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International Congress on Advances in Welding Science and Technology for

Construction, Energy and Transportation Systems (AWST - 2011)


24-25 October 2011, Antalya, Turkey
AWST-11/04

Product and Process Aspects When Welding Press-hardened


Automotive Components
J. K. Larsson
Volvo Car Corporation, Advanced Body Engineering, Dept. 93620-PVS23, 40531 Gothenburg, Sweden
jlarsso1@volvocars.com

Abstract

This paper will discuss the experience from high volume production conditions, but also the overall performance
automotive production with a specific emphasis on the of the body structure.
welding of press-hardened steels and the quality
Table 1. Nominal chemical composition the Aluminium-Silicon
assurance of these welds. Different solutions about how
coated USIBOR 1500P.
to solve weld brittleness at resistance spot welding will
be described; including advanced welding schedules but C Si Mn P S Cr Al Ti B
also tailored tempering of the hot-formed components 0.23 0.2 1.1 0.01 0.00 0.1 0.03 0.03 0.002
themselves. 4 4 6 1 4 9 6 9 4
One section will exclusively describe the comprehensive
quality assurance procedures for the structural laser
welds in crucial crash protective components of the 2. The Press-Hardening Process
company's latest car models. Laser welding showed to be
superior to other alternative joining methods regarding Press-hardening or hot-stamping and die quenching is a
the fulfillment of crash related tests in early development method to produce ultra high strength components for the
phases of these car programmes, however such a welding automotive industry. It has been used since the mid-
method puts specific requirements on both equipment but 80ies, and typical components produced by the press-
also on parts accuracy and assembly tolerances. hardening process are e.g. A- and B-pillar
reinforcements, floor sills, cantrails, side impact door
Keywords: Automotive car body structures, Press- beams and bumper beams. To enable the Boron-alloyed
hardened steels, Resistance spot welding, Laser beam steel material to be formed and further on cooled down
welding, Weld quality assurance to a fully martensitic structure, the material first has to be
heated up to its austenitization temperature at around
1. Introduction 880-950C. To achieve a fully martensitic structure, the
cooling rate must exceed 25-30C/s. The small amount
Environmental aspects have become extremely important of Boron is used to facilitate the quenching process,
when engineering new passenger cars in order to reduce wherefore the material often is referred to as Boron steel
fuel consumption and toxic emissions. One step is to in colloquial terms.
decrease the weight of the vehicle, which for the car The hot forming process is mainly divided into two
body structure means down-gauging the components and different approaches, the indirect and the direct one,
introduce more advanced high strength steels (AHSS) to where the direct process is the most commonly used
be able to maintain a high performance in terms of among the automotive OEMs (Original Equipment
crashworthiness, durability etc. Manufacturers). These two processes offer different
One such steel is the ultra high strength (UHS) press- advantages for the final application in terms of design
hardened and hot-formed Boron-alloyed steel. Apart versus cost, and available choices for surface protection.
from a unique process technology, when manufacturing Making the first forming step(s) by conventional cold
automotive components in this material, it also contains forming, the indirect process offers the possibility for
specific alloy elements in order to guarantee a high more complex geometries and undercut designs before
ultimate strength (Tab. 1). The drawback is that due to the shaped components are heated, transferred to the
the alloy content these components become more oven and finally tempered (Fig. 1). This means that two
difficult to weld, regardless which welding method used. sets of tools are necessary, one for pressing and one for
At various loading conditions, these welds also present a cooling. One advantage however, with this process is that
different behaviour to what is common for welds applied it offers the possibility to use a conventional zinc-based
in lower strength steel grades. Therefore, the introduction coating for cathodic corrosion protection.
of press-hardened body components not only affects the
production, whereas Volvo Cars purchase all Boron
alloyed parts from external suppliers.

3. General Aspects on Welding of Ultra High


Figure 1. Schematic description of the indirect hot-forming process; Strength Press-Hardened Steels
Cold-forming of the blank, heating of the pressed part, rapid
cooling, post processing like laser- or tool cutting etc. When welding in press-hardened body components there
are numerous aspects to be considered. If we look at the
In the direct process, the forming operation is integrated most commonly used assembly method, resistance spot
with the cooling in the same tool (Fig. 2), This means welding, first of all the surface condition is to be
that the parts reach their final shape and strength in one discussed. The hot-forming process leads to the
single press operation, and are therefore often referred to formation of a thin oxide layer. This must be removed,
as "hot-stamped" or "hot-formed". The formed which today usually is done by a shot-blasting operation,
components remain in the dies until they have cooled in order to have better conditions for the welding
down to between 100-200C. All Boron-alloyed steel process. One of the characteristics of a shot-blasted
components in today's Volvo cars are manufactured surface is however the variation of the electric resistance
using the direct process. Most car applications such as of the surface (Fig. 4). This is especially pronounced
door beams, bumper beams, sill reinforcements, A, B and when the component has a complex shape, which limits
C-pillars and roof bows can be produced with the direct the accessibility of the shot-blasting nozzle and therefore
process. The indirect process might however be results in an inadequate cleaning of the surface. The
necessary if more advanced parts are considered. variation of the electric resistivity of shot-blasted
surfaces is sufficient to disturb the spot welding process
and significantly decrease the weld quality of a
conventionally welded spot. For that reason, the
recommendation is to use adaptive weld timers for those
welding guns that have to apply spot welds in un-coated
Boron-alloyed steel components [2]. Adaptive weld
timers work in such a way that the system measures the
Figure 2. Schematic description of the direct hot-forming process; resistance, in the equipment itself and the sheet
Heating of the blank, forming of blank to final shape, consequent components that are to be welded, and compares the
rapid cooling, post processing like laser- or tool cutting etc.
voltage curve to a calibrated one, which will guarantee
an approved weld nugget size. The system then reacts
The upper limit for Boron steel in a car body is judged to
either by increasing the current or prolonging the
be around 45%, which more or less includes the whole
welding time if there are any deviations from the nominal
safety cage with its backing structure. A rough estimation
values. Another solution to establish homogenous surface
gives that an increase of Boron steel from 10% to 40%
conditions is to introduce a surface coating on the
would reduce the body weight with approximately 30 kg
material intended for hot-forming. In such a case it might
with unchanged properties, i.e. stiffness, strength, crash
be possible to utilize conventional constant current
and NVH (Noise, Vibrations & Harshness).
regulation for the welding process. The dominating
coating type is an aluminium-silicon mixture with an
approximate thickness of 45 m, however many steel
suppliers are developing alternatives based on more
conventional zinc layers.

Figure 3. Development trends regarding the utilization of press-


hardened body components at Volvo Car Corporation.

The amount of Boron steel in body structures from Volvo


Cars has increased from 3% in 2000 to 18% in 2010 [1],
Figure 4. The surface resistivity of a shot-blasted, hot-formed
and will exceed 20% in the near future (Fig. 3). Fiat, VW
component revealing the variation between measurement points.
and BMW show similar figures today, but the difference is
that today these companies have their own in-house
International Congress on Advances in Welding Science and Technology for
Construction, Energy and Transportation Systems (AWST - 2011)
24-25 October 2011, Antalya, Turkey
AWST-11/04
There are some other approaches to design and produce a However, at crash tests the results were the opposite, as
press-hardened part that influences the spot welding here it looked as the reduced cooling time had a positive
process. First the so called tailored-rolling process that effect on the energy absorption. These tests were
will results in a thickness variation of the component. In performed on simple overlap test specimens with single
the transition zone between thick and thin material, spot welds, shear loaded at a speed rate of 10 m/sec. It
which length in general is 100 the local sheet thinning, can be understood that the longer cooling time leads to a
it is recommended to avoid the positioning of a spot weld more rapid cooling of the weld metal and thereby
right there. Another positioning aspect is when patch increasing martensite formation and embrittlement in the
technology is used. Here the spot welding process is spot weld. The shorter hold time allows the weld metal to
performed in soft material condition before the hot- cool down under slower conditions, however the cooling
forming is carried out, when a local reinforcement plate speed is still too high to be able to avoid the martensitic
is welded on top of the main component. This means that region in the phase diagram (Fig. 6). This can only be
it is important to put the spot welds outside the radii in done at such a slow cooling rate as 25 C/s, which is
the final component. Otherwise there is an obvious risk impossible to reach with the described approach.
for cracking in the weld circumference. Therefore other solutions must be introduced in order to
increase the ductility of the spot welds, something that
will be described further on.
4. Early Experiences About How Weld
Parameter Settings can Influence Spot Weld
Properties

One early observation of the specific behaviour of spot


welds applied in hot-formed components came after the
Volvo Body Manufacturing Team requested to shorten
the cycle time during spot welding. The idea was to
significantly reduce the hold time in order to be able to
put more spot welds with each robot during the station
cycle time, which today is around 67 seconds in the
companys high volume plants. The effect from a short
hold time of 30 ms was neglectible in terms of the static
shear and peel strength of the spot weld. However, when
the spot welds behaviour under fatigue and crash loads
were investigated other concerns arose.
In the fatigue tests, performed on H-shaped specimens
with a load ratio of R = 0.05 and a cyclic frequency of 20
Hz, it was observed that the reduced hold (or cooling)
time had a negative effect. Compared to those welded Figure 6. The CCT diagram revealing that a cooling rate lower
with the normal hold time of 200 ms, the fatigue life was than 25 C/s is necessary to avoid the martensitic region.
almost 50% less. The explanation is that the shorter
cooling time does not allow the weld nugget to fully
develop, which in turn will introduce sharp notch effects 5. How to Increase Spot Weld Ductility by
(Fig. 5). Specific Pulse Programmes

Spot welds applied in press-hardened steel parts often


show a tendency for less ductile fracture behavior
compared to welds in mild steel and the softer grades of
high strength steels, with fracture types such as
interfacial fracture or partial plug failure. The load
capacity may still be high or very high, but the
elongation values are lower, which reduces the energy
absorption capability in the weld in the event of a car
crash. As can be seen from Figure 7, the ductility in
terms of elongation and energy absorption is strongly
dependent of the fracture mode, where samples showing
Figure 5. The sharp notch effect (circled), which is devastating full button pull-out failure are much more ductile. Thus,
from a fatigue loading perspective, is a result of a too short if the weld parameters can be chosen in order to create
cooling (hold) time. full button pull-out failure behaviour, improvements in
ductility will be achieved. This will be done if the
microstructure can be changed in such a way that the
fracture will propagate through the sheet (red arrow in allowing it to grow or simply just heat-treat it. The
Fig. 8) instead of through the weld (blue arrow). purpose is to get an annealed and/or tempered structure
in the heat-affected zone, and variations of pause time,
post-pulse time and current will influence the result.
Testing was carried out on specimen consisting of two
1.8 mm thick AlSi-coated Boron steel (USIBOR)
coupons. The chemical composition of the material can
be seen in Table 1. A resistance spot welding gun with
MFDC (Medium Frequency Direct Current ~1000Hz)
was used for the welding trials. The inverter was a
Matuschek Auto SPATZ M600 with a maximum short
circuit current of 21 kA and the electrode force was
variable between 1-6.2 kN. The programming unit was a
PC-based Matuschek SPATZ AS-1 system. Figure 9
shows a picture and data on the spot welding gun used in
the investigation.
Figure 7. Tensile test curves with correspondent images for the
three typical fracture modes.

Figure 9. The spot welding gun of X-type used for the trials, with
additional technical information above.

Two fundamentally different ways to achieve full button


pull-out through post pulsing was found. Post pulse A,
which aims to increase the size of the weld nugget and
the soft zone surrounding it. The other one, post pulse B,
is aimed to create two soft zones. The later is more time
consuming and needs a longer pause time than pulse A,
but it is useful if one wants to keep the original nugget
size. The ductility was evaluated in terms of energy
absorption and elongation during linear tensile shear
testing at room temperature. The investigations made so
far have shown that it is possible to improve the ductility
Figure 8. Fracture propagation for interfacial failure (blue arrow)
and full button pullout failure (red arrow). The later allows a
in terms of elongation and energy absorption capability
larger amount of plastic deformation (right), with a typical during tensile shear testing by using a post pulse.
rotation of the weld plug during loading.

Therefore different pulse sequences were investigated in 5.2. The effects of two different welding pulse
order to increase the elongation values for spot welded sequences
joints, and with the objective to avoid partial plug or
The two weld schedules and their effects can be
interfacial failures [3].
described as follows:
5.1. Widening of the soft zone Post pulse type A: A shorter pause time and high energy
input during the post pulse is creating a large nugget
To achieve a full button pullout failure the soft zone in
diameter as well as a wide soft zone. If the current is
the heat-affected zone (HAZ) must be wide enough to be
further increased the risk for expulsion will increase and
able to undergo the amount of plastic deformation
an extended post pulse time will not increase the nugget
involved with the rotation described above when the spot
size. These parameters, short pause time and high current
weld is loaded. The soft zone is here defined as the area
in the second welding pulse, are believed to generate the
with hardness below 400 HV. The area of the soft zone is
highest possible energy absorption during tensile shear
believed to be increased when increasing the heat input.
testing, due to that 100% full button pullout fracture is
This can be done by using a second welding pulse. The
achieved.
first pulse would in this case be the welding pulse which
Post pulse type B: A longer pause time and less energy
creates the nugget. After a pause time, the second pulse
input during the post pulse is used in this case in order to
is triggered and it could either re-melt the nugget,
International Congress on Advances in Welding Science and Technology for
Construction, Energy and Transportation Systems (AWST - 2011)
24-25 October 2011, Antalya, Turkey
AWST-11/04
maintain the nugget diameter. A second soft zone is of the steel sheet material. In such a case it would be
created by the post pulse. The pause time is optimized to detrimental to widen the soft zone as described above,
position this soft zone adjacent to the soft zone from the because this will serve as an initiator for cracks
initial weld pulse, thereby forming a wider soft zone. propagating from the spot welds and through the metal in
This alternative is more time consuming and might the weld flange. One solution to prevent such behaviour
require a total welding cycle time of about 2 seconds. is to manufacture the press-hardened part according to
The two different approaches of post pulsing, as well as a the tailored tempering methodology. This means that
reference weld carried out by conventional single pulse some areas in the component are not tempered to its full
welding, were tested by tensile shear loading of 10 strength, something that could be achieved either by
samples of each version. The fracture mode, energy different heating/cooling conditions during the hot-
absorption, elongation, maximum load and button forming process, but also through a subsequent operation
diameter were recorded (see Table 2). after forming by local tempering of such areas [4].
Regarding spot welding it is preferable to have not fully
Table 2. Results from tensile shear testing of spot welds made by hardened weld flanges, which will help overcome both
using various pulse programmes. the problem with brittle weldment behavior, but also to
prevent crack initiations around the spot welds.
Maximu Energy Full
m load absorption button Button size
There are two main techniques to obtain such soft areas.
pullout
Reference 32 kN 25 J 20 % 9.1 mm
In the first one a two-parted oven is being used meaning
Post pulse A 37 kN 82 J 90 % 11.1 mm that in the beginning the whole sheet is heated to the
Post pulse B 30 kN 60 J 100 % 9.0 mm austanization temperature. Later on the sheet reaches the
area with the split part of the oven where one section is
still kept around 920C, whereas the other one has a
The most promising parameter sets were also tested lower temperature (Fig. 10). This means that when the
using high speed tensile shear testing. The test equipment sheet is taken from the oven and put into the forming
is designed to perform tensile tests with a maximum tool, only a limited area will have the high
speed of 20 m/s, and the test specimen is positioned time/temperature cooling rate and result in the typical
between two grippers in the machine. A catapult, driven ultimate strength of around 1,500 MPa. The remaining
by an MTS hydraulic test machine, accelerates a drop part of the component will be much softer, and the
weight which hits the lower grip, initiating the test strength in this area can be tailored to in practice any
procedure. The maximum speed of the piston in the MTS strength wanted, but in general typical strength values are
machine is 1 m/s which, after a specially designed around 600 MPa.
hydraulic gear, generates a speed of 20 m/s for the
catapult. The improvements in ductility in terms of
energy absorption during regular tensile shear testing
created by the post pulses are also exhibited during high
speed testing.
The introduction of specific welding schedules and
optimized welding parameters have shown to be
successful for the enlargement of the softer HAZ around
the spot welds, which improves the ductility at spot weld
Figure 10. The principle of the two-parted oven in order to manufacture
failure and thereby the energy absorption. In general this
press-hardened components with locally softer areas. When lowering the
leads to longer welding cycles, which however might be oven temperature it will be possible to reformate the austenite in the
acceptable for a limited number of spot welds, which are ferritic microstructure.
crucial for the component behaviour in that respect that
they need to present a more ductile behavior when The other technique to achieve these uneven cooling
loaded. conditions are more sophisticated and therefore also
more expensive, but allows more than just one softer
area. Here the sheets are heated in the regular oven, but
6. Think Outside the Box Tailored the cooling channels in the forming tool are positioned at
Tempering for Increased Spot Weld different distances from the tool surface (Fig. 11).
Ductility Cooling channels close to the surface means a more rapid
cooling compared to those areas where the channels are
In the previous chapter it was described how to improve put deeper into the tool body.
the energy absorption at spot weld failure in press- Another advantage with this method is that the transition
hardened components, but for most applications the zone between the fully hardened area and the softer one
dimensioning criteria is that the weld shall stay intact. is very narrow, between 10-30 mm, whereas the
The spot welded joint shall guarantee a good backing and technique with the split oven normally results in a 100
allow the body components to deform just by plasticizing mm wide transition zone.
the desired behaviour of no spot weld failure indicating
that this technology seems to be very robust. The
recommendation is however to specify the weld flanges
to a hardness of 300 Hv (Fig. 13 and 14).

Figure 11. The complexity of cooling channels for a front side


member hot-forming tool, which makes it possible to improve
buckling behaviour and energy absorption by reducing the
strength and hardness in specific areas of the component.

Numerous trials were performed as dynamic four-point


bending testing, with an impact speed between 7-10
m/sec, on spot welded box beams to validate the effects
of the softer weld flanges [5]. The beams normally
consisted of an omega shaped hat-profile where the
flanges were softened to different hardness levels and a
flat lid made out of DP600 material. The drop weight
impactor always hit on the hat-side. Observing the
difference in failure behaviour between fully hardened
and soft flanges was astonishing. The completely
hardened beams collapsed already at moderate loading
conditions by cracks occurring around the spot welds and Figure 13. Drop weight testing of beams with soft flanges (200 Hv)
in the hat profiles; impact velocity 9.5 m/sec.
then propagating through the weld flange to the flange
edge (Fig. 12).

Figure 14. Drop weight testing of beams with soft flanges (300 Hv)
Figure 12. Drop weight testing of beams with fully hardened hat in the hat profiles; impact velocity 9.5 m/sec.
profiles; impact velocity 9.0 m/sec.
Another observation made was that if two press-hardened
The beams with the soft weld flanges could withstand parts are spot welded together it is important that both of
much larger deformations while the spot welds still them are manufactured with soft flanges, otherwise the
remained intact. Conventionally hardened Boron steel positive effects shown above will be lost (Fig. 15).
presents a Vickers hardness of more than 400 Hv. In the
tests, flanges softened to between 200-350 Hv all gave
International Congress on Advances in Welding Science and Technology for
Construction, Energy and Transportation Systems (AWST - 2011)
24-25 October 2011, Antalya, Turkey
AWST-11/04

Figure 16. Display of the on-line monitoring of various laser


welding parameters.

Figure 15. Drop weight testing of beams with soft flanges (200 Hv)
in the hat profiles but fully hardened lids; impact velocity 7.9
m/sec.
Figure 17. A purpose developed tool for post-checking of laser
7. Extensive Quality Assurance Procedures weld quality by ultrasonic inspection.

When Laser Welding in Press-Hardened


In the event of an alert from the on-line monitoring
Steels system, that specific body is taken out of the line for
further diagnosis by ultrasonic and visual checking.
Laser welding of car bodies has been used by Volvo Cars Furthermore, 3 car bodies per work shift are randomly
since 1991; however the early applications were limited picked out for ultrasonic inspection, and one of these is
to less critical connections such as roofs to body-sides then the subject of destructive checking procedures in
and for other outer skin panels. But starting with the order to correlate the non-destructive results with the
launch of the XC60 model in 2008, all newer models destructive outcome. If any deviations from the
present an extended use of laser welding, around 10 acceptable quality are found a direct feed-back is given
meters per car body. This also includes more critical for necessary adjustments of the production process. In
welds in the safety cage structure and is done on press- the case that the specified laser weld quality is not
hardened components such as the A-pillar, B-pillar and fulfilled, repair actions have to be taken.
floor sill reinforcements. Since the laser welds now are
important elements for the structural integrity of the car
body, it is obvious that the quality assurance procedures
of these welds in high volume production has been high-
lighted.
Nowadays Volvo Cars two European volume plants,
Gent in Belgium and Torslanda in Sweden, have
common procedures about how to secure the quality of
the structural laser welds mentioned above [6]. An on-
line monitoring system (Fig. 16) guarantees that the
welding parameters stay within certain limits necessary
for an appropriate weld quality. Furthermore, post
checking of these welds is done with a purpose
developed ultrasonic device (Fig. 17). These actions are
complemented with monitoring of the cover slide Figure 18. The advanced work flow of quality checking and potential
repair of laser welds in high volume car body production.
contamination and other crucial parameters, preventive
maintenance schedules and weld inspection instructions.
For laser welded joints with only single-sided access,
The workflow of the laser weld quality assurance is
repair can be performed as laser welding. Alternative
shown in Figure 18.
joining processes at single-sided accessibility are any
suitable gas-metal-arc welding (GMAW) method, e.g.
metal-arc active gas welding (MAG), metal-arc inert gas
welding (MIG), tungsten inert gas arc welding (TIG), [3] Rydgren, P., Wahlsten, J. and Hedegrd, J., Increasing the
ductility of RSW joints in UHS steel through parameter
etc. When repairing with a gas-metal arc method the area adjustment, Part 1, KIMAB report 2010-544
in question first has to be cleaned with a steel brush. [4] Hedegrd, O. and slund, M., Tempering of hot-formed steel
Then the weld is repaired in the positions described in using induction heating, Chalmers university of technology
the appropriate repair instruction and correspondent report 54/2011 (Masters thesis)
[5] Wstlund, C., "Tailored Properties for Press-hardened Body
repair drawing. After once more having cleaned the area Parts, Automotive Circle International (ACI), Insight Edition,
with a steel brush the weld is grinded to a flush condition Gothenburg, Sweden, September 20-21, 2011
by removing excessive weld metal, and finally a third [6] Larsson, J.K. and Palmquist, N.T., " Two Intensively Laser
steel brush cleaning operation is performed. Welded Body Versions Built on One Platform and Manufactured
in Two Plants" European Automotive Laser Applications
For joints with double-sided access, resistance spot (EALA), Bad Nauheim, Germany, February 9-10, 2011
welding (RSW) can be used as a repair method provided
that this is approved by the responsible Body
Engineering Department. This is due to that exchanging a
continuous joint with an intermittent one might affect the
performance of the car body. In the case of substituting a
complete body component with a new one, such as a roof
panel, this new component shall be attached using
regular laser welding parameters. If, for any reason, the
repair cannot be carried out in accordance with any of
the actions described above, a Temporary Part Deviation
(TPD) has to be requested by the manufacturing unit.

8. Conclusions and Recommendations

Considered for a high strength steel scenario in the


automotive industry, press-hardened Boron steel is quite
unchallenged regarding the attributes of ultra high
strength in combination with high formability from the
hot-forming process. However, a lot of work yet remains
to fully utilize a robust implementation from a virtual
point of view, together with refined solutions for
surrounding techniques such as welding in order to
minimize the influences of brittle behavior.
To fully meet these demands there should be a mutual
interest from both the material suppliers and hot-forming
suppliers together with the automotive OEMs to establish
guidelines for the required test data and format, e.g. hot
forming simulations generating mapping data for e.g.
advanced crash and welding simulations. The car
manufacturers generally lack the needed competence and
resources so this must also be provided by the suppliers.
Otherwise, there is a risk that the development of new
Boron steel technology will slow down as OEMs
continue to use well known materials and processes to
ensure CAE predictability as well as a high weld quality
for the assembly of tomorrows car body structures.

References
[1] Fermr, M., Jergeus, J., Johansson, R., Larsson, J. K., "Hot-
Formed Steel in Car Body Structures", International Automotive
Body Conference (IABC), Munich, Germany, September 22-23,
2010
[2] Larsson, J.K., Lundgren, J, Asbjrnsson, E. and Andersson, H.,
"Extensive Introduction of Ultra High Strength Steels sets New
Standards for Welding in the Body Shop", Proceedings 61st
Annual Assembly of the International Institute of Welding (IIW),
Joint Workshop Commission III & SC-Auto, Graz, Austria, July
6-11, 2008

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