 is a micrograph of an embodiment of a titanium carbide particle/titanium host metal matrix composite material in accordance with the invention formed in laboratory work carried out by the applicant;
  • Figure 2 is a micrograph of an embodiment of a titanium metal matrix composite material casting
  • the applicant has carried out laboratory experimental work in relation to composite metal matrix materials in accordance with the invention formed from titanium carbide particles dispersed in a titanium host metal matrix.
  • the applicant has also carried out laboratory experimental work in relation to composite metal matrix material castings in accordance with the invention comprising titanium carbide and titanium boride particles dispersed in a titanium host metal matrix.
  • the laboratory experimental work included work in relation to composite metal matrix material castings in accordance with the invention comprising two or more of carbides and/or nitrides and/or borides of titanium dispersed in a titanium host metal matrix.
  • known ceramic materials namely tungsten carbides, silicon carbides, and partially stabilised zirconia (PSZ) formed by sintering processes.
  • Titanium carbides, titanium borides, and titanium nitrides are chemically inert and the corrosion resistance of titanium host metal (which term includes metal alloy) has been proven in HPAL slurries under actual operating conditions — the proof is successful operation of existing valve bodies that are made from titanium Grade 12 metal (nominal chemical composition, in wt.%: Fe ⁇ 0.30; O ⁇ 0.18; Ti balance; C ⁇ 0.08; H ⁇ 0.15; N ⁇ 0.03; Mo 0.2- 0.4, Ni 0.6-0.9) .
  • Titanium carbides, titanium borides, and titanium nitrides are extremely hard (>2000 HV) . Also, titanium- based refractory materials including titanium carbides, titanium borides, and titanium nitrides have very similar thermal expansion coefficients as the host metal matrix material, namely titanium. This usually implies a higher resistance to thermal shock which is critical for HPAL applications, especially, when materials are used for valve trims .
  • Titanium is a tough metal .
  • Titanium metal matrix composite material castings comprising (a) hard titanium carbide particles and a tough host metal matrix of titanium Grade 12 metal or (b) hard titanium carbide/boride particles and a tough host metal matrix of titanium Grade 12 metal, have resistance to corrosion-erosion and thermal shock . These properties can be adjusted as required by changing the relative amounts of the refractory particles and the host metal matrix and other variables, such as refractory particle size and shape .
  • Titanium metal matrix composite material castings comprising dispersions of two or more than two of titanium carbides, titanium borides, and titanium nitrides have high hardness due to the particles and high toughness due to the titanium matrix and high overall corrosion
  • Titanium carbides and titanium carbides/borides can be in situ-synthesised in titanium Grade 12 metal directly in a liquid metal manufacturing process of the applicant to ensure strong bonding between the titanium carbides and the host titanium matrix.
  • the host titanium matrix of the metal matrix composite material castings can be further optimised to increase hardness and/or corrosion resistance.
  • compositions and expected properties for titanium metal matrix composite material castings comprising dispersions of titanium carbides are as follows :
  • composition of a metal matrix composite material casting consisting of titanium carbide in a host titanium metal matrix is as follows.
  • compositions and expected properties for titanium metal matrix composite material castings comprising dispersions of titanium carbides and titanium borides are as follows :
  • composition of a metal matrix composite material casting consisting of titanium carbide and titanium boride in a host titanium metal matrix is as follows .
  • Figure 1 is a micrograph of an embodiment of a titanium carbide particle/titanium host metal matrix composite material casting in accordance with the invention formed in laboratory work carried out by the applicant .
  • the composite material shown in Figure 1 comprises 30 vol . % titanium carbide particles having a major diameter of approximately 15 microns and a titanium Grade 12 host metal having the nominal composition described above.
  • the metal matrix composite material casting was produced by casting an ingot from a titanium Grade 12 melt produced in an electric arc melting furnace under a partial pressure of argon in a water cooled copper hearth, i.e. the ingot was chill cast.
  • the titanium carbide particles were added to the furnace melt as discrete particles having a major dimension of approximately 15 microns .
  • Figure 2 is a micrograph of an embodiment of a titanium metal matrix composite material casting in accordance with the invention comprising dispersions of titanium carbides and titanium borides in a titanium matrix accordance with the invention formed in laboratory work carried out by the applicant.
  • the composite material casting shown in Figure 2 comprises 30 vol . % titanium carbides and titanium borides and a titanium Grade 12 host metal having the nominal composition described above.
  • the titanium carbides precipitated as dendrites and the titanium borides precipitated as angular particles during solidification of the composite material casting are illustrated.
  • the bulk hardness of the composite material casting shown in Figure 2 was 350HV.
  • the present invention also extends to metal matrix composite materials formed from zirconium or hafnium or tantalum or combinations of these four elements in the host metal matrix and refractory particles comprising two or more carbides and/or nitrides and/or borides of at least one of the host metals.
  • the term “comprises” or its grammatical variants as used in this specification and claims is equivalent to the term “includes” and is not to be taken as excluding the presence of other features or elements .

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Composite Materials (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Powder Metallurgy (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
EP17836105.1A 2016-08-04 2017-08-04 Giessen eines metallmatrixverbundmaterials Pending EP3507388A4 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AU2016903066A AU2016903066A0 (en) 2016-08-04 Metal matrix composite materials
AU2017901644A AU2017901644A0 (en) 2017-05-05 Metal matrix composite material casting
PCT/AU2017/050822 WO2018023171A1 (en) 2016-08-04 2017-08-04 Metal matrix composite material casting

Publications (2)

Publication Number Publication Date
EP3507388A1 true EP3507388A1 (de) 2019-07-10
EP3507388A4 EP3507388A4 (de) 2020-09-23

Family

ID=61072444

Family Applications (1)

Application Number Title Priority Date Filing Date
EP17836105.1A Pending EP3507388A4 (de) 2016-08-04 2017-08-04 Giessen eines metallmatrixverbundmaterials

Country Status (8)

Country Link
EP (1) EP3507388A4 (de)
CN (1) CN109689905B (de)
AU (1) AU2017306581B2 (de)
BR (1) BR112019002148B1 (de)
CL (1) CL2019000297A1 (de)
PE (1) PE20190647A1 (de)
PH (1) PH12019500234A1 (de)
WO (1) WO2018023171A1 (de)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112481522B (zh) * 2020-04-13 2021-11-12 国核宝钛锆业股份公司 锆合金以及锆合金和锆合金型材的制备方法
DE102022104752A1 (de) 2022-02-28 2023-08-31 Trumpf Laser- Und Systemtechnik Gmbh Additives Fertigungsverfahren unter Reduzierung der Oberflächenrauheit eines in dem Fertigungsverfahren hergestellten Formkörpers

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Also Published As

Publication number Publication date
BR112019002148B1 (pt) 2022-06-14
CL2019000297A1 (es) 2019-06-28
EP3507388A4 (de) 2020-09-23
AU2017306581B2 (en) 2022-09-08
AU2017306581A1 (en) 2019-03-07
PH12019500234A1 (en) 2019-10-21
CN109689905B (zh) 2021-12-21
BR112019002148A2 (pt) 2019-05-14
WO2018023171A1 (en) 2018-02-08
CN109689905A (zh) 2019-04-26
PE20190647A1 (es) 2019-05-06

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