Arc welding is a metal joining process. It fuses two or more metal pieces using heat from an electric arc between an electrode and the metals. This method creates strong joints. It is commonly used in construction, manufacturing, and repair applications. Arc welding is efficient and versatile, making it a preferred choice for many projects.
Flashcards can help reinforce these concepts. A Quizlet guide can provide definitions, examples, and images for key terms related to arc welding. This visual aid enhances comprehension and retention of information, making learning engaging and efficient.
As we delve deeper into arc welding, we will explore its various types and applications. Each type serves specific purposes in different industries, from construction to automotive manufacturing. Understanding these applications will help you grasp how arc welding contributes to modern fabrication techniques. The next section will focus on different types of arc welding, providing insights into their methodologies and advantages. This knowledge is essential for aspiring welders and professionals seeking to expand their skills in this vital field.
What is Arc Welding and Why Is It Important?
Arc welding is a process that uses an electric arc to melt and join metal components. The electric arc is generated between an electrode and the base material, creating heat that fuses the pieces together.
According to the American Welding Society (AWS), arc welding is “a process that uses electricity to generate sufficient heat to join metals.” This definition emphasizes the method’s reliance on electrical power for its operation.
Arc welding encompasses various techniques, including Shielded Metal Arc Welding (SMAW), Gas Metal Arc Welding (GMAW), and Tungsten Inert Gas (TIG) welding. Each technique has unique characteristics, applications, and materials suited for welding, influencing their effectiveness in different industrial contexts.
The National Institute for Occupational Safety and Health (NIOSH) defines welding as “a fabrication process that joins materials, usually metals or thermoplastics, by using high heat to melt the parts together.” This definition highlights the thermal operation central to welding processes.
Factors contributing to the importance of arc welding include its versatility, efficiency, and ability to produce strong joints. The technique is used extensively in construction, manufacturing, and repair industries, providing essential infrastructure development.
The global welding market was valued at approximately $15.3 billion in 2020, with projections indicating growth to $22.40 billion by 2026, according to Mordor Intelligence. This reflects the increasing demand for welding applications in various sectors.
Arc welding has significant impacts on industries, driving productivity and innovation while enhancing infrastructure. Its importance is underscored in sectors like automotive and aerospace, where high-quality joints are vital for safety and performance.
Beyond industrial significance, arc welding impacts health, the environment, and the economy. Health risks include exposure to harmful fumes and UV radiation. Environmentally, processes can generate pollutants, while economically, it supports millions of jobs worldwide.
For example, the aviation industry relies on precise arc welding to ensure the integrity and reliability of aircraft structures. Similarly, the construction industry utilizes welding for strong steel frameworks in buildings.
To address welding-related health and environmental concerns, organizations like the Occupational Safety and Health Administration (OSHA) recommend protective measures, including ventilation systems and personal protective equipment. Proper training and adherence to safety protocols further mitigate risks.
Strategies like automated welding systems and the use of advanced materials can enhance efficiency and reduce hazards. Implementing robotics in welding applications can improve precision while minimizing worker exposure to dangerous conditions.
What Are the Key Terms You Need to Know About Arc Welding?
Arc welding is a process that uses an electric arc to create heat for joining metal pieces together. Understanding key terms related to arc welding is essential for both beginners and experienced professionals.
The main key terms related to arc welding include the following:
1. Electrode
2. Arc Length
3. Shielding Gas
4. Filler Metal
5. Welding Machine
6. Contact Tip
7. Workpiece
8. Inverter Technology
These key terms provide a foundational understanding of arc welding procedures and equipment. Each term plays a crucial role in achieving successful welds.
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Electrode: An electrode in arc welding is a conductor used to carry electric current into the workpiece. It can be consumable, meaning it melts during the welding process, or non-consumable. A consumable electrode, like in MIG welding, adds filler material to the weld.
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Arc Length: Arc length refers to the distance between the electrode and the workpiece during welding. A shorter arc length can create a hotter and narrower weld pool, which is important for various welding techniques.
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Shielding Gas: Shielding gas is a protective gas used in some arc welding processes to prevent oxidation of the weld. For instance, MIG welding commonly uses argon or a mix of argon and carbon dioxide. Proper selection of shielding gas is crucial for weld quality.
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Filler Metal: Filler metal is added to the weld area to help bond materials. It compensates for gaps in the weld joint and is often used in processes like TIG welding. The choice of filler metal depends on the base metals being joined.
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Welding Machine: A welding machine is the equipment that generates the necessary electrical current for welding. Various types of machines are available, such as transformers, rectifiers, and inverters. Inverter technology machines are gaining popularity due to their efficiency and lightweight design.
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Contact Tip: The contact tip is the part of the welding torch that transfers electricity to the electrode within MIG welding. It is essential for maintaining an accurate and stable arc and is often made of copper to conduct heat effectively.
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Workpiece: The workpiece is the material being welded. Understanding the properties of the workpiece, including its thickness and type, can significantly influence welding techniques and parameters used.
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Inverter Technology: Inverter technology refers to a method of controlling electric current in welding machines. It allows for precise adjustments and improved performance compared to traditional transformer-based machines. Studies suggest that inverter machines are more energy-efficient and lighter than conventional models.
These key terms embody fundamental concepts crucial for those practicing or learning about arc welding. Understanding each term enhances welding proficiency and promotes better outcomes in metal fabrication.
What Is an Electrode in Arc Welding?
An electrode in arc welding is a conductive tool that carries electricity to create an arc between itself and the workpiece, facilitating the melting of metal for joining. It comes in both non-consumable and consumable types, depending on its role in the welding process.
According to the American Welding Society, electrodes are critical components in arc welding, providing the necessary electrical current to produce heat for melting metals. They can play distinct roles in various welding processes, such as MIG (Metal Inert Gas) or TIG (Tungsten Inert Gas) welding.
Electrodes can vary in shape, size, material composition, and coating. Non-consumable electrodes, like tungsten, remain intact during the welding process, while consumable electrodes, such as filler wires, add material to the weld. The selection of the electrode affects weld quality, penetration, and stability.
The Lincoln Electric Company defines welding electrodes as metal rods or wires used in conjunction with an electric welding machine. The electrode type and the welding technique influence factors such as arc stability and spatter control.
Factors affecting electrode performance include electrical current settings, welding speed, and material type. Proper selection based on these conditions is essential for optimal welding.
American Welding Society reports that the global arc welding market is projected to reach $28.7 billion by 2026, driven by increasing manufacturing and construction activities globally.
The use of appropriate electrodes impacts the effectiveness and efficiency of welding operations. Poor electrode selection can lead to joint failures, increased production costs, and safety hazards.
Electrodes can affect worker health through exposure to harmful fumes and gases produced during welding. Implementing proper ventilation and personal protective equipment can mitigate these effects.
Examples include the use of fume extraction systems and training programs that focus on safety protocols in welding environments.
To address the challenges of electrode usage, the American Welding Society recommends regular training for welders, adherence to safety standards, and the use of automated welding systems to improve precision and reduce exposure to hazards.
Strategies such as consistent equipment maintenance, thorough planning for material use, and advanced welding technologies can enhance arc welding processes and results.
What Is a Welding Arc, and How Does It Function?
A welding arc is an electrical discharge between two electrodes that generates intense heat. This heat melts both the workpieces and the filler material, allowing them to fuse together.
According to the American Welding Society (AWS), a welding arc is characterized by a glowing column of ionized gas that forms when an electric current passes through the air or other medium.
The welding arc operates primarily in shielded metal arc welding (SMAW), tungsten inert gas (TIG), and metal inert gas (MIG) processes. The arc enables the controlled melting of materials for strong, durable joints in metal fabrication.
The Occupational Safety and Health Administration (OSHA) emphasizes the importance of maintaining the arc for safety and quality purposes. Proper maintenance prevents irregularities in the weld and reduces risks of accidents.
Factors affecting a welding arc include electrode material, voltage, and distance between the electrodes. A precise balance of these elements dictates the characteristics and stability of the arc.
The National Center for Welding Education and Training reports that proper arc management can enhance welding efficiency by up to 30%. Improved technologies are projected to increase productivity and reduce material wastage.
A well-functioning welding arc helps create robust structures, vital for industries such as construction and manufacturing.
This process can impact worker safety, operational costs, and product quality within the economy.
For example, inconsistencies in the weld can lead to structural failures, which may result in economic losses and safety hazards.
To mitigate risks associated with welding arcs, organizations like AWS recommend proper training for welders and regular equipment maintenance. Utilizing advanced monitoring technologies can also enhance arc quality.
Implementing digital arc monitoring, employing skilled technicians, and adhering to safety regulations are effective strategies to ensure weld integrity and minimize safety risks.
What Are the Main Techniques of Arc Welding?
The main techniques of arc welding include several distinct methods utilized for various applications in metal joining.
- Shielded Metal Arc Welding (SMAW)
- Gas Metal Arc Welding (GMAW)
- Gas Tungsten Arc Welding (GTAW)
- Flux-Cored Arc Welding (FCAW)
- Submerged Arc Welding (SAW)
These techniques offer different benefits and drawbacks, depending on the specific needs of the project. For example, some methods may be more suitable for outdoor work, while others provide greater precision and control in delicate applications. The choice of technique often depends on factors like material type, thickness, and desired weld quality.
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Shielded Metal Arc Welding (SMAW):
Shielded Metal Arc Welding (SMAW) is a manual arc welding process that uses a consumable electrode coated in flux. An electric arc forms between the electrode and the workpiece, melting both to create a weld. SMAW is widely used for its simplicity and versatility. According to the American Welding Society, it is one of the most common welding methods, particularly in construction and repair work. Case studies show that SMAW can be effective for welding various materials, including structural steel and alloys. -
Gas Metal Arc Welding (GMAW):
Gas Metal Arc Welding (GMAW), also known as MIG welding, uses a continuous feed of solid wire electrode and a shielding gas to protect the weld from contamination. GMAW is favored for its speed and ease of use, making it suitable for high-production environments. According to a 2019 study by the Welding Research Council, GMAW can significantly reduce the heat-affected zone, leading to better mechanical properties in the finished weld. Industries such as automotive and manufacturing often employ this technique. -
Gas Tungsten Arc Welding (GTAW):
Gas Tungsten Arc Welding (GTAW), or TIG welding, uses a non-consumable tungsten electrode and an inert gas for shielding. GTAW offers high precision and is ideal for welding thin sections of stainless steel and non-ferrous metals. Its high skill requirement can be a hurdle for some operators. A 2020 analysis in the Journal of Materials Science highlights that GTAW provides excellent control and weld quality, making it preferred in aerospace and high-end applications. -
Flux-Cored Arc Welding (FCAW):
Flux-Cored Arc Welding (FCAW) is similar to GMAW but uses a tubular wire filled with flux. The flux generates a shielding gas when heated, protecting the weld pool. FCAW can be used without shielding gas in some applications, making it suitable for outdoor work in windy conditions. According to the AWS, FCAW combines the benefits of SMAW and GMAW, offering versatility for different material types, including construction and shipbuilding. -
Submerged Arc Welding (SAW):
Submerged Arc Welding (SAW) involves the formation of an arc beneath a blanket of granular flux. This method offers deep penetration, high deposition rates, and minimal fume production, making it effective for thick materials. A study conducted by the European Welding Federation indicates that SAW is often used in large-scale applications, including shipbuilding and pressure vessel manufacturing, due to its efficiency and weld quality.
These arc welding techniques provide a variety of options for meeting specific welding needs and project requirements. Each method has unique attributes that can influence its suitability in specific applications.
What Is Shielded Metal Arc Welding (SMAW) and How Is It Used?
Shielded Metal Arc Welding (SMAW) is a manual arc welding process that uses a continuously-fed electrode coated in flux to create a weld. The electrode melts, forming a molten pool that fuses with the base metal upon cooling.
According to the American Welding Society, SMAW is fundamental in joining metals and is widely utilized in construction and manufacturing.
SMAW involves generating heat through an electric arc between the coated electrode and the workpiece. The flux coating creates a gas shield that protects the molten weld pool from contamination. This process is versatile; it can be performed in various positions and on different materials.
The Welding Handbook describes SMAW as effective for both ferrous and non-ferrous metals, making it suitable for various applications from pipe welding to structural components.
Factors influencing SMAW include material type, thickness, and welding position. Environmental conditions like wind and humidity also affect the welding quality.
According to the Welding Equipment Manufacturers Association, in 2022, approximately 35% of welding operations in the U.S. utilized SMAW, highlighting its significance in the industry.
SMAW has economic impacts, providing jobs in various sectors, but it also poses health risks such as exposure to fumes and radiation.
Examples include exposure to dangerous welding fumes in confined spaces leading to respiratory issues.
To address these issues, organizations like OSHA recommend adopting safety measures, including using appropriate ventilation and personal protective equipment.
Strategies to improve safety involve training programs, better work practices, and advanced welding technologies that focus on reducing hazardous exposure.
What Is Gas Metal Arc Welding (GMAW), and What Are Its Benefits?
Gas Metal Arc Welding (GMAW) is a welding process that uses a continuous wire feed as an electrode. This technique creates an electric arc between the wire and the workpiece, melting both to form a strong joint.
The American Welding Society defines GMAW as a process that “uses a continuously fed filler metal electrode and a shielding gas.” It is widely recognized in the welding industry for its efficiency and versatility in different applications.
GMAW encompasses several components, including the welding gun, filler wire, shielding gas, and power supply. The process can be performed in various positions and is suitable for welding different materials, such as steel and aluminum.
According to the International Institute of Welding, GMAW is characterized by its ability to produce high-quality welds with minimal post-weld treatments. This feature enhances production efficiency and reduces material waste, making it a preferred choice in manufacturing.
Factors influencing GMAW effectiveness include welder skill, equipment settings, and environmental conditions. Proper training and equipment maintenance are crucial for optimal results.
Data from the Welding Industry Association indicates that GMAW accounts for approximately 50% of all welding processes used in production environments today. Projections suggest this percentage may increase due to advancements in technology.
GMAW improves manufacturing speed and product quality while reducing costs. It enables industries to meet high demand efficiently and sustainably.
The process is significant for public health as safer working environments can be created. Environmentally, GMAW produces less hazardous waste compared to other welding methods, contributing positively to sustainability efforts.
For instance, automotive manufacturers benefit from GMAW due to its ability to deliver high-strength welds quickly, reducing production time without compromising quality.
Key measures to enhance GMAW include investing in advanced training programs, adopting automatic welding machines, and using high-quality materials. Recommendations from the American Welding Society suggest increasing focus on safety protocols and regular maintenance of equipment.
Technological advancements such as robot-assisted GMAW and improved filler materials can help boost efficiency and safety. Moreover, practices like regular monitoring of gas composition can maintain weld quality and minimize environmental impact.
What Safety Precautions Should You Take When Arc Welding?
To ensure safety during arc welding, you should take specific precautions. These precautions help minimize risks related to burns, electrical shocks, and inhalation of harmful fumes.
- Wear Protective Gear
- Ensure Proper Ventilation
- Maintain Equipment
- Be Aware of Your Environment
- Follow Electrical Safety Practices
- Avoid Flammable Materials
- Understand Fume Extraction
- Get Proper Training
While these safety measures are crucial, differing opinions may suggest that workplace or project-specific factors can alter the emphasis placed on certain precautions. For example, some might argue that adequate training is more critical than protective gear, depending on the level of experience of the welder.
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Wear Protective Gear:
Wearing protective gear involves using equipment designed to shield against welding hazards. Essential items include welding masks, gloves, aprons, and shoes. According to the American Welding Society, protective gear reduces the risk of serious injuries. For example, welding goggles protect the eyes from bright arcs and flying sparks, while gloves prevent burns from hot metal. -
Ensure Proper Ventilation:
Ensuring proper ventilation means maintaining good air quality when welding. Arc welding generates harmful fumes and gases. The Occupational Safety and Health Administration (OSHA) recommends sufficient ventilation to dilute and remove harmful substances. Proper ventilation systems may include exhaust fans or localized fume extraction equipment. -
Maintain Equipment:
Maintaining equipment involves regular inspections and upkeep of welding machines and tools. Faulty equipment increases the risk of accidents. For instance, worn cables can lead to electrical shocks, while malfunctioning regulators can cause explosions. It’s vital to follow manufacturer guidelines for maintenance. -
Be Aware of Your Environment:
Being aware of your environment means monitoring surroundings for potential hazards. Identify risks such as flammable materials, crowded workspaces, or elevated surfaces that could cause falls. The National Fire Protection Association (NFPA) emphasizes assessing your work area before beginning any welding project. -
Follow Electrical Safety Practices:
Following electrical safety practices involves using proper grounding techniques and inspecting power sources. Unsafe electrical setups can lead to shocks or even electrocution. The American National Standards Institute (ANSI) provides standards on electrical safety procedures for welders to follow. -
Avoid Flammable Materials:
Avoiding flammable materials means keeping combustible items away from welding zones. Sparks can ignite materials such as paper, wood, or gas. The NFPA advises creating a fire-safe buffer zone around welding activities to minimize fire hazards. -
Understand Fume Extraction:
Understanding fume extraction involves recognizing the importance of systems designed to capture welding fumes. Effective fume extraction prevents workers from inhaling harmful chemicals. The American Conference of Governmental and Industrial Hygienists (ACGIH) recommends using fume hoods or portable extraction units. -
Get Proper Training:
Getting proper training entails participating in instructional programs focusing on safe welding practices. Training equips workers with skills to recognize hazards and respond to emergencies. An OSHA report states that trained welders are less likely to experience accidents at work.
By taking these precautions, welders can create a safer working environment, reducing the risk of injuries and health hazards.
What Common Hazards Should Be Acknowledged in Arc Welding?
Common hazards in arc welding include electrical shock, exposure to harmful fumes, fire hazards, and eye damage.
- Electrical Shock
- Fume Exposure
- Fire Hazards
- Eye Damage
- Burns
- Inhalation Risks
Understanding these hazards is crucial for ensuring safety while performing arc welding.
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Electrical Shock:
Electrical shock occurs when a person comes into contact with live electrical parts. The high voltage in welding equipment can cause severe injury or even death. According to the Occupational Safety and Health Administration (OSHA), electrical hazards are a leading cause of injury in welding. Proper grounding of equipment and wearing insulated gloves can minimize this risk. -
Fume Exposure:
Fume exposure happens when welder’s inhalation of harmful gases and particulates occurs. Welding generates fumes that contain metal oxides, silica, and other toxic chemicals. The American Conference of Governmental and Industrial Hygienists (ACGIH) notes that long-term exposure can lead to respiratory problems, neurological damage, and even cancer. Using adequate ventilation systems or respiratory protection can help reduce this hazard. -
Fire Hazards:
Fire hazards arise from the heat and sparks produced during welding. Flammable materials nearby can ignite, causing fires. An estimated 5,000 fires each year in the United States are linked to welding activities, according to the National Fire Protection Association (NFPA). It is essential to maintain a clean workspace and keep flammable materials away from welding zones to mitigate this risk. -
Eye Damage:
Eye damage occurs from exposure to intense light, ultraviolet (UV) rays, and flying particles. Welders can suffer from arc eye, which is a painful condition caused by UV light exposure. The American Welding Society (AWS) states that proper eye protection, such as welding helmets with filter lenses, is critical to protect against these hazards. -
Burns:
Burns can occur from hot metal, sparks, or slag during the welding process. These injuries can range from minor to severe. The U.S. Bureau of Labor Statistics reports that workplace burns account for a significant number of injury claims. Using personal protective equipment (PPE), like leather gloves and flame-resistant clothing, is essential for burn prevention. -
Inhalation Risks:
Inhalation risks involve breathing in harmful welding fumes and gases. Inadequate ventilation can increase the concentration of toxic elements in the air. Research shows that exposure to fumes can lead to long-term health issues, such as lung diseases. Employing fume extraction systems and ensuring proper airflow is vital for worker safety.
How Can Quizlet Be an Effective Tool for Learning Arc Welding?
Quizlet can be an effective tool for learning arc welding by providing interactive study materials, customizable flashcards, and collaborative learning opportunities. These features enhance understanding and retention of key concepts and skills necessary for mastering arc welding.
Interactive study materials: Quizlet offers a variety of learning modes, such as matching games and tests. These formats engage learners actively, making study sessions more enjoyable and effective. Research by Heitzman et al. (2021) found that interactive learning approaches lead to a 30% improvement in information retention compared to traditional study methods.
Customizable flashcards: Users can create flashcards featuring important arc welding terminology, processes, and safety standards. Customization allows learners to focus on areas requiring additional practice. A study by Ness et al. (2019) showed that students who used flashcards scored 20% higher on practical exams after repeated self-testing on key concepts.
Collaborative learning opportunities: Quizlet’s social features enable users to share study sets and collaborate on learning objectives. Engaging with peers boosts motivation and facilitates knowledge exchange. According to Johnson and Johnson (2020), collaborative learning can improve individual performance by up to 25% through peer interaction and feedback.
In summary, Quizlet’s interactive materials, customizable flashcards, and collaborative features create a comprehensive learning environment. This environment is especially useful for grasping the technical aspects of arc welding, ensuring learners gain the necessary expertise to excel in the field.
What Are the Advantages of Using Flashcards for Mastering Arc Welding Concepts?
Using flashcards for mastering arc welding concepts offers several advantages. These advantages include enhanced retention, active recall practice, portability, customization options, and engagement through interactive learning.
- Enhanced retention
- Active recall practice
- Portability
- Customization options
- Engagement through interactive learning
These points illustrate the various benefits of using flashcards while also emphasizing potential trade-offs compared to other study methods.
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Enhanced Retention: Employing flashcards enhances retention of arc welding concepts through spaced repetition. This technique involves reviewing the material at increasing intervals, which strengthens memory. Studies show that spaced repetition can improve recall rates by up to 200% compared to cramming (Cepeda et al., 2006). For example, a welder may use flashcards to repeatedly review terms like “arc length” and “electrode polarity,” leading to better understanding and mastery.
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Active Recall Practice: Active recall practice occurs when learners test themselves on the information presented on flashcards. This method fosters deep learning by requiring individuals to retrieve information from memory rather than passively reviewing it. An example in arc welding might involve recalling the properties of different welding electrodes. Research indicates that active recall significantly enhances long-term retention (Roediger & Butler, 2011).
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Portability: Flashcards offer greater portability than traditional textbooks or notes. Learners can carry them easily in pockets or bags, allowing for quick study sessions anywhere. This feature is particularly beneficial for welders who may have busy schedules or travel frequently to job sites. Mobile applications for flashcards, such as Quizlet, make digital study more convenient, accommodating modern learning styles.
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Customization Options: Flashcards can be customized to suit individual learning preferences. Users can create flashcards that focus on specific welding techniques, safety protocols, or equipment. This adaptability allows learners to prioritize areas where they feel less confident. For instance, a student may choose to focus on flashcards addressing MIG welding processes if they are less familiar with them.
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Engagement Through Interactive Learning: Flashcards encourage active engagement with the material. The process of reviewing and quizzing oneself can be more stimulating than conventional memorization. Additionally, some flashcard apps incorporate games or quizzes to further increase engagement. This interactivity can lead to a more enjoyable learning experience, making it easier to grasp complex welding concepts.
The combination of these advantages outlines why flashcards are effective tools for mastering arc welding concepts. Each attribute contributes to a well-rounded and efficient study experience.
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