Slidbestandige støbegods til minedriftudstyr

1. Indledning

Mineindustrien står over for nogle af de hårdeste driftsmiljøer, med maskiner, der konstant udsættes for ekstreme forhold såsom slid, påvirkning, og kemisk korrosion.

Mineudstyr såsom knusere, møller, og gyllepumper udsættes for ubarmhjertig stress, resulterer i hyppige fejl og betydelige driftsafbrydelser. Dette påvirker i sidste ende produktiviteten, sikkerhed, og rentabilitet.

Udstyrsfejl på grund af slidrelaterede skader fører til kostbar nedetid, nødvendiggør reparationer eller udskiftninger og medfører høje vedligeholdelsesomkostninger.

De økonomiske konsekvenser af sådanne forstyrrelser er betydelige, påvirker både kortsigtet pengestrøm og langsigtet levedygtighed.

Den voksende efterspørgsel efter højere produktivitet i minedrift forstørrer kun vigtigheden af ​​slidstyrke for at sikre jævn og effektiv drift.

Således, implementering af avancerede løsninger som slidbestandige støbegods er afgørende for at afbøde disse problemer og opretholde optimal ydeevne.

Rollen af ​​slidstærke støbegods

Slidfaste støbegods er afgørende for at forbedre holdbarheden af ​​mineudstyr.

These castings are designed with advanced alloy materials that provide superior resistance to abrasion, påvirkning, and chemical wear.

By incorporating the latest innovations in materials science and precision casting techniques,

manufacturers can create parts that offer not only better performance but also a longer service life for mining components.

The reduction of wear-related failures leads to fewer interruptions, which boosts the overall efficiency of mining operations.

Advanced wear-resistant castings provide essential benefits in the mining industry by:

• Reducing equipment failure and downtime.
• Lowering maintenance and replacement costs.
• Increasing operational efficiency and profitability.

2. Forståelse af slidmekanismer i minedrift

Typer af slid i minedriftsudstyr

Mining operations involve various types of wear, each impacting equipment in different ways:

• Abrasive Wear: This type of wear occurs when hard particles or materials grind against metal surfaces, causing the material to erode over time.
  Mining machinery used in ore crushing and grinding, such as mill liners and crusher hammers, are highly susceptible to abrasive wear.
  The constant friction between hard minerals and metal components accelerates material degradation.
• Impact Wear: Frequent, high-impact collisions between machinery and materials cause this wear, which is especially common in crushers and grinding mills.
  The impact forces repeatedly stress the components, leading to fatigue, revner, and ultimately material failure.
• Corrosive/Erosive Wear: I minedrift, many components, especially in slurry transport systems, are exposed to corrosive liquids and chemicals.
  The combined effect of these aggressive environments and high fluid velocities degrades equipment, eroding components like slurry pumps and valves.
  The erosion worsens in conditions involving abrasive particles carried by the slurry.

Kritiske komponenter, der kræver slidstyrke

Several mining equipment components face the most severe wear and thus benefit most from wear-resistant castings:

• Crushers: Jaw plates, cone liners, and impact hammers undergo both abrasive and impact wear during the crushing process.
• Grinding Mills: Ball mill liners and grinding balls face substantial abrasive wear as they continuously grind ore.
• Transportører: Conveyor systems handle large volumes of ore, subjecting the components to continuous abrasion.
  Key parts such as chute liners, idlers, and belt scrapers are all prone to wear.
• Excavators & Loaders: Components such as bucket teeth, shovel lips, and track pads
  experience high levels of impact and abrasive wear due to constant contact with rocks, smuds, and ore.
• Slurry Pumps: Impellers and casing components in slurry pumps face corrosion, erosion, and abrasion from the fluid mixture of chemicals, vand, and abrasive particles.

3. Materialevidenskab af slidstærke støbegods

The material composition and properties of wear-resistant castings are the cornerstone of their performance in mining equipment.

Understanding the relationship between material selection, forarbejdning,

and wear mechanisms is essential to creating components that can withstand the extreme conditions of mining operations.

The right combination of alloys, Varmebehandlinger, and metallurgical processes significantly influences the durability and performance of these castings.

This section dives into the key alloys, deres egenskaber, and the role of heat treatment and metallurgy in enhancing wear resistance.

Nøglelegeringer og deres egenskaber

The materials used in wear-resistant castings need to exhibit exceptional toughness, hårdhed, og slidstyrke.

Several alloys stand out in this regard, hver designet til specifikke minedriftsapplikationer:

Høj-krom hvidt jern (HCWI)

• Hårdhed: 600+ Hb
• Egenskaber: HCWI-legeringer er kendt for deres enestående slidstyrke, hvilket i høj grad skyldes dannelsen af ​​hårdmetalfaser i jernmatrixen.
  Tilstedeværelsen af ​​chrom og kulstof tillader dannelsen af ​​chromcarbider, som forbedrer materialets hårdhed og evne til at modstå slibende slid.
  Dette gør den ideel til applikationer, der involverer slibning, knusende, og fræsning, hvor materialer som sten og malm hurtigt kan slide almindelige stålkomponenter ned.

  

• Applikationer: HCWI bruges almindeligvis til mølleforinger, knuser hamre, og slibekugler.
  Disse komponenter nyder godt af legeringens høje hårdhed, hvilket reducerer slitage over længere tids brug i slibende miljøer.

Mangan stål (Hadfield stål)

• Hårdhed: 200–550 HB (afhænger af graden af ​​arbejdshærdning)
• Egenskaber: Manganstål er unik i sin evne til at hærde, hvilket betyder, at dens hårdhed øges med den stød og friktion, den oplever under drift.
  Det er et ideelt materiale til miljøer med stor påvirkning, da dens sejhed forbedres, da den absorberer energi.
  Denne hærdningsevne gør manganstål særligt effektivt i udstyr, der udsættes for gentagelser, kraftige påvirkninger, såsom knusere, skovl spande, og gravemaskiner.
• Applikationer: Manganstål bruges almindeligvis til kæbeplader, knusere, og læsserskovle på grund af dens bemærkelsesværdige slagfasthed og arbejdshærdende egenskaber.

Nikkel-hårde strygejern og kompositmaterialer

• Egenskaber: Nikkelbaserede legeringer og kompositmaterialer er designet til høj sejhed og forbedret modstandsdygtighed over for både slid og korrosion.
  Nickel alloys excel in highly erosive environments where chemical wear and physical wear are prevalent.
  They offer better corrosion resistance compared to other hard alloys, which makes them ideal for slurry pumps and hydrocyclones exposed to abrasive slurries and corrosive fluids.
• Applikationer: Nickel alloys are typically used in slurry pumps, hydrocyclones,
  and other equipment exposed to highly corrosive and abrasive environments, such as those found in chemical and acid-processing operations.

Varmebehandling og metallurgiske forbedringer

Once wear-resistant alloys are cast into components, the material’s microstructure can be further enhanced through various heat treatments.

These processes improve hardness, sejhed, and wear resistance to extend the service life of the parts.

Slukning og temperering

• Behandle: Quenching and tempering are common heat treatment processes that improve the hardness and toughness of castings.
  The components are heated to a high temperature and then rapidly cooled (slukket) in water or oil.
  This process hardens the alloy, gør den mere modstandsdygtig over for slid.
  The subsequent tempering process involves reheating the material to a lower temperature to relieve stresses and improve its ductility, thus reducing the risk of brittleness and cracking.
• Fordele: Quenching and tempering increase the wear resistance of components while maintaining an optimal balance of hardness and toughness.
  This process is essential for components like crusher liners, which need to endure high-impact forces without cracking.

Austempering

• Behandle: Austempering is another heat treatment technique used primarily for high-carbon steels and irons.
  It involves heating the material to a temperature where the austenite phase forms, followed by rapid cooling in a bath of molten salt.
  This process results in the formation of a bainitic microstructure, which provides higher toughness than conventional quenching while maintaining high hardness.
• Fordele: Austempering is ideal for components that need a combination of toughness and abrasion resistance, such as grinding mill liners and certain types of bucket teeth.
  The high hardness ensures wear resistance, while the improved toughness prevents cracking under impact.

Karbiddannelse

• Behandle: Carbide formation is a crucial metallurgical process in the production of HCWI alloys.
  Under casting, carbon and chromium interact to form hard carbide particles within the iron matrix.
  These carbides are extremely hard and significantly enhance the wear resistance of the casting.
  The distribution and concentration of these carbides affect the overall wear resistance and impact resistance of the casting.
• Fordele: Carbide formation is one of the primary reasons for the high abrasion resistance of HCWI,
  making it suitable for applications such as mill liners, knuser hamre, and other parts exposed to severe abrasion.

Sammenlignende materialeanalyse

Selecting the best material for a given mining application involves balancing trade-offs between hardness, sejhed, koste, and other performance factors.

Understanding the relative advantages and disadvantages of different alloys is critical for manufacturers and engineers when choosing the right material for specific applications.

Materiale	Hårdhed	Sejhed	Koste	Bedste applikationer
Høj-krom hvidt jern	600+ Hb	Moderat til lav	Moderat til høj	Mill liners, knusere, grinding balls
Mangan stål	200–550 HB	Høj	Lav til moderat	Jaw plates, loader buckets, knuser hamre
Nikkellegeringer	450–550 HB	Moderat	Høj	Slurry pumps, hydrocyclones
Ceramic-Enhanced Composites	800+ Hb	Lav	Høj	Grinding media, specialized wear components

HCWI vs. Mangan stål

While HCWI is harder and provides superior wear resistance, it can be more brittle under impact loads compared to manganese steel.

Manganese steel, with its unique ability to work-harden under impact, is often chosen for components that face repeated, high-energy impacts.

The key trade-off is between durability (Slidbestandighed) og sejhed (Konsekvensmodstand), and the choice depends on the specific nature of the mining operation.

Keramiske forstærkninger i støbegods

Ceramic-reinforced materials combine the extreme hardness of ceramics with the toughness of metallic alloys.

These composites are often used in areas where maximum hardness is required, such as grinding media or specialized wear components.

Imidlertid, ceramic reinforcements tend to be brittle, which limits their applications in high-impact environments.

Despite this limitation, these materials offer significant advantages in specific applications where abrasion resistance is critical, and impact forces are lower.

Nikkellegeringer vs.. Krom jern

Nickel alloys offer better corrosion resistance than chromium-based alloys, making them ideal for use in slurry pumps and other equipment exposed to harsh, erosive chemicals.

Imidlertid, chromium irons, particularly HCWI, are typically more cost-efficient when abrasion resistance is the primary concern,

as they provide excellent wear properties without the high cost of nickel alloys.

4. Fremstillingsprocesser for slidbestandige støbegods

Støbningsteknikker

De casting technique selected for producing wear-resistant components depends on factors such as component geometry, størrelse, and the required precision of the part:

• Sandstøbning: This method is ideal for large and thick-walled components such as mill liners and crushers. It is cost-effective for large-scale production.
• Investeringsstøbning: Denne teknik producerer højpræcisionsstøbegods, som er ideel til indviklede geometrier, såsom pumpehjul eller gyllepumpehus.
• Centrifugalstøbning: Denne metode bruges til cylindriske komponenter som bøsninger og foringer, sikre ensartede materialeegenskaber gennem hele støbningen.

Post-casting-behandlinger

Efterstøbningsbehandlinger kan yderligere forbedre slidstyrken af ​​støbte dele:

• Overfladeteknik: Teknikker såsom hardfacing, termisk sprøjtning,
  og laserbeklædning kan bruges til at tilføje et beskyttende lag til støbeoverfladen, derved øger dens modstandsdygtighed over for slid og forlænger dens levetid.
• Ikke-destruktiv test (Ndt): Kvalitetskontrol er afgørende for at sikre pålideligheden af ​​slidbestandige støbegods.
  NDT metoder såsom røntgen, Ultralydstest, og magnetisk partikelinspektion bruges almindeligvis til at opdage potentielle defekter i støbegods, før de tages i brug.

Bæredygtighed i produktionen

Efterhånden som miljøhensyn vokser, bæredygtighed i støbeprocessen bliver vigtigere:

• Genbrug af metalskrot: Genanvendelse af metalskrot reducerer efterspørgslen efter nye materialer, sænke produktionsprocessens CO2-fodaftryk.
• Energieffektiv smeltning: Implementering af energieffektiv praksis i støberier hjælper med at reducere den samlede miljøpåvirkning af støbeproduktion.

5. Industriapplikationer og casestudier

I dette afsnit, vi udforsker nøgleanvendelser af slidbestandige støbegods i mineudstyr og

præsentere virkelige casestudier, der fremhæver fordelene ved disse materialer til at forbedre minedriften.

Crusher Liners i Hard Rock Mining

Problem:

I hard rock minedrift, knusere udsættes for ekstreme kræfter på grund af den høje slibeevne af materialer som granit, basalt, and ore.

Traditional manganese steel crusher liners often require frequent replacements due to excessive wear, resulting in costly downtime and increased maintenance expenses.

Løsning:

Høj-krom hvidt jern (HCWI) was chosen as an alternative material for the crusher liners.

HCWI alloys offer superior abrasion resistance due to the formation of hard chromium carbide phases within the iron matrix,

making them much more durable compared to standard manganese steel.

Resultat:

The introduction of HCWI liners extended the service life of crusher components by 35%, significantly reducing the frequency of replacements.

This reduction in downtime not only cut maintenance costs but also improved operational efficiency, as crushers could operate longer before requiring part replacements.

Derudover, the mining company observed fewer operational interruptions, contributing to a more stable production flow.

Gyllepumpehjul i sure miljøer

Problem:

I minedrift, der involverer gyllehåndtering (F.eks., ved forarbejdning af mineraler eller tailings), pumpehjul er udsat for både slid fra faste partikler og korrosion fra sure væsker.

Traditionelle materialer fejler ofte hurtigt på grund af kombinationen af ​​disse barske forhold, fører til hyppige udskiftninger og driftsforstyrrelser.

Løsning:

Nikkelbaserede legeringer blev udvalgt til gyllepumpehjulene.

Nikkellegeringer giver fremragende korrosionsbestandighed, især i sure miljøer, mens den stadig opretholder tilstrækkelig sejhed til at modstå slammets slibende natur.

I nogle tilfælde, kompositmaterialer blev også indarbejdet, yderligere at forbedre både slidstyrken og korrosionsbestandigheden af ​​løbehjulene.

Resultat:

Brugen af ​​nikkel-baserede legeringer forlængede gyllepumpens løbehjuls levetid med 40%, hvilket direkte bidrog til reducerede nedetid og vedligeholdelsesomkostninger.

Derudover, den forbedrede korrosionsbestandighed forbedrede pumpernes generelle pålidelighed, sikre mere ensartet gylletransport i forarbejdningsanlægget.

Innovationer i transportørsystemer

Problem:

Transportørsystemer i minedrift udsættes ofte for alvorligt slid fra slibende materialer såsom knust malm, smuds, og sand.

Transportørdele som sliskeforinger og båndskrabere oplever betydeligt slid over tid, fører til hyppige udskiftninger og højere driftsomkostninger.

Løsning:

At tackle dette, modulære slidbestandige støbegods blev introduceret i designet af transportørsystemer.

Disse afstøbninger, fremstillet af materialer med høj hårdhed såsom HCWI eller keramisk forstærkede kompositter, blev brugt til slidstærke komponenter såsom liners og bælteskrabere.

The modular design also allowed for easy and quick replacement of worn components without having to shut down the entire conveyor system.

Resultat:

The modular wear-resistant castings reduced maintenance time by 50%, allowing mining operations to maintain continuous production.

The durability of these components also decreased the need for frequent part replacements, leading to long-term cost savings and reduced material waste.

Desuden, the efficiency of the conveyor system improved as it was able to transport materials without interruption, even in high-wear environments.

Gravemaskineskovle og skovltænder

Problem:

Excavator buckets and shovel teeth are subject to extreme wear due to high-impact loading and abrasive materials, such as gravel, rock, and dirt.

The wear and tear on these components often result in downtime, reducing the efficiency of mining operations.

Løsning:

Manganese steel (Hadfield steel) was selected for the excavator buckets and shovel teeth.

Its work-hardening properties make it ideal for handling high-impact forces, such as those encountered during digging, while maintaining excellent toughness even under repetitive stress.

Derudover, some components were surface-hardened using techniques such as laser cladding to further enhance their wear resistance.

Resultat:

The work-hardening properties of manganese steel enabled the excavator buckets and shovel teeth to last significantly longer in the field.

Maintenance intervals were extended by 30–40%, and the frequency of replacement was reduced, resulting in lower operating costs and improved machine availability.

The toughness of the material also minimized the risk of component failure, increasing the overall reliability of the mining equipment.

6. Standarder og test for slidbestandige støbegods

To guarantee that these castings meet the required performance standards, strict global quality benchmarks and rigorous testing methods are followed.

This section highlights the key industry standards and testing processes used to assess the quality of wear-resistant castings.

Globale kvalitetsbenchmarks

To ensure the reliability of wear-resistant castings, manufacturers follow established international standards that regulate their performance.

These standards help ensure that the castings are durable enough to withstand the harsh conditions of mining operations.

ASTM A532: Slidbestandigt støbejern

ASTM A532 is a standard that defines the properties of abrasion-resistant cast irons used in mining equipment.

It specifies the required hardness and microstructure of materials, particularly high-chromium white irons, which provide excellent abrasion resistance.

These materials are commonly used in crusher liners, grinding mills, and other equipment exposed to wear.

ISO 21988: Metoder til slidtestning

ISO 21988 sets the guidelines for testing wear-resistant materials.

It provides standardized methods for simulating the wear conditions that materials face in mining, such as abrasion, erosion, og korrosion.

By adhering to this standard, manufacturers can ensure that castings are reliable and durable for real-world mining operations.

Laboratorie- og feltforsøg

In addition to following global standards, manufacturers perform both laboratory and field testing to validate the performance of wear-resistant castings.

These tests simulate real-world conditions to evaluate how well the materials stand up to the challenges they will face in mining operations.

ASTM G65: Test af tørt sand/gummihjul

De ASTM G65 test is used to simulate abrasive wear conditions by exposing materials to dry sand and a rubber wheel.

This test helps manufacturers determine how well castings will resist abrasion in applications like crushers and grinding mills.

Feltforsøg: Test i den virkelige verden

While laboratory tests offer valuable insights, field trials provide real-world data on how wear-resistant castings perform in actual mining environments.

These trials help evaluate how castings hold up in extreme conditions, såsom høje temperaturer, exposure to corrosive chemicals, and high-abrasion situations.

7. Udfordringer og løsninger i slidstærke støbegods

Wear-resistant castings significantly improve equipment lifespan and operational efficiency,

There are several challenges that manufacturers and mining operators face in ensuring optimal performance.

Almindelige industrismertepunkter

Balancering af omkostninger vs. Præstation

One of the main challenges in selecting wear-resistant materials is balancing cost and performance.

Premium alloys with high abrasion resistance, such as high-chromium white iron (HCWI) and manganese steel, often come with higher upfront costs.

While these materials extend the lifespan of mining equipment, the initial investment can be substantial, especially for smaller operators.

• Løsning: Manufacturers and operators can optimize their material selection process by carefully analyzing the cost-benefit trade-offs based on expected wear rates and equipment usage.
  Derudover, advancements in manufacturing processes, such as precision casting and additive manufacturing, help reduce production costs while maintaining high material performance.
  For eksempel, hybrid materials or composite alloys can offer a more cost-effective solution by combining the strengths of different metals, offering good wear resistance at a lower price point.

Forstyrrelser i forsyningskæden

Specialized alloys and materials, such as high-chromium white iron and advanced composites, are often sourced from limited suppliers.

Dette kan føre til forsyningskædeforstyrrelser, forsinkelser i produktionen, og øgede omkostninger på grund af knaphed eller geopolitiske faktorer.

• Løsning: For at afbøde denne udfordring, mineselskaber kan arbejde tæt sammen med støberier og materialeleverandører for at sikre en konstant forsyning af materialer af høj kvalitet.
  Derudover, producenter udforsker alternativer,
  såsom genanvendelse af skrot eller udvikling af lokale forsyningskæder til kritiske råvarer, at reducere afhængigheden af ​​lange forsyningskæder.

Tekniske begrænsninger

Skørhed i legeringer med høj hårdhed

Legeringer med høj hårdhed, such as high-chromium white iron, giver fremragende slidstyrke, men har tendens til at være skør.

Denne skørhed øger risikoen for revner og svigt under stødbelastninger, hvilket kan føre til katastrofale skader på udstyr og dyr nedetid.

• Løsning: En af de mest effektive løsninger på denne udfordring er udviklingen af ​​materialer med optimerede mikrostrukturer.
  For eksempel, researchers are focusing on alloy compositions that promote toughness while maintaining high hardness,
  such as the addition of certain elements (F.eks., nickel or molybdenum) to improve the impact resistance of high-hardness alloys.
  Derudover, heat treatment processes like tempering and austempering can enhance the ductility of these materials without sacrificing their wear resistance.

Svejse- og reparationsudfordringer for slidte støbegods

Worn-out castings are often difficult to repair, especially when they are made from high-hardness materials like HCWI or ceramic composites.

These materials are challenging to weld due to their high hardness and low weldability, which can lead to poor bonding and ineffective repairs.

• Løsning: To address this issue, manufacturers have developed specialized welding techniques and materials,
  such as high-hardness welding rods and surface cladding methods, to repair worn castings more effectively.
  I nogle tilfælde, wear-resistant coatings like hardfacing and thermal spraying can be used to restore the surface integrity of components without the need for welding.
  Derudover, innovative technologies such as laser cladding and electron beam welding offer more precise and effective ways to repair worn parts.

Optimeringsstrategier

AI-drevne slidsimuleringsværktøjer

Predicting the wear patterns of mining equipment is essential for optimizing maintenance schedules and ensuring the longevity of wear-resistant castings.

Traditional methods of wear prediction are often time-consuming and imprecise, making it difficult to plan for equipment downtime effectively.

• Løsning: The integration of artificial intelligence (AI) and machine learning (Ml) technologies into wear simulation tools is revolutionizing the ability to predict wear behavior accurately.
  Disse avancerede værktøjer bruger realtidsdata fra sensorer indlejret i mineudstyr til at simulere slid under forskellige driftsforhold,
  giver mulighed for mere præcise forudsigelser af komponentlevetid og optimerede vedligeholdelsesstrategier.
  Denne proaktive tilgang til vedligeholdelse reducerer uventede nedbrud og maksimerer udstyrets oppetid.

Samarbejde mellem OEM'er og metallurger

Optimering af slidstærk støbeydelse kræver tæt samarbejde
mellem producenter af originalt udstyr (OEMS) og metallurger til at designe skræddersyede løsninger skræddersyet til specifikke minedrift.
Minemiljøer er forskellige, med varierende grad af slid, påvirkning, og korrosion, og generiske støbeløsninger giver muligvis ikke altid optimal ydeevne.

• Løsning: Samarbejdspartnerskaber mellem OEM'er, materialeforskere, og metallurger er afgørende for at udvikle skræddersyede løsninger.
  By analyzing specific mining conditions and wear mechanisms, these collaborations enable the creation of alloys and casting designs that are optimized for a particular application.
  Desuden, this collaboration helps OEMs gain insights into material behaviors in real-world conditions, allowing them to continuously improve their casting technologies.

8. Nye trends og innovationer

Avancerede slidbestandige materialer

The next generation of wear-resistant materials promises even more durability:

• Nano-Structured Alloys: These alloys improve hardness while maintaining flexibility, making them more effective in handling both abrasion and impact wear.
• Gradient Materials: These materials have varying hardness levels from the surface to the core, allowing them to handle extreme stress more efficiently.

Digitalisering i slidovervågning

The use of IoT-enabled sensors integrated into mining equipment enables real-time tracking of wear and tear, giver værdifuld indsigt til forudsigelig vedligeholdelse.

Dette reducerer nedetiden ved at identificere problemer, før de forårsager udstyrsfejl.

Additiv fremstilling af sliddele

• 3D-trykte forme: Additiv fremstilling giver mulighed for hurtig prototyping og tilpasning af sliddele, hvilket er særligt værdifuldt for lavvolumen eller højt specialiserede komponenter.

9. Konklusion

Slidfaste støbegods er uundværlige for at reducere nedetiden, vedligeholdelsesomkostninger, og øge den samlede produktivitet i minedrift.

Med løbende fremskridt inden for materialevidenskab, Fremstillingsteknikker, og forudsigelig vedligeholdelse, fremtiden for slidbestandige støbegods ser lovende ud.

Minevirksomheder, der anvender de seneste innovationer inden for slidbestandige materialer og produktionsteknikker, vil være godt positioneret til at være foran i en stærkt konkurrencepræget og krævende industri.

Hvis du leder efter slidstærke støbegods af høj kvalitet, vælger DENNE er den perfekte beslutning til dine produktionsbehov.

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