Filler Metals and Allied Materials for Metal Arc Welding: Standards and Guidelines

Filler metals and allied materials are key consumables in metal arc welding. CSA W48 provides specifications for choosing the right electrodes and rods. This standard helps classify and evaluate filler materials. Proper selection leads to strong, durable joints in welding methods like gas-shielded metal arc welding (GMAW) and gas tungsten arc welding (GTAW).

Filler metals must match the base materials’ characteristics. This compatibility prevents issues like joint failure or material deterioration over time. Additionally, guidelines stipulate proper storage and handling of these materials to maintain their integrity. Common filler metals include consumables like rods and wires, each designed for different applications and welding techniques.

Understanding these standards is vital for welders seeking quality results. Complying with guidelines helps maintain industry standards and enhances the overall safety of welding processes.

In the next section, we will explore specific types of filler metals, their applications, and the importance of selecting the right materials for various welding tasks. This knowledge will empower welders to achieve optimal performance and reliability in their projects.

Table of Contents

What Are Filler Metals in Metal Arc Welding and Why Are They Important?

Filler metals in metal arc welding are materials added to the weld pool to help join two base metals together. They are essential for creating strong, durable welds and can significantly influence the properties of the finished weld.

Key points about filler metals and their importance in metal arc welding include:

Definition and purpose of filler metals.
Types of filler metals.
Composition of filler metals.
Welding processes utilizing filler metals.
Impact of filler metals on weld quality.

Understanding filler metals is crucial in metal arc welding applications.

Definition and Purpose of Filler Metals: Filler metals refer to materials that are melted in the welding process and used to fill the joint between two base metals. Their primary purpose is to ensure a strong bond and maintain structural integrity.
Types of Filler Metals: Various types of filler metals exist, including bare and flux-cored wires. Bare wires are used in processes like Gas Metal Arc Welding (GMAW), while flux-cored wires contain a flux-forming agent that shield the weld from contamination. Each type serves different applications and environments.
Composition of Filler Metals: The composition of filler metals is critical. Filler metals can be made from materials such as steel, aluminum, or nickel. The choice of composition affects corrosion resistance, tensile strength, and overall weld characteristics.
Welding Processes Utilizing Filler Metals: Filler metals are integral to several welding processes, including Gas Tungsten Arc Welding (GTAW) and Shielded Metal Arc Welding (SMAW). Each technique requires specific filler materials to achieve the desired weld properties.
Impact of Filler Metals on Weld Quality: Filler metals significantly influence the quality of the weld. Properly chosen and applied filler materials can enhance weld strength, reduce defects, and ensure the weld meets designated standards and specifications. According to a study by Chmielewski et al. (2021), selecting the right filler metal can improve the performance of welds in high-stress environments, leading to increased safety and reliability.

In summary, filler metals play a crucial role in metal arc welding by creating strong bonds, influencing the quality of the weld, and being integral to various welding processes.

What Types of Filler Metals Are Commonly Used in Metal Arc Welding?

The common types of filler metals used in metal arc welding include steel, stainless steel, aluminum, and nickel alloys.

Steel
Stainless steel
Aluminum
Nickel alloys

These filler metals each offer distinct characteristics and suitability for specific applications in welding. Understanding their properties can help in selecting the right filler metal for a project.

Steel: Steel filler metals are widely used due to their strength and versatility. This category includes carbon steel and low-alloy steel fillers. According to the American Welding Society (AWS), carbon steel fillers are often chosen for general-purpose applications because they provide strong welds and good ductility. A common carbon steel filler is ER70S-6, widely noted for its excellent welding characteristics and a suitable balance of chemistry for various steel grades.
Stainless Steel: Stainless steel filler metals are essential when working with materials that require corrosion resistance. These fillers, such as ER308 and ER316, contain chromium and nickel, which enhance their resistance to rust and oxidation. Studies by the National Institute of Standards and Technology (NIST) show that the use of stainless steel fillers can significantly increase the longevity of welded structures in corrosive environments, making them ideal for industries like food processing or pharmaceuticals.
Aluminum: Aluminum filler metals are used to weld aluminum and its alloys. Common aluminum fillers include 4047 and 5356. These fillers are known for their lightweight properties and are frequently used in aerospace and automotive applications. The Aluminum Association notes that aluminum welding demands specific techniques, such as using a filler metal that has compatibility with the base metal, to ensure strong and durable joints.
Nickel Alloys: Nickel alloy fillers are used for welding high-strength steel and materials subjected to extreme temperatures or corrosive environments. Examples include ERNiCrMo-3 and ERNiCr-3 fillers. According to a 2019 study by the Welding Institute, these fillers maintain their mechanical properties even at elevated temperatures, making them appropriate for industries like oil and gas, where high performance is critical.

Choosing the correct filler metal is crucial for maintaining weld integrity and overall performance based on environmental and mechanical requirements.

How Does E6010 Filler Metal Function in the Welding Process?

E6010 filler metal functions in the welding process by providing a stable welding arc and facilitating penetration into the base material. The core components of E6010 include a carbon steel electrode and a chemical coating that generates shielding gases during welding. This shielding protects the weld pool from contamination.

During welding, the welder strikes an arc between the electrode and the workpiece. The heat generated melts both the filler metal and a portion of the base metal. The molten filler metal then fills the joint, forming a strong bond as it solidifies. The E6010 is particularly well-suited for pipe welding and overhead applications due to its deep penetration and excellent arc stability.

The E6010’s composition allows it to produce a strong, clean weld even on rusty or dirty surfaces. This characteristic is essential in fields like construction and maintenance. Additionally, the rod’s cellulose coating creates a shielding gas that further protects the weld from impurities.

In summary, E6010 filler metal enhances welding quality by offering deep penetration, strong bonds, and contamination protection, making it a preferred choice in various welding applications.

What Unique Features Does E7018 Filler Metal Offer?

E7018 filler metal offers unique features that make it suitable for a wide range of welding applications. Its primary advantages include high tensile strength, excellent impact resistance, and usability in different positions.

Key features of E7018 filler metal:
1. High tensile strength
2. Low hydrogen content
3. Excellent impact toughness
4. Versatile usability
5. Enhanced arc stability

The discussion on E7018 can further illuminate its advantages.

High Tensile Strength: E7018 filler metal provides high tensile strength, typically around 70,000 psi. This characteristic ensures strong welded joints that can withstand significant stress. Its strength makes it ideal for structural applications where high durability is necessary.
Low Hydrogen Content: E7018 has a low hydrogen content, which reduces the risk of hydrogen-induced cracking. As per the American Welding Society (AWS), low-hydrogen electrodes minimize imperfections in welds, enhancing overall weld integrity. This feature is critical in applications where weld failure can be catastrophic.
Excellent Impact Toughness: E7018 maintains excellent impact toughness even at lower temperatures. This property is vital for applications in industries such as construction or pipeline welding, where structures must endure extreme weather conditions. Research by Wiley et al. in 2018 demonstrates that E7018 maintains integrity down to -20°F.
Versatile Usability: E7018 filler metal is suitable for different welding positions, including flat, horizontal, vertical, and overhead. This flexibility allows welders to use it across various projects without compromising quality. Its ease of use is acknowledged by many seasoned welders who appreciate its forgiving nature.
Enhanced Arc Stability: E7018 electrodes provide stable arcs during welding, leading to smoother welds with less spatter. This stability improves the welder’s control, resulting in cleaner and more efficient welds. A study by Smith & Associates in 2019 confirmed that stable arcs lead to higher productivity rates in welding tasks.

In summary, E7018 filler metal combines strength, safety, and versatility, making it an essential choice in modern welding practices.

Are There Specialized Filler Metals for Specific Applications in Welding?

Yes, there are specialized filler metals for specific applications in welding. These filler metals cater to a variety of materials and welding processes, ensuring strong, durable joints based on the unique requirements of each scenario.

Specialized filler metals include those designed for specific materials, such as stainless steel, aluminum, and nickel alloys. For example, austenitic stainless steel filler metal, like ER308L, is ideal for welding austenitic stainless steels. In contrast, aluminum welding often uses filler metal 4047 for its compatibility with aluminum components. Each filler metal consists of distinct chemical compositions and properties, allowing for the optimal fusion of the base materials.

The benefits of using specialized filler metals are significant. They provide improved joint strength, corrosion resistance, and thermal properties tailored to specific applications. According to the American Welding Society, using the correct filler metal can increase the overall lifespan of welded structures by up to 30%. This tailored approach results in welds that meet stringent industry standards and perform well under various conditions.

However, there are drawbacks to consider. The availability of specialized filler metals can sometimes be limited. Additionally, selecting an inappropriate filler metal can lead to issues such as cracking or insufficient stress resistance. A study by Smith et al. (2021) indicates that approximately 15% of weld failures are attributed to improper filler metal usage. These consequences may lead to costly repairs or compromised structural integrity.

To ensure successful welding outcomes, it is essential to carefully select filler metals based on application requirements. Consider the base material, environmental conditions, and necessary mechanical properties. Consulting material data sheets and industry guidelines can help make informed choices. Always prioritize specialized filler metals that align with the specific needs of each welding project.

What Are the Essential Allied Materials Used in Metal Arc Welding?

The essential allied materials used in metal arc welding include gases, fluxes, and filler materials. These materials are critical for achieving quality welds and ensuring safety during the welding process.

Shielding Gases
Filler Metals
Flux
Electrodes

Shielding gases protect the molten weld pool from atmospheric contamination. Common shielding gases include argon, carbon dioxide, and helium.

Filler metals provide additional material to strengthen the weld joint. Examples include various types of aluminum and steel rods, such as ER70S-6 for carbon steel.

Flux helps to prevent oxidation and can stabilize the arc. It comes in the form of granules or powders, and specialized fluxes can be tailored for specific metals.

Electrodes, which can be consumable or non-consumable, serve as the source of heat for the arc. Different electrode classifications exist based on their coating and composition.

In summary, these materials play distinct roles in ensuring the effectiveness and quality of metal arc welding, reflecting varied perspectives in their application based on specific welding requirements.

Shielding Gases: Shielding gases protect the weld area from atmospheric gases that can lead to defects. Argon is often used in TIG welding for its inert properties. Carbon dioxide is less expensive and used in MIG welding. Helium can provide greater heat input, useful for thicker materials.
Filler Metals: Filler metals contribute additional strength to the weld. They are specified based on the base materials being welded. For instance, 4047 aluminum filler is ideal for welding aluminum components. These metals enhance the joining process and can improve corrosion resistance.
Flux: Flux’s role is to prevent oxidation during welding by creating a protective layer over the weld pool. It ensures proper fusion by allowing the molten filler to flow evenly. The American Welding Society (AWS) outlines flux classifications and their applications based on metal types.
Electrodes: Electrodes create the arc between the electrode and base material. Consumable electrodes contribute to the weld, while non-consumable electrodes generate heat without melting. The selection of electrode type, such as E6011 for general-purpose welding, significantly affects weld quality.

Each of these allied materials contributes to the overall welding process, ensuring strength, quality, and reliability in welded joints.

Why Are Flux Materials Important in Metal Arc Welding?

Flux materials are important in metal arc welding because they serve to protect the weld pool from atmospheric contamination, facilitate the flow of molten metal, and enhance the mechanical properties of the weld.

According to the American Welding Society (AWS), flux is a chemical substance that, when heated, promotes the fusion of metals during the welding process.

Flux materials play several critical roles in welding. First, they prevent oxidation. Oxidation can weaken welds by forming a barrier between metal surfaces. Second, they lower the melting point of metal and improve the fluidity of the molten pool. This assists in achieving a better bond between the welded pieces. Third, they often contain alloying elements that improve the strength and corrosion resistance of the weld.

In welding, “oxidation” refers to the reaction of metal with oxygen in the air, leading to the formation of oxides. Oxides can impede proper fusion between weld materials. The process of lowering the melting point means that the addition of flux allows welding to occur at lower temperatures, which is beneficial for reducing warping or damaging heat-sensitive components. Alloying elements are additional metals mixed into the weld to enhance specific properties, such as tensile strength or durability.

Flux materials work by forming a protective slag layer on the surface of the weld pool during the welding process. This slag acts as a shield, preventing oxidation and contamination from the surrounding air. Upon cooling, the slag can be removed to reveal a strong, clean weld beneath. For example, in shielded metal arc welding (SMAW), the rod coating serves as flux, ensuring that the molten weld metal is insulated from contaminants during solidification.

Specific conditions that influence the effectiveness of flux include humidity, as excess moisture can affect its properties. For instance, improper storage of flux can lead to moisture absorption, resulting in a compromised weld. Understanding these factors and selecting the appropriate type of flux for the materials being welded is crucial for achieving quality welds in metal arc welding applications.

What Standards and Specifications Guide the Use of Filler Metals and Allied Materials?

The standards and specifications guiding the use of filler metals and allied materials include various industry standards from organizations like the American Welding Society (AWS), International Organization for Standardization (ISO), and the American Society for Testing and Materials (ASTM).

American Welding Society (AWS) Standards
International Organization for Standardization (ISO) Standards
American Society for Testing and Materials (ASTM) Standards
National Sanitation Foundation (NSF) Guidelines
Military Specifications (Mil-Specs)

The standards mentioned above are critical for ensuring quality, safety, and compatibility in welding processes.

American Welding Society (AWS) Standards:
The American Welding Society (AWS) standards provide a comprehensive framework for the use of filler metals and allied materials. These standards cover specifications for welding procedures, materials, and testing methods. For example, AWS A5.1 deals with carbon steel electrodes, outlining their classification and mechanical properties. According to AWS, adherence to these standards ensures performance reliability and consistency in welding applications.
International Organization for Standardization (ISO) Standards:
The International Organization for Standardization (ISO) standards play a crucial role in establishing global benchmarks for filler metals. ISO 9001, for instance, focuses on quality management systems, promoting effective practices in production and delivery. ISO standards facilitate international trade by ensuring that products meet accepted quality and safety criteria across borders. Research conducted by the ISO shows that organizations with ISO certifications saw a production efficiency increase of up to 20%.
American Society for Testing and Materials (ASTM) Standards:
The American Society for Testing and Materials (ASTM) sets standards relevant to the specifications of materials used in welding. For example, ASTM A36 outlines the properties for structural steel, while ASTM E8 specifies the tension testing of metallic materials. These standards help ensure that the selected filler metals meet specific mechanical and chemical properties necessary for structural integrity.
National Sanitation Foundation (NSF) Guidelines:
The National Sanitation Foundation (NSF) guidelines are essential for industries requiring sanitary conditions, such as food and beverage manufacturing. NSF/ANSI 51 specifies the materials that can be used in food equipment, ensuring that soldering and welding processes do not compromise food safety. Compliance with these guidelines protects public health and assures consumers.
Military Specifications (Mil-Specs):
Military specifications (Mil-Specs) define the standards for materials used in defense applications. These specifications often require higher performance criteria due to extreme conditions. Mil-Specs provide guidelines for the selection of filler metals that can withstand harsh environments, which is crucial for military operations. According to a report from the Department of Defense, using Mil-Spec materials has resulted in increased equipment reliability in combat scenarios.

How Do AWS Standards Impact Filler Metal Selection?

AWS standards significantly influence filler metal selection by ensuring optimal performance, quality, and compatibility in welding materials. These standards dictate the specifications related to chemical composition, mechanical properties, and usability of filler metals.

Chemical composition: AWS standards define the allowable chemical elements in filler metals. For example, AWS A5.1 specifies classifications of carbon steel electrodes, which must comply with exact impurity levels. This ensures that the filler metal will react predictably with the base metals during welding.
Mechanical properties: Standards outline the required mechanical properties of filler metals, including yield strength, tensile strength, and elongation. AWS D1.1 provides guidelines for structural steel welding, specifying that the filler metal must match the mechanical properties of the base metals to ensure structural integrity.
Compatibility: AWS standards ensure that filler metals are compatible with various base materials. For instance, AWS A5.18 specifies filler metals for gas shielded arc welding of stainless steels. This compatibility is crucial for achieving sound welds with no defects.
Quality assurance: AWS standards facilitate quality assurance in the welding process. Compliance with standards such as AWS QC1 ensures filler metals undergo rigorous testing and certification. This testing includes assessments of impact toughness and corrosion resistance, providing confidence in the materials used.
Safety and performance: AWS standards promote safety and effective performance during welding operations. For example, AWS A5.3 outlines classification for low hydrogen electrodes, which are designed to minimize the risk of hydrogen-induced cracking, a critical safety concern in welding applications.

By adhering to AWS standards, manufacturers and welders can select appropriate filler metals that meet the necessary requirements, ensuring high-quality and durable welds in various applications.

What Best Practices Should Be Employed in Choosing and Using Filler Metals?

When choosing and using filler metals, it is essential to follow best practices for optimal results in welding applications. These best practices ensure compatibility, enhance weld strength, and improve overall performance.

The key best practices for selecting and using filler metals are as follows:
1. Match filler metal to base materials.
2. Consider the welding process type.
3. Evaluate mechanical property requirements.
4. Assess corrosion resistance needs.
5. Review heat treatment compatibility.
6. Pay attention to filler metal classification.

To better understand these practices, we can look more closely at each one.

Matching Filler Metal to Base Materials: Selecting the right filler metal involves matching its chemical composition to the base materials being welded. For instance, if you are welding carbon steel, an appropriate filler metal would have similar iron content to ensure proper fusion and minimize contamination. The American Welding Society (AWS) provides classification systems to aid in this matching process.
Considering the Welding Process Type: The choice of welding process impacts the selection of filler metals. Processes like MIG, TIG, or SMAW have different requirements. For example, TIG welding often demands higher purity filler metals, as it operates with less heat input, while MIG welding may allow for a wider range of filler options. The process influences the arc characteristics and speed of welding, which can affect the selection.
Evaluating Mechanical Property Requirements: Filler metals should meet specific mechanical property criteria based on the application. Applications requiring high tensile strength or impact resistance will necessitate filler metals designed to withstand those stresses. A study by ASM International highlights that the strength of the weld joint must be comparable to that of the base materials to ensure structural integrity.
Assessing Corrosion Resistance Needs: Depending on the environment, filler metals must also be selected based on their corrosion resistance properties. Stainless steels, for example, have filler metals specifically designed to resist corrosion in acidic or saline environments. The National Association of Corrosion Engineers provides guidelines on selecting materials based on exposure conditions.
Reviewing Heat Treatment Compatibility: Some filler metals can alter the heat treatment characteristics of the welded assembly. It is crucial to assess how the chosen filler metal will behave under heat treatment processes. This consideration is important for applications requiring post-weld heat treatment to develop desired mechanical properties, as noted by welding experts in the “Welding Handbook” published by the AWS.
Paying Attention to Filler Metal Classification: Different classifications indicate the welding characteristics and usability of filler metals. For instance, AWS specifications categorize filler metals based on their strengths and application types. Understanding these classifications helps in selecting the right product efficiently.

By adhering to these best practices, welders can ensure the structural quality and longevity of welded joints. Selecting the appropriate filler metal is a fundamental part of successful welding, impacting both performance and safety in various applications.

What Challenges Do Welders Face When Using Filler Metals and Allied Materials?

Welders face several challenges when using filler metals and allied materials, including compatibility issues, quality variability, and handling safety.

Compatibility with Base Materials
Quality and Composition Variability
Handling and Storage Challenges
Safety and Health Risks
Performance Under Different Conditions

These challenges can affect the overall welding process and the quality of the final product. Understanding and addressing these issues is essential for successful welding operations.

Compatibility with Base Materials:
Welders confront issues of compatibility when selecting filler metals that must join specific base materials. The chosen filler metal needs to match or complement the base material in terms of mechanical properties and chemical composition. For instance, using a filler metal that has a significantly different expansion or contraction rate can lead to cracking. Research by the American Welding Society (AWS) emphasizes the importance of compatibility in producing strong, durable welds.
Quality and Composition Variability:
Quality and composition variability in filler metals can lead to inconsistent welding results. Filler metals may differ from batch to batch, affecting the weld’s strength and integrity. According to a 2020 report by the Welding Institute (TWI), this variability can arise from production processes, leading to differences in alloy content. Poor quality can compromise the welded structure’s overall longevity.
Handling and Storage Challenges:
Welders face challenges in handling and storing filler metals and allied materials. Since they can be sensitive to environmental conditions like moisture, proper storage is crucial. Moisture can lead to hydrogen-induced cracking in welds. The National Association of Manufacturers (NAM) suggests that welders must ensure that filler metals are stored in dry, controlled environments to maintain their efficacy.
Safety and Health Risks:
Welders face safety and health risks when working with filler metals and allied materials. Fumes emitted during welding can be hazardous. The Occupational Safety and Health Administration (OSHA) states that prolonged exposure to these fumes can lead to respiratory issues and other health complications. Welders should use appropriate protective equipment and ensure proper ventilation in their work areas.
Performance Under Different Conditions:
The performance of filler metals varies under different environmental conditions, leading to challenges during welding processes. For example, extreme temperatures can affect the mechanical properties of the filler metal. Studies, like one conducted by Lincoln Electric in 2021, have shown that weld quality is significantly impacted by external factors such as ambient temperature and humidity. This variability demands close attention to welding procedures and conditions to ensure optimal results.

How Can Welders Overcome Common Challenges in Filler Metal Usage?

Welders can overcome common challenges in filler metal usage by selecting the appropriate filler metal, ensuring proper storage and handling, and maintaining consistent application techniques. These strategies effectively address common issues such as contamination, premature deterioration, and poor bonding.

Selecting the appropriate filler metal: Choosing the right filler metal enhances weld quality. Welders must consider factors such as base metal composition, joint design, and service conditions. According to a study by K. K. Pashchuk et al. (2020), unsuitable filler materials can lead to defects like cracking and porosity. For example, using a stainless-steel filler metal for a carbon-steel base can result in metallurgical incompatibility.

Ensuring proper storage and handling: Filler metals should be stored in a controlled environment to prevent moisture absorption and contamination. The American Welding Society (AWS) recommends keeping filler metals in sealed containers and away from extreme temperatures. Failure to do so can result in reduced mechanical properties, as documented in a 2021 study conducted by M. L. H. Elarabi and D. P. O. Hohwald. They found that exposure to moisture caused significant hydrogen-induced cracking.

Maintaining consistent application techniques: Welders should apply filler metals at the correct temperature and speed to ensure proper fusion. Techniques like maintaining the appropriate arc length and angle can prevent issues such as undercutting and incomplete fusion. The Welding Institute (TWI) emphasizes the importance of training and practice to refine these skills, aligning with their findings that skilled welders produce stronger, more reliable welds.

By focusing on these strategies, welders can effectively address and mitigate the challenges associated with filler metal usage, thereby improving weld quality and performance.

What Future Trends Are Shaping the Development of Filler Metals and Allied Materials?

The future trends shaping the development of filler metals and allied materials focus on improved performance, sustainability, and innovative technologies.

Increased focus on sustainability
Development of high-performance alloys
Integration of smart materials
Advancements in additive manufacturing
Research on biocompatible filler metals

The exploration of these trends reveals diverse perspectives on how they impact industries and the environment.

Increased Focus on Sustainability:
Increased focus on sustainability in filler metals refers to the growing demand for eco-friendly materials and processes. Manufacturers seek to reduce environmental impact through recyclable materials and lower emissions. A 2021 study by the International Institute for Sustainability highlights that companies adopting sustainable practices can enhance their market competitiveness. Additionally, industry leaders such as Lincoln Electric emphasize the importance of sustainable welding solutions that meet modern regulations.
Development of High-Performance Alloys:
Development of high-performance alloys addresses the needs for stronger, lighter, and more corrosion-resistant materials. High-performance alloys often combine various elements to achieve specific characteristics, enhancing mechanical strength and durability. Research by the American Welding Society indicates that these alloys are crucial in aerospace and automotive sectors, where performance can directly influence safety and efficiency.
Integration of Smart Materials:
Integration of smart materials in filler metals refers to the use of materials that can respond to environmental changes, such as temperature and stress. These materials can self-heal or change properties under different conditions. According to MIT researchers, smart metals can significantly enhance structural integrity and lifespan. Examples include shape-memory alloys, which revert to their original shape after deformation.
Advancements in Additive Manufacturing:
Advancements in additive manufacturing, also known as 3D printing, are revolutionizing how filler metals are produced and applied. This technology allows for precise deposition of materials, reducing waste and enabling complex shapes. A study published in the Journal of Materials Processing Technology explains how additive manufacturing can tailor properties for specific applications. Industries using this technology, such as biomedical and aerospace, benefit from reduced lead times and customized solutions.
Research on Biocompatible Filler Metals:
Research on biocompatible filler metals is gaining attention in the medical field. These materials are designed to interact safely with biological systems, minimizing the risk of adverse reactions. The World Journal of Surgery outlines the importance of using biocompatible fillers in implants and medical devices, ensuring better patient outcomes. Ongoing studies explore various metal compositions to enhance biocompatibility and functionality in medical applications.

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