April 2004.pdf - Materials Australia

Materials News
The Newsletter of the Victorian Branch of the Institute of Materials
Engineering Australasia Limited, April, 2004
www.mateng.asn.au
Stop Press: Dr Karlis Gross will be giving a talk on biomaterials technology
at Redback Brewery Hotel on Wednesday May 12 th . Ref page 4 for details!
A Technical Society of IEAust
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Editor: Gary Bunn
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2004 Gifkins Lecture
“Do we understand creep under moderately high stresses”
Due date for submissions: 20 th of
month of cover date.
The Victorian Branch is now
sending an electronic form of this
newsletter to members who choose
to receive it. Email us at
imea@mateng.asn.au to register for
receipt of this electronic version
(sent as a Adobe Acrobat file).
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Professor Bob Gifkins and Professor Frank Nabarro kindly pose for a photo following
Prof Nabarro’s thought-provoking lecture on the phenomenon of creep.
An audience of around fifty interested people listened attentively as Prof
Nabarro told the story of how our understanding of the nature of creep at
moderate temperatures has evolved during the last century. Several
members of the privileged audience, including Professor Gifkins, took the
opportunity to ask Professor Nabarro questions relating to their own
research on this fascinating topic and were given insights and suggestions
from Prof Nabarro’s vast experience. During his lecture Prof Nabarro paid
tribute to the research work carried out by Prof Gifkins and his co-workers at
CSIRO and Melbourne University. Twenty Members of IMEA later took the
advantage of extending the discussions by joining Professor Frank Nabarro,
Professor Bob Gifkins and his wife Betty, for the annual dinner at the
University Club at Monash University.

Professor Frank Nabarro clarifies a feature of particular interest during the course of his lecture.
Abstract of the 2004 Gifkins Lecture.
DO WE UNDERSTAND CREEP UNDER MODERATELY HIGH STRESSES
F.R.N. Nabarro
School of Physics, University of the Witwatersrand
Private Bag 3, WITS 2050, Johannesburg, South Africa
In conventional creep tests of moderately pure metals there is a period of creep at an almost constant
strain rate. There is a range of stresses in which the creep rate is close to a power of the stress, with
an exponent of about 5, followed by a region of "power law breakdown" with a closely exponential
dependence. Are the dominant physical processes in these two ranges the same The simplest
application of rate theory, with an activation volume independent of the applied stress, leads at once
to an exponential law. A model of this kind seems to be quantitatively plausible. Theoretical models
of power-law creep all assume that deformation occurs predominantly by homogeneous shear within
the grains, although in the model of Spingarn and Nix the rate-controlling process occurs in the grain
boundaries. Experimental observations nearly all indicate that deformation is occurring
predominantly at or near to the grain boundaries. It is not clear whether these observations were
made in the power-law or the exponential range. Those of Andrade's group were probably in the
exponential range, these of Hanson and Wheeler at the top of the power-law range.

The members of the audience anticipate the commencement of this year’s AGM and the Gifkins Lecture
IMEA
Victorian Branch Report
The IMEA Victorian Branch committee this year has grown to ten people who come from a diverse
range of organisations and companies. Monthly meetings are usually held at the Redback Hotel to
encourage networking and creativity by providing an informal and social atmosphere. Committee
members can often be found in ongoing discussions long after the meeting has officially closed.
These meetings are not restricted to the Committee and all interested members are encouraged to
come along (see newsletter for details of meetings).
Branch Activities
Traditional activities such as the Gifkins Lecture, Technologists’ Picnic and Borland Forum were
popular again in 2003. The AGM was delayed until May to enable Terence Langdon to present the
Gifkins Lecture. This year sees the AGM and Gifkins Lecture delayed until April to fit in with the travel
schedule of Prof. Frank Nabarro. Prof. Nabarro will present the lecture, titled “Do we understand
creep under moderately high stresses”.
Training courses in welding (as an in-house course for GM) and wear were run and it is planned that
the range of courses on offer will be expanded in the next year. 2004 will also see the introduction of
more technical events run in conjunction with kindred organisations.
Events since the last AGM include:
22 nd May Gifkins lecture, AGM and dinner. “Grain Boundary Sliding in Creep and Superplasticity:
The Gifkins Decades and Twenty-five Years Later” Terence Langdon (University of
Southern California)
20 th August 2003 Borland Forum – Annual postgraduate student presentation competition, won by
Chamini Mendis (Monash University).

9 th September One day training course presented by Dr Jeff Gates: “Materials Selection for Wear”
18 th Sept Visit to Challicum Wind Farm, Buangor (near Ararat). Joint function with IEAust.
19 th Sept Annual Technologists’ Picnic: “Reducing Central Victoria’s Greenhouse Gas Emissions
to Zero by 2020”, Sovereign Hill, Ballarat.
23 rd October La Trobe Valley Power Station Site Visit – cancelled due to low participation.
11-13 th November International Symposium on Ultrafine Grained Structures, Geelong.
The committee is also taking the first steps towards the introduction of a mentoring program to
encourage new members to join. This has proved successful for the Metals Club where newer
members have been supported in their careers by more senior members.
Branch Awards
Awards have been presented to the following people:
Dr. Elena Pereloma - Florence Taylor Medal
Dr. Karlis Gross – Edgerton Award
Mr. David Menzies – IMEA Prize
Ms Sarah Khor – I.J. Polmear Award
Ms Chamini Mendis – Borland Prize
Newsletter. The newsletter is now delivered electronically with members able to receive it by e-mail
or download it from the IMEA website. This change in delivery has enabled Gary Bunn (newsletter
editor) to extend the newsletter and include more detail and photographs than before.
Dr Georgina Kelly (President)
“Biomaterials Technology”
Dr Karlis Gross, winner of the Edgerton Award for 2003, will be giving a
presentation on the topic of biomaterials technology at The Redback
Brewery Hotel, 75 Flemington Road, North Melbourne on
Wednesday May 12 th .
The presentation will start at 7.30 pm. Counter meals and refreshments are
available prior to the event
“Traditional biomaterials relied on material development from other markets such as the aeronautical
industry. The increased support to the biomaterials field has allowed the development of new
compositions, complex porous structures emphasized the need for new techniques for material
testing and characterisation. This presentation will outline the chemical development of
hydroxyapatite, discuss the strategies for producing and characterizing porous materials for tissue
engineering applications.”

I. J. Polmear Award for 2003 awarded to Andrew Micallef from the School of
Physics and Materials Engineering, Monash University.
Georgie Kelly (IMEA Victorian Council President) presents Andrew Micallef with his certificate and the
I.J.Polmear Award for 2003.
This award is made to the student who achieves the best result in the first year of any “Materials
Education” course at any Victorian University. The term “Materials Education” includes both
Materials Science and Materials Engineering and the course must be one, which leads to a major
sequence in the discipline at the university concerned. One award is made per year and the value of
the award is $250 plus an appropriate certificate.
Andrew Micallef, winner of the I.J.Polmear Award for 2003, shown holding his well deserved certificate in the
company of his father Joe, sister Sarah and mother Jane.

Australian Engineers win UK Materials Award
A team of Australian materials engineers has won the prestigious UK Institute of Materials Minerals &
Mining Guy Bengough Award for their “outstanding contribution to the subject of corrosion and
degradation of all types of materials and their control”.
Dr Ivan Cole, Dr David Paterson and Wayne Ganther of CSIRO Novel Materials & Processes were
recognised for a paper on the team's holistic approach to corrosion. “The holistic approach is a
critical step on the path to a Genesis Model, to accurately predict the degradation of infrastructure
anywhere in the world and its associated recurrent cost,” Cole said.
The winning paper was the first of a series outlining the use of the holistic approach to predict
corrosion in marine environments. "A Holistic Model for Atmospheric Corrosion: Part 1 - Theoretical
framework for the production, transportation and deposition of Marine Salts " was published in the
Institute's journal of Corrosion Engineering, Science and Technology, 1 June 2003, vol 38, no2,
pp129-134(6). (Source : Australasian Corrosion Association Gazette, April 2004)
Award for Scientist Behind Super-Strong Carbon Fibres
Later this month (April), one of the pioneers of carbon fibre technology, Roger Bacon, will accept the
International Benjamin Franklin Medal in Mechanical Engineering at the Franklin Institute Science
Museum.
Bacon first experimented with graphite some four decades ago. There in Ohio, Bacon subjected
graphite to high heat and pressure, discovering stronger-than-steel microscopic "whiskers." He
eventually discovered a process for making continuous threads of carbon fibre, a high-strength
material with numerous commercial, industrial and military applications. Bacon documented all of the
properties and published his results in the Journal of Applied Physics in 1960.
"If you turn a good scientist loose, he'll come up with something useful, once in a while," said Bacon
"I don't like it to sound like I did it all myself - there were so many people who helped."
Bacon holds several patents for the process, but the company owns them and retains subsequent
profits. Until now, Bacon's name was recognized only in the most elite scientific circles.
The U.S. military began using Bacon's discoveries in the 1960s. Soon, reinforced rocket nozzles,
heat shields for ballistic missiles, space shuttle wings and aircraft brakes contained carbon fibres,
which dissipate heat.
"Every single aircraft that flies today uses carbon fibre, and Roger's invention enabled that to
happen," said Brian Sullivan, a Villanova University adjunct professor specializing in carbon fibres
who nominated Bacon.
Awards in seven science fields are announced yearly in the international competition. Many
recipients have gone on to win Nobel Prizes. (Source : netcompositesnews 23rd April 2004)
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VicStart - Expressions of Interest Sought
VicStart is the Victorian Government's second-generation technology commercialisation program. It
aims to improve the linkages, processes and skills needed to successfully commercialise Victoria's
science, technology and innovation.
As part of VicStart, Expressions of Interest are sought from individuals, companies, organisations and
consortia (both public and private) to design and deliver projects that address areas of priority in
technology commercialisation. These areas are: Capability Building, Access to Finance and
Technology Transfer.
The Expression of Interest documentation, which includes further information about the three areas,
is available at www.tenders.vic.gov.au under Department of Innovation, Industry and Regional
Development, reference number VS1EOI.
An Information session will be held: 3-4pm, Monday, 26 April 2004 at the Centre for Innovation and
Technology Commercialisation, Level 1, 257 Collins Street, Melbourne. To attend please email
vicstart@iird.vic.gov.au or call VicStart administration on 9651 9030. Please note that pertinent
issues raised at the information sessions will be published on: www.innovation.vic.gov.au.
For further information please call Hugh Moor on 61 3 9651 9111.
Registrations are due by Monday, 3 May 2004.
International registrations are due by 10 May 2004.
Australian Scientists' Revolution in Casting Technology
Press Release: 30 Mar 2004 Ref: 2004/54
(Built Environment & Manufacturing Innovation)
Australian researchers who have worked quietly over several years
in a long-ignored area of metallurgy, have been rewarded with a
startling discovery, which is set to reshape the way metals are
manufactured around the world.
CSIRO's (Commonwealth Scientific & Industrial Research
Organisation) Advanced Thixotropic Metallurgy (ATM) casting
technology is now in the final proving-out stage and the results
herald a new age of quality high-pressure die-casting (HPDC).
ATM is particularly suited to aluminium or magnesium alloys and
offers consumers lower costs and improved quality across a wide
range of product applications, from safety-critical automotive
components to cases for mobile phones, laptops and cameras.
Traditional HPDC involves molten metal being rammed into a
casting through small tunnels called runners, which traditionally
have overflow zones or spaces on the exit side of the die to
reduce/improve internal porosity. Mr Barrie Finnin of CSIRO Elaborately Transformed Metals says,
'CSIRO's approach is a radical rethink of high-pressure die-casting runner design'. 'It moves in
completely the opposite direction to recent die-casting technology based on larger runner apertures
and hotter castings designed to reduce porosity – the enemy of the die-caster.'Mr Finnin says, 'ATM is a
system that, linked to the principle of a semi-solid feed (cooler molten metal) and narrower runners
with reduced overflows, reduces the cost of manufacturing castings'. 'ATM essentially covers off on the
die-caster's wish list – reduced reject rates, and reduced cycle (production) time lowering labour and
machine costs, with a system that can be applied to most existing machines and using stockfeed
materials. 'Finnin says, 'The overall effect of ATM is an exceptionally low-porosity casting, with very
low wastage'. ATM casting is a CSIRO-patented breakthrough technology, and has 'the new Australian
runner system'. Mr Finnin says, 'The commercial impact of CSIRO's ATM technology will be greater,
thanks to the development of CSIRO-designed software tools which enable a dramatic reduction in cost
and time-to-market'. Early applications of the technology were hampered by the need for computer
modelling and simulation, which is expensive and time consuming, involving special skills to simulate

complex shapes and to analyse data produced. 'In a complete turnaround', Finnin says, 'We were able
to design an ATM runner system for an automotive aluminium alloy (ADC12) extension housing, and
conduct the trial at Nissan Casting Australia Pty Ltd, all in one day'.
Nissan's R&D Coordinator, Ms Jenny Law, has called the trial, 'the wonder trial' and says, 'The parts
passed Nissan's production quality standards, with X-ray results showing they were better than
conventional HPDC castings'.
Other benefits offered by the CSIRO ATM include:
• Reduced projected area, resulting in the
possibility of a smaller machine than
conventional HPDC or more die cavities per
casting
• Shorter cycle time, improving plant
productivity
• Finer microstructure (associated with improved
strength)
• Redesign of components for thinner sections,
offering weight/cost reductions
• Expanded design limits for components beyond
the capability of HPDC
Photo courtesy of Excel Pacific Die-Casting
• Increased energy efficiency
The CSIRO ATM Team belongs to CSIRO Elaborately Transformed Metals, a team of 80 engineers, scientists and
technicians with a high international standing in research and development focussing on light alloys, casting,
joining, tooling and advanced metals processing. The group has considerable expertise with aluminium,
magnesium and titanium.
CSIRO ATM is protected by a number of international patents. Licenses and support for CSIRO ATM is available
within Australia now, and CSIRO is talking to a number of selected offshore manufacturers interested in
technology licenses.A small but growing number of license agreements have been finalised with licensees in
North America and Europe.
New Research Facility at University of Auckland
A new research facility at The University of Auckland's Faculty of Engineering will help New Zealand industries
keep abreast with cutting edge technologies. The Centre for Advanced Composite Materials research facility
was officially opened by the Minister for Research, Science and Technology, the Hon. Pete Hodgson.
The Centre has been established as a joint venture between The University of Auckland and Forest Research
(FRNZ). It is also supported by a consortium of industries and the Foundation for Research, Science and
Technology. The composites research group was also named as a recipient of a Foundation for Research,
Science and Technology (FRST) grant for the designing, developing and manufacturing of advanced
composite structures. The group will receive more than $10.2 million over a period of six years from this FRST
grant, in addition to the support received from other New Zealand and overseas sources.
Faculty of Engineering Dean Professor Peter Brothers says he is delighted with the addition of the research
facility to the Faculty's existing research and teaching programme. "The new facility will take research in the
area of composite products and manufacturing processes to a new level and it offers a wide range of research
and learning opportunities to our academics and students. "In addition, we welcome the opportunity to work
with Forest Research on this initiative, as well as other members of New Zealand industry who have a stake in
the ongoing development of these research programmes," says Professor Brothers.
Research in advanced composite materials at the University first started in 1987, while the joint venture was
formally established in 2002. It aims to pioneer innovative technologies in advanced composite products and
manufacturing processes, to enhance the wealth of its members and to provide new business opportunities
that will benefit New Zealand's economy. Centre Director and Head of the Mechanical Engineering
Department, Professor Debes Bhattacharyya, says increased interest in the research carried out by the
Faculty meant that bigger custom-made premises were required.
"Since we first started research in this area, we have gone from strength to strength in terms of our research
projects and opportunities and we have had growing support for our work from industry collaborators and
overseas institutions.
"Interest is coming from a wide range of industries, varying from marine and forest product manufacturers,
polymer and consumer products manufacturers, and aircraft maintenance and parts manufacturers," says
Professor Bhattacharyya.

Forest Research Chief Executive Bryce Heard says the organisation is pleased to be so closely involved with
an area of research that has the potential to drive real growth in the New Zealand economy. "The area of
composites research opens up a whole new area of opportunities for New Zealand businesses and industry,"
says Mr Heard.
""New Zealand organisations are already world-leaders in this area of development and this new centre of
research at the University will help all of us stay ahead of the competition. It's an exciting development for
everyone involved."
"Research areas include innovative manufacturing processes like modified rotational moulding, development
of novel biopolymers and polymer blends, modifications of synthetic and natural fibres like wood fibres, and
the applications of nano- and micro-fibrillar polymers in composites ma
nufacturing.
"The Centre for Advanced Composite Materials is part of the Faculty of Engineering's Mechanical Engineering
Department, but it also utilises the skills of researchers from a variety of disciplines including Engineering
Science, Chemical & Materials Engineering, Civil and Environmental Engineering and Chemistry. Forest
Research staff will also contribute to research and are likely to be based at the Centre from time to time.
"The CACM has been set up initially for six years, with a possible extension after an independent
mid-term review. (Source: netcompositesnews 23 rd April 2004)
WWW Link: http://www.auckland.ac.nz
Composite Tooling Saves £1.4 Million for MG Production
The use of carbon fibre composite tooling for the MG X-Power SV road
car is claimed to have saved MG Rover around £1.4 million compared
with more traditional steel tools.
DPS Composites in Surrey, UK, produced the composite tools for all 36
body panels that comprise the entire silhouette of the car.
Layups and templates were designed and developed at DPS in
conjunction with SP Systems, for use with SP Sprint. This enabled
material for each part in full-scale production to be supplied in pre-cut
form ready to be dropped in place and moulded, in turn saving
additionally on production time and costs with the added benefit of improved consistency and quality of parts.
In addition to the more traditional benefits of using composite tooling and production against steel and
aluminium for body panels, a further benefit is that composite tooling can be typically produced in less than
half the time of steel tooling. At present, as production quantities rise above 2000 sets and approach or
exceed 20,000 sets, the economics increasingly favour more traditional methods where high performance is
not an important requirement. However, in the future, composites look set to further encroach in to the medium
volume production sector.
On the MG X-Power SV all of the exterior body panels are made of carbon fibre composite. These make up a
sandwich with a syntactic core. These panels have the same stiffness as steel, but weigh only 25% of the
equivalent steel components.
DPS Composites have developed, tooled, prototyped and manufactured Formula One chassis and
components in carbon fibre composite since 1987 where advances in performance, reliability and safety have
been self-evident. The new, lower cost methods of production are seeing many less exotic applications
designed, developed and prototyped in Surrey in areas such as automotive bodies and engines, marine craft,
unmanned aerial vehicles, medical applications, structures and engineering applications.
(Source : netcompositesnews 16 th April 2004)
WWW Link: http://www.dpscomposites.com

Niche Market with Waste
An innovative Queensland company is manufacturing building
products out of polystyrene waste that previously was dumped in
Brisbane landfill.
Such has been the success of Quik'n Tuff Pty Ltd's marketing efforts
that its "Conpolcrete" wall panels are now being exported to New
Zealand. The Conpolcrete panels are manufactured from recycled
virgin waste polystyrene which is crushed and blended with concrete
and alkaline-resistant fibreglass mesh.
The finished product is a relatively light-weight, insulated, fire-rated
panel that is used for external walls in residential and commercial construction. Currently Quik'n Tuff
sources the polystyrene from three or four local manufacturers.
"We're based at Acacia Ridge and most of the polystyrene manufacturers that make the refrigeration
panels and cut polystyrene for architectural reasons are based in this area," said managing director
Vincent Martin, a plasterer by trade. "We're trying to negotiate a deal where we can get all the
polystyrene waste from all the manufacturers in southeast Queensland."
In the past, manufacturers often had to pay to have this waste carted away and much of it ended up
in landfill. When Mr Martin came to Australia 19 years ago, he found the Australian building
techniques less advanced than what he was used to in the UK and Europe. Six years ago, he started
experimenting with different materials and eventually came up with Conpolcrete.
"We initially tried other materials but since polystyrene waste was a problem for the environment we
saw that it was a good avenue to go down," he said. A manufacturing plant was built four years ago
and the company, which employs 25 people, now produces 1000 to 1200 square metres of panelling
a day.
Quik'n Tuff head of marketing and sales Michael Ross said Conpolcrete was being tested in the UK
and US markets.
"There are at least half a dozen other regions under consideration," he said.
WWW Link: http://www.quikntuff.net
ICOMS® –2004 – International Conference of Maintenance Societies
This year the conference will mark the coming of age of the old “maintenance” regime completing its
transformation into a lifecycle Asset Management system that covers physical assets from “lust to dust”. This
transformation requires a top down bottom up approach. You are invited to be part of this brave new world,
and explore new perspectives on Asset Management and Maintenance. Venue is Star City, Sydney, Australia
from 25 to 28 May 2004.
Please note that the latest conference program has been posted on the web
http://www.icoms.org.au/reg_broch.htm You will also find the registration form in the program and if you
register and pay for full registration by 30 th April, 2004 there is a discount of A$176. So be early and have
extra to spend in Sydney

The 2nd Annual Australia-China Metals & Minerals Conference
Four Points by Sheraton Darling Harbour, Sydney
IBC Conferences: 8 - 9 Jul 2004
Assessing investment in China's mining sector; Insights to Chinese investment in local
mining projects; Analysis of China's future demand for various commodities/metals
• The Hon Ian Macfarlane MP, Minister for Industry,Tourism and Resources
• The Hon Clive Brown MLA, Minister for State Development,Western Australia
• The Hon Tony McGrady, Minister for State Development and Innovation, Queensland
This AJM event has become the definitive Australia-China conference for the mining sector. We are proud to bring you
a speaker panel that provides presentations ranging from macro level government policy to detailed expert analysis.
You will receive updated and timely information on China's impact on various commodities to specific project updates.
For more information or to register, simply click below to download booklet (pdf).
Click here for more information about this event - The 2nd Annual Australia-China Metals & Minerals Conference (pdf)
IMEA Victorian Branch2004 Technical Program and
other Events of Interest
12 th May “Biomaterials Technology” – Dr Karlis Gross, Redback Brewery Hotel,
Flemington Road, North Melbourne. 7.30 pm start!
9 th June Joint Meeting with ACA – “Advances in Thermal Spraying”, Elgin Inn Hotel, 75 Burwood Rd,
Hawthorn
18 th June Social Event
7 th July Topic TBA – Redback Brewery Hotel
July
Failure Analysis Course (Date and details yet to be announced.)
11 th August Borland Forum
17 th Sept “Technologists’ Picnic”, Sovereign Hill
13 th October Plant Visit – Capral Aluminium
10 th Nov “Refractories Today” – Ionik Consulting
Please note that the dates and contact details for some of these events are to be confirmed and will be made
available as soon as possible.
CENTRE FOR ADVANCED MATERIALS TECHNOLOGY (CAMT)

Monash University,
Wellington Road, Clayton, Vic. 3168
Ph: (03) 9905 5791 Fax: (03) 9905 4940
Website: http://www.spme.monash.edu.au/camt/
R&D Consulting; Contract R&D; Materials Analysis;
Plastics, Metals, Ceramics, Composites; Corrosion;
Product Testing; Materials Development;
Microscopy and Microanalysis;
Conferences; Education.
IMEA Victorian Branch Council 2004
"We seek to foster the values of mutual help, recognition and respect between our members
and the wider community."
Georgie Kelly glkelly@deakin.edu.au (Honorary President) http://www.deakin.edu.au/
Bronwyn Fox blfox@deakin.edu.au (Honorary Vice-President) http://www.deakin.edu.au/
Mark Hickson mark.hickson@gm.com (Honorary Treasurer) http://www.holden.com.au/
Chamini Mendis chamini.mendis@spme.monash.edu.au (Honorary Secretary)
http://www.spme.monash.edu.au/
Gary Bunn gary.bunn@tkl.com.au (Newsletter Editor) http://www.tkl.com.au/
Fiona Nelson Fiona.Nelson@mel.ionikconsulting.com (Awards) http://www.ionikconsulting.com/
Paul Howard paul.howard@hardchrome.com.au(Technical Program) http://www.hardchrome.com.au/
Nick Birbilis nick.birbilis@spme.monash.edu.au (Student Liaison) http://www.spme.monash.edu.au/
Libby Ackers Libby.Ackers@bluescopesteel.com(Committee) http://www.bluescopesteel.com/
Rob O’Donnell Rob.O'donnell@csiro.au(Committee) http://www.csiro.au/
Would you like to advertise here
Phone: 03 9326 7226
Fax: 03 9326 7272
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