copy of md-002 material selection-copy

NUMBER: MD-002

WORKSHEET: Matl Summary PAGE: 1/14

ISSUE DATE: Nov 12/07

REVISION: 8

PREPARED BY: G. COOKE

APPROVED BY:G. COOKE

ATS Automation Tooling Systems Inc.

Cambridge Machine Tool Division

Tel: (519) 653-6500 FAX: (519) 650-6692

MATERIAL SELECTION GUIDECARBON STEELS

Material Heat Treatment/ Heat Temper Hardness Yield Ultimate % Elong Mach'ty Grind'ty Weld'ty Toughness Wear Distortion Mech Property Notes Typical Applications

Process °C °C HB=Brinell ksi ksi Resist in heat-treat Flame Case Nitride Other

HRC=Rockwell C Harden Harden

1018 Cold rolled --- --- 126 HB 50 64 18.0 70% poor high low/med low low 30-35 HRC 58-60 HRC NO NO Cold rolled material has high residual stresses. Caps, simple shafts.

(due to (for case harden) (Not recommended) Prone to distortion during machining, especially if Simple, low precision, generally

instability) uneven sections. unhardened parts.

A36 Hot rolled --- --- 137 HB 36 58 20.0 fair fair excellent med low N/A 40-45 HRC NO NO Armaloy, Armoloy XADC Does not have residual stresses like 1018 CRS. med strength, low hardness

(Not recommended) Excellent weldability. parts with med toughness.

Excellent for weldments

44W Hot rolled --- --- 140 HB 44 62 20.0 fair fair excellent med low N/A 40-45 HRC NO NO Armaloy, Armoloy XADC Same as A36 but…

(CSA G40.12) (Not recommended) Higher strength than A36

Excellent for weldments

1045 Hot rolled --- --- 163 HB 45 82 16.0 60% fair low low/med low med 55-60 HRC NO NO Armaloy, Armoloy XADC More readily available than 1060. Machine components, linkages.

Cold drawn --- --- 179 HB 77 91 12.0 55% fair low low/med low med 55-60 HRC NO NO Armaloy, Armoloy XADC

1060 As rolled --- --- 23 HRC 70 118 17.0 60% fair low low/med low med 60-64 HRC NO NO Armaloy, Armoloy XADC Low toughness, med strength. Cams, low pressure wear pads.

normalized, air cool 900 --- 20 HRC 61 113 18.0 low fair low low/med low/ med. med 60-64 HRC NO NO Armaloy, Armoloy XADC

annealed 690 --- 8 HRC (179HB) 54 90 20.0 low fair low med low/ med. med 60-64 HRC NO NO Armaloy, Armoloy XADC

ALLOY STEELS




4140 annealed --- --- 13 HRC 60 95 25.7 66% good low med low low/med 54-58 HRC NO see below Tenifer, Armoloy, Armoloy XADC Typical as-received from mill. Shafts, pins, linkages, clamp arms.

normalized, air cool 870 --- 30 HRC 95 148 17.7 fair good low med/high low/med low/med NO NO see below NO Purchased as "Pre-hardened" (4140 HT). Good when tough, med hard

normalized, Q&T 870 425 45 HRC 195 210 15.0 low good low high low/med low/med NO NO see below NO High hardness, moderate toughness. material req'd.

oil quench & dbl temper 845 540 33 HRC 140 165 18.0 fair good low high low/med low/med NO NO see below NO Good balance of hardness and toughness. Lower cost than tool steels.

Nitrided see notes 28-32 HRC core 100 150 17.0 N/A med N/A med/high high low N/A N/A 54-58 HRC N/A Nitrided 4140 has excellent wear resistance. Items under high stress and wear

Nitriding is expensive and long lead time process.

4340 annealed --- --- 24 HRC 68 108 22.0 50% good low med low low/med 55-60 HRC NO see below Tenifer, Armoloy, Armnoloy XADC Typical as-received from mill Gears, pins, linkages, clamp arms.

normalized, air cool 870 --- 39 HRC 125 186 12.2 fair/low good low med/high low/med low/med NO NO see below NO Med hardness, med toughness.

oil quench & temper 800 540 38 HRC 166 175 17.0 fair/low good low high low/med low/med NO NO see below NO Stronger and tougher than normalized.

oil quench & dbl temper 845 315 49 HRC 235 255 12.0 fair/low good low med/high med low/med NO NO NO NO Excellent strength and fatigue resistance.

Nitrided see notes 34-39 HRC core 120 180 12.5 N/A med N/A med/high high low N/A N/A 54-58 HRC N/A Excellent wear and fatigue resistance. Items under high stress and wear.

Nitriding is expensive and long lead time process.

8620 as rolled --- --- 162HB 65 93 25.0 65% fair low med low N/A 40-45 HRC (*) N/A NO NO High surface hardness w/ good

case hardened 925 150 42 HRC (core) 150 189 11.5 very low good N/A med very high low N/A 62-64 HRC, 1.9mm DP N/A N/A Deepest case, highest hardness, good core props. internal toughness.

case hardened 925 230 38 HRC (core) 134 181 12.8 very low good N/A med/high high low N/A 56-58 HRC, 1.3mm DP N/A N/A Thinner case, less hard, but tougher core props. Shafts, gears, rotary distributors,

Spindle noses, fixture clamp arms,

dowel pins.

1144 hot rolled --- --- 10 HRC (187 HB) 53 97 15.0 65% fair low med low med 56-58 HRC NO NO Armoloy, Armnoloy XADC

cold drawn --- --- 13 HRC (197 HB) 90 100 10.0 65% fair low med low med 56-58 HRC NO NO Armoloy, Armnoloy XADC Improved strength over hot rolled. Med strength pins, shafts.

TOOL STEELS




A2 annealed --- --- 19 HRC 55 115 18.0 med high low med low/med very low (*) NO NO NO As received from mill. Forming dies, plug and ring gauges

air qench & dbl temper 970 650 43-45 HRC 160 210 10.0 low high low med/high med very low N/A NO NO NO Med hardness with very good toughness. Non-critical wear pads

air qench & dbl temper 970 595 51-53 HRC 195 250 6.0 low high low med med/high extremely low N/A NO NO NO Hard but good toughness remaining.

air qench & dbl temper 970 540 56-58 HRC 210 270 3.0 low high low low/med med/high very low N/A NO NO NO Max recommended hardness for most applications.

air qench & dbl temper 970 205 60-62HRC 230 310 2.0 very low high low low high low N/A NO NO NO Brittle. Avoid using.

air qench & dbl temper 970 150 62-64HRC 230 310 <2.0 very low high low brittle high low/med N/A NO NO NO Very brittle. NOT RECOMMENDED

D2 annealed --- --- (**) (**) (**) med med low low/med low/med low (*) NO NO Arvin TD Forming dies, chuck inserts, clamp

air qench & dbl temper 1010 595 47-49 HRC (**) 260 (**) (**) low/med med low med med very low N/A NO NO D2 has its best impact resistance at this temper. pads, plug and ring gauges.

air qench & dbl temper 1010 510 56-58HRC (**) 425 (**) (**) low med low low high low N/A NO NO NO D2 has good hardness/ OK impact resistance at this temper.

air qench & dbl temper 1010 200 60-62HRC (**) 440 (**) (**) low med low very low very high low N/A NO NO NO Brittle. Avoid using.

air qench & dbl temper 1010 95 62-64HRC (**) 415 (**) (**) very low med low brittle excellent low N/A NO NO NO Very brittle. NOT RECOMMENDED

O1 annealed --- --- 9 HRC 70 85 25.0 high high low med low/med med/high 56-60 HRC NO NO NO As received from mill. Low cost, med hardness parts.

oil quench & dbl temper 800 540 40-44HRC 125 145 8.0 low high low low/med med med/high N/A NO NO NO OK for med hard, low precision parts. Low precision, hardened parts.

oil quench & dbl temper 800 315 54-56HRC 272 280 2.0 low high low very low med med/high N/A NO NO NO Brittle. Avoid using.

oil quench & dbl temper 800 230 60-62HRC 280 310 <2.0 very low high low brittle med/high med/high N/A NO NO NO Very brittle. NOT RECOMMENDED

S7 annealed --- --- med/high med low med low low/med (*) NO NO NO As received from mill. Parts subject to high shock loads.

air quench & dbl temper 940 315 53-55 HRC 215 280 10.0 low med low very high low low/med N/A NO NO NO Best heat treat for toughness and strength.

air quench & dbl temper 940 150 58-60 HRC 200 335 5.0 low med low high low low/med N/A NO NO NO Heat treat for highest S7 hardness

CPM 10V air quench & triple temper 1120 550 58-60 HRC low med N/A low/med excellent low/med N/A NO NO NO Good combination of toughness and wear resistance. Wear pads subject to high abrasion.

NOTES: Properties shown above are typical for 1" (25mm) dia bars. Material properties may vary with part thickness/diameter.

For critical applications involving safety, fatigue resistance, etc. consult the manufacturer's product data.

(*) This particular heat treat process is feasible, but generally better material/heat treat choices are available.

(**) Compressive properties are shown. D2 is not rated for tensile applications.

MECHANICAL DESIGN STANDARDS

Surface Heat Treatments



228381983.xls.ms_office

NUMBER: MD-002



REVISION: 8




NUMBER: MD-002



REVISION: 8




Machine Tool Div. 250 Royal Oak Road, Box 32100, Preston Centre, Cambridge, ON N3H 5M2

Tel: (519) 653-6500 FAX: (519) 650-6692

CAST IRON SELECTION GUIDE

Material Heat Treatment/ Hardness Yield Ultimate % Elong Mach'ty Grind'ty Weld'ty Toughness Wear Mech Property Notes Typical Applications General Notes

Process ksi ksi Resist

ASTM poured or continuous cast 183-285 HB --- 40 --- very good good N/A low med Better damping properties than 65-45-12 & 80-55-06. (2 - 20X greater.) Tombstones, complex fixtures, deep risers, large bases, NOTE: Do not use A48CL30 as it is too

A48CL40 spindle housings, columns, axis slides & saddles. soft and has low ultimate. strength.

gray iron Cast iron has better vibration damping

See HT notes for poured casting critical drawing notes. properties than steel. (10 to 60X greater.)

See Damping Notes for damping properties.

Poured castings are often more practical than continuous cast (below)

if shape is complex and/or quanitity is large.

Continuous cast material does not have porosity. X-ray inspection not required.

Better lead time than poured castings. (Typically one week or less.)

ASTM poured or continuous cast 131-220 HB 45 65 12 very good good low low/med med (Same drawing notes as above for poured castings.) Items requiring higher strength than A48CL40 but more damping (Same notes as above regarding continuous cast versions.)

A536 Stronger and tougher than A48CL40. Tougher than 80-55-06. than steel. (E.g. fixture blocks)

65-45-12 Less damping than A48CL40, but better than steel and 80-55-06. Avoid using where vibration damping is critical See Damping Notes for damping properties.ductile iron See HT notes for poured casting critical drawing notes. (e.g tombstones, slides, columns or bases)

ASTM poured or continuous cast 187-269 HB 55 80 6 good good low low med (Same drawing notes as above for poured castings.) Items requiring higher strength than A48CL40 or 65-45-12 (Same notes as above regarding continuous cast versions.)

A536 Stronger than 65-45-12, not as tough. Stronger & tougher than A48CL40. but more damping than steel.

80-55-06 Less damping than 65-45-12 & A48CL40 but better than steel. Avoid using where vibration damping is critical See Damping Notes for damping properties.

ductile iron See HT notes for poured casting critical drawing notes. (e.g. fixtures, tombstones, slides, columns or bases)


NUMBER: MD-002



REVISION: 8



General Notes

Not recommended for weldments

if stress relief is required

May distort during maching. Not suited

for high accuracy applications

Hot rolled exterior wears tooling

during machining. Core has fair

machinability.

Hot rolled exterior wears tooling

during machining. Core has fair

machinability.

Stronger than 1018, less distortion.

DO NOT use for bending, torsion,shear or

impact applications.

Low cost.

General Notes

Nitride should be used for when wear and

and abrasion resistance are required.

Tenifer process may be used for high surface

hardness and low friction (gears, splines.)

Do not use 4140HT if further heat treating is required.

4140 has low corrosion resistance, needs surface

treatment (black oxide, tenifer, nitride)

Good for severe service with good core props.

Good when tough, med hard material req'd.

More expensive than 4140.

Tenifer may be used -- see 4140 notes.

Use when stength & wear resistance are required.

Primarily used when case hardened,

where high surface hardness and good

toughness are required.

Much more stable in machining than 1018 CRS.

Not as strong or tough as 4140, 4340.

General Notes

General purpose tool steel.

Very low distortion in heat treat.

Material cost more than O1, less than D2.

Overall cost often less than O1 because

less machining required after heat treat.

Tougher than O1 and D2.

Not as tough as S7, A2 or O1

Better wear resistance than A2 and O1.

Avoid using hardened O1 as distortion

after heat treat is significant.

A2 or D2 are usually better choices

when hardness and dim. accuracy required.

Best tool steel for toughness but lowest for

wear resistance.

Med cost (more than A2, O1, less than D2)

About 25% toughe than D2, apprx 5 x more wear resitant.

Expensive. Proprietary metal made by Crucible Steels.


NUMBER: MD-002



REVISION: 8




NUMBER: MD-002



REVISION: 8



NOTE: Do not use A48CL30 as it is too


Poured castings are often more practical than continuous cast (below)

if shape is complex and/or quanitity is large.

Continuous cast material does not have porosity. X-ray inspection not required.

Better lead time than poured castings. (Typically one week or less.)

(Same notes as above regarding continuous cast versions.)


(Same notes as above regarding continuous cast versions.)



NUMBER: MD-002

WORKSHEET: Wear & Tough PAGE: 7/14


REVISION: 8





Tel: (519) 653-6500 FAX: (519) 650-6692

TOOL STEEL RELATIVE TOUGHNESS AND WEAR RESISTANCE CHARTS



NUMBER: MD-002

WORKSHEET: HT Notes PAGE: 8/14


REVISION: 8





Tel: (519) 653-6500 FAX: (519) 650-6692 MECHANICAL DESIGN STANDARDS

Material Process Drawing/Process Notes Informational Notes (Not on Drawing)

1018 Case Harden Case harden to 58-60 HRC, effective case depth 1mm. (Note: Use less case depth on small parts or thin sections.

Carburize and cool. Reduce case depth in thin sections (should be <0.2 of thickness)

Reheat, water quench. Temper

1045 Flame Harden Flame harden to 55-60 HRC, case depth 2 to 3 mm. (Indicate areas to be flame hardened with leader on drawing)

Reduce case depth in thin sections (should be <0.2 of thickness)

1060 Normalize Heat to 900C, air cool to 20 HRC

Flame Harden Flame harden to 60-64 HRC, case depth 2 to 3 mm. (Indicate areas to be flame hardened with leader on drawing)


4140 Normalize, Q & T Normalize at 870C, reheat to 845C.

Quench in oil, double temper at 425C to 44-46 HRC.

Temper time minimum 2 hr per 25 mm thickness per cycle.

Oil Quench & Temper Oil quench from 845C, temper at 540C to 31-33 HRC.

Temper time minimum 2 hr per 25 mm thickness.

Flame Harden Flame harden to 54-58 HRC, case depth 1.5 to 2 mm. (Indicate areas to be flame hardened with leader on drawing)


Nitride Oil Quench & Temper to 28-32 HRC For nitride process to have adequate hardness,

Temper time minimum 2 hr per 25 mm thickness. initial core hardness of 28-32 HRC is critical.

Rough Machine

Stress Relieve (If items are to be left soft, they can be masked.

Finish machine Mark "leave soft" areas on the drawing.)

Nitride to 0.25 to 0.50 mm DP. to 54-58 HRC.

Final lap or grind.

Tenifer Oil quench & Temper to 34-38 HRC Core must be hardened before tenifer treeatment.

Temper time minimum 2 hr per 25 mm thickness. Good process for sliding parts (gears, splines).

Ferritic nitrocarburize to 55 HRC. Coeff of friction can be as low as 0.12.

White layer depth 0.04 to 0.05 mm. Parts may grow ~5 microns per side after treatment.

Improves corrosion resistance significantly.

Heat Treat Detailed Process Notes


NUMBER: MD-002



REVISION: 8





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4340 Normalize, air cool Normalize at 870C, air cool to 37-39 HRC.

Oil Quench & Temper Oil quench from 800C, temper at 540C to 36-38 HRC.


Oil Quench & double temper Oil quench from 845C, double temper at 315C to 48-50 HRC.


Flame Harden Flame harden to 55-60 HRC, case depth 1.5 to 2 mm. (Indicate areas to be flame hardened with leader on drawing)


Nitride Oil Quench & Temper to 34-39 HRC For nitride process to have adequate hardness,

Temper time minimum 2 hr per 25 mm thickness. initial core hardness of 34-39 HRC is critical.

Rough Machine

Stress Relieve (If items are to be left soft, they can be masked.

Finish machine Mark "leave soft" areas on the drawing.)

Nitride to 0.25 to 0.50 mm DP. to 54-58 HRC.

Final lap or grind.

Tenifer Oil quench & temper to 36-40 HRC Core must be hardened before tenifer treeatment.

(Ferritic Nitrocarburizing) Temper time minimum 2 hr per 25 mm thickness. Good process for sliding parts (gears, splines).

Ferritic nitrocarburize to 55 HRC. Coeff of friction can be as low as 0.12.

White layer depth 0.04 to 0.05 mm. Parts may grow ~5 microns per side after treatment.

Improves corrosion resistance significantly.

8620 Case Harden Carburize at 925C.

(For good case & core) Case Harden to 62-64 HRC, 1.7 to 1.9 mm effective case depth. Do not case harden holes or areas to be threaded.

Cool & reheat. (If items are to be left soft, they can be masked.

Quench in agitated oil. Temper at 150C. Mark "Leave soft. Do not carburize" areas on the drawing.)

Temper time minimum 2 hr per 25 mm thickness. Reduce case depth in thin sections (should be <0.2 of thickness)

Case Harden Carburize at 925C. Do not case harden holes or areas to be threaded.

(For max core toughness) Case Harden to 56-58 HRC, 1.2 to 1.4 mm effective case depth. (If items are to be left soft, they can be masked.

Quench in agitated oil. Temper at 230C. Mark "Leave soft. Do not carburize" areas on the drawing.)

Temper time minimum 2 hr per 25 mm thickness. Preferred process for shafts due to better core toughness.

Shorter lead time, less costly than cool/re-heat process above.


1144 Flame Harden Flame harden to 56-58 HRC, case depth 1.5 to 2 mm.


NUMBER: MD-002



REVISION: 8





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A2 Air Quench & double temper Air quench from 970C, double temper at 650C to 43-45 HRC.


Air Quench & double temper Air quench from 970C, double temper at 595C to 51-53 HRC.




Air Quench & double temper Air quench from 970C, double temper at 205C TO 60-62 HRC. BRITTLE. AVOID USING.


Air Quench & double temper Air quench from 970C, double temper at 150C TO 62-64 HRC. VERY BRITTLE. NOT RECOMMENDED.


D2 Air Quench & double temper Air quench from 1010C, double temper at 595 C to 56-58 HRC. Best D2 temper for impact resistance.

Temper time minimum 1 hr per 25 mm thickness per cycle. (Note there are much better alloys than D2 for impact resistance.)

Air Quench & double temper Air quench from 1010C, double temper at 510 C to 56-58 HRC. Best D2 temper for hardness with reasonable toughness.


Air Quench & double temper Air quench from 1010C, double temper at 200C to 60-62 HRC. BRITTLE. AVOID USING.


Air Quench & double temper Air quench from 1010C, double temper at 95C to 62-64 HRC. VERY BRITTLE. NOT RECOMMENDED.


Arvin TD (Contact Arvin TD for details.) Capable of surface hardness >90 HRC. Extreme wear resistance.

(Thermal Diffusion) Low friction surface, well suited for sliding applications.

Expensive, long lead time (~3 weeks) process.

O1 Flame Harden Flame harden to 56-60 HRC. Case depth 2.0 to 3.0mm. (Indicate areas to be flame hardened with leader on drawing)


Oil Quench & Temper Oil quench from 800C, double temper at 540C to 40-44 HRC.


Oil Quench & double temper Oil quench from 800C, double temper at 315C to 54-56 HRC.


Oil Quench & double temper Oil quench from 800C, double temper at 230C to 60-62 HRC. VERY BRITTLE. NOT RECOMMENDED.


S7 Air Quench & double temper Air quench from 940C, double temper at 315C to 53-55 HRC.




CPM 10V Vaccum quench & triple temper Quench & Triple temper to 58-60HRC Triple tempering is critical to achieve toughness.

First Stage Preheat 820-845C, second stage 1010-1040C

Austenize at 1120C.

Vacuum quench to 50C.


Cool to room temperature between temper cycles.


NUMBER: MD-002



REVISION: 8





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(Various) Armoloy Armoloy TDC to 70/72 HRC Low coefficient of friction (0.17)

Note: not Hard surface (Diamond deposited on part surface)

compatible with Good corrosion resistance.

aluminum, Part will grow 0.00001" to 0.0006" per side (0.0001" to 0.0002" typical)

titanium, Needs 12 to 32 microinch surface finish for good adhesion.

magnesium. Note: Minimum batch charge of $360US -- expensive for

low volume parts.

Does not change properties of parent material (e.g. yield, etc.)

Generally easy to leave areas soft if required.

Armoloy XADC Armoloy XADC to 90/92 HRC Very low coefficient of friction (0.12)

Extremely hard surface (Diamond deposited on part surface)

Excellent corrosion resistance.

Needs 8 to 32 microinch surface finish for good adhesion.

Part will grow 0.00001" to 0.0006" per side (0.0001" to 0.0003" typical)

Note: Minimum batch charge of $360US --expensive for

low volume parts.

Does not change properties of parent material (e.g. yield, etc.)

Generally easy to leave areas soft if required.


NUMBER: MD-002



REVISION: 8





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Gray Iron (Poured from mould) (General Notes -- All Poured Castings)

or Ductile Stress relieve at 650C prior to machining.

Iron Shot blast and remove loose sand after stress relief.

All rads 5mm unless otherwise specified.

All dimensions <100mm: +3mm, -0mm unless otherwise noted.

All dimensions >100mm: +5mm, -0mm unless otherwise noted.

Machining allowances do not include draft angle.

(Notes for areas with no fluid through)

Reference ASTM E446/E186/E280 Only allow level 4 in special cases, when the affected area will

Porosity: Level 3 not be machined and is not under high stress.

Inclusions: Level 3 Level 4 should not be put on a drawing as acceptable.

Shrinkage: Level 3

Hot Tears & cracks: None

(For areas where fluids flow through the casting)

Inspect per ASTM E446/E186/E280 Procedures

Porosity: Level 2

Inclusions: Level 2 (Level 3 if >50mm thick)

Shrinkage: Level 2

Hot Tears & cracks: None

To detect internal casting defects,

radiographic inspection is required.


NUMBER: MD-002

WORKSHEET: Damping PAGE: 13/14


REVISION: 8





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DAMPING NOTES

Material

Relative

Decrease in

Amplitude Per

Cycle

Carbon Steel 1-2

Malleable Iron 3-6

Ductile Iron 3-9

High Strength Gray Iron 4-9

Low Strength Gray Iron 20-60

Hypereutectic Gray Iron >100

Figure 2

Figure 3

Damping is the ability of a material to absorb vibrational energy by some form of internal friction. In metals the primary damping mechanism is localized non-elastic (microplastic)

behaviour. Under cyclic loading conditions this microplastic behaviour, shown in Figure 2, produces a hysteresis loop whose area is proportional to the energy absorbed during each

cycle (vibration). The low stress behaviours of Gray Iron, Ductile Iron and mild steel, see Figure 1, indicate their relative damping capacities. Gray Iron, which exhibits non-elastic

behaviour at very low stresses, has the highest damping capacity, while steel, which behaves elastically up to its yield point, has the lowest damping capacity. Figure 3 schematically

illustrates the relative damping capacities of these materials through a comparison of reduction in vibrational amplitude with time. The relative decreases in vibrational amplitude

illustrated in this Figure can vary as follows for ferrous materials:


NUMBER: MD-002

WORKSHEET: Damping PAGE: 14/14


REVISION: 8



Note the damping for Grey Iron is better

Figure 1 than Ductile, which is better than Steel.


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