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Composites: Part A 36 (2005) 739–746

www.elsevier.com/locate/compositesa

Bubble free resin for infusion process


Md Afendi*, W.M. Banks, D. Kirkwood
Department of Mechanical Engineering, Centre of Advanced Structure Material, University of Strathclyde,
James Weir Building, 75 Montrose Street, Glasgow, Scotland G1 1XJ, UK
Received 15 October 2004; accepted 25 October 2004

Abstract
The vacuum infusion process has been found to be very versatile for making large composite structures. During the resin impregnation
process, the vacuum causes the nucleation and formation of air bubbles from gasses dissolved in the resin. One solution to this would be a
degassing process prior to infusion. Recent experiments have shown that a degassing process, conducted in batches with a small quantity of a
bubble nucleation agent (Scotch–Brite) and an air sparging method could reduce void formation in the vacuum infusion process. At 90 mbar,
this method of degassing may remove 40–50% of the dissolved gas. However, despite reducing the level of dissolved gas, some micro-
bubbles remain suspended due to the viscosity of the resin and contribute to void formation. While these results were quite encouraging, there
is a need to design a system to ensure a continuous supply of degassed resin as a better way forward. In a continuous degassing system, it is
necessary to establish the relationship between the degassing process quality and void content reduction from the perspective of strength and
performance, besides signifying the most viable method of degassing.
q 2004 Elsevier Ltd. All rights reserved.

Keywords: B. Mechanical properties; Vacuum infusion

1. Introduction dielectric properties and surface finish [1,2]. Judd and


Wright [3] reviewed the effects of voids on the mechanical
Developments in the field of advanced composite materials properties of composites and ‘concluded that, regardless of
over the past decades have significantly altered both their resin, fibre type or fibre surface treatment, the interlaminar
current and potential role in structural applications. Composites shear strength of a composite decreases by about 7% for
offer structural designers materials of higher strength, stiffness, each 1% voids up to a total of about 4% (beyond which the
and lower distortion than previously available engineering rate of decrease of interlaminar shear strength diminishes).
materials. Fibre-reinforced epoxy resin composites are one Other mechanical properties are also affected, although not
example of such a material. These composite systems are to the same degree, or extent’. Hence, it is beneficial to keep
finding widespread use in the transportation, marine, aerospace, the void content to a minimum. Judd and Wright also
energy and even sporting goods industries. As these structures identify the difficulties in determining the void content
become more optimized for mechanical properties in terms of especially at percentages in the region of 1%.
performance and consistency, there is a requirement to Ghoirse [4] also investigated the effect of voids on the
improve material quality while reducing the weight and cost. mechanical properties and reported that flexural and inter-
laminar strengths are reduced by 10% for every 1% addition
1.1. Effects of voids of void contamination, whereas the flexural modulus is
affected by 5%. Above 5% void content, crack initiation was
Voids are undesirable within composite materials owing identified as becoming complex. Harper and Staab [5] and
to their effect on mechanical properties especially strength, Tang and Lee [6] have also reported that the mechanical
properties of composites are very sensitive to voids.
* Corresponding author. Tel.: C44 141 548 2321.
To produce composite products with very low void
E-mail addresses: affendi@fkm.utm.my (M. Afendi), bill.banks@ volume fractions requires dependable controlled
strath.ac.uk (W.M. Banks). manufacturing techniques especially, where composites
1359-835X/$ - see front matter q 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.compositesa.2004.10.030
740 M. Afendi et al. / Composites: Part A 36 (2005) 739–746

with fibre volume fractions in excess of 50% and void


content below 1% are required.

1.2. Effect of the manufacturing process on void content

Kardos et al. [7] have reviewed the growth of voids


during manufacture of polymer composites. According to
Yu and Middleman [8] and Kurematsu and Koshi [9], the
main driving force for void formation in resin transfer
moulding is related to the heterogeneous nature of the
preform at the micro-structural level, where it is composed
of arrays of fibre bundles (tows). In fast flow conditions, the
resin tends to flow around the tow, as the open space
between adjacent tows is much less resistant to flow than the
tows themselves. Void formation occurs primarily within
the tows in this flow regime. Alternatively, the flow front
within the fibre tows may lead the bulk flow front owing to
wicking processes when capillary forces outweigh viscous
forces. In this case, void formation is more likely to occur in
the open space between the tows.
Oliver [10] stated that there are several causes of void Fig. 1. Typical capillary pressure–wetting fluid saturation curves
formation, with two of them being the focus of significant illustrating hysteresis.
study and modelling. The first factor is the entrapment of
gases (most often wet air) during the lay up or during is in the non-wetting fluid. At Snw%Snwo, the non-wetting
impregnation of the fibre reinforcement with resin. The fluid ceases to flow.
second factor is volatile materials within the resin system. Kiljanski [13], in a study of centrifugal degassing, states
Void growth may occur via diffusion of air or by that surface tension tends to make the bubble spherical. In
agglomeration with other surrounding voids. Beyond these 1928, Bond [13] proposed a simplified formula for the
two phenomena, void growth can also occur as the critical diameter at which a gas bubble or liquid droplet is
temperature increases. In the later case, the equilibrium midway between the rigid and fluid state:
between the void and the resin pressures and the void
rffiffiffiffiffiffiffiffiffi
surface tension is disturbed. s
For epoxy resin, Wood and Bader [11] measured the dcr Z 2 (1)
Drg
equilibrium gas concentration of nitrogen at atmospheric
pressure to be approximately 1.7% by volume. This 1.7% of
For an epoxy resin of surface tension sZ32 dyne/cm
dissolved gas may not seem like a considerable amount of
(32!10K3 N/m) and resin density rZ1102.8 kg/m3 with
gas, but at a vacuum pressure of 20 mbar, which is
gZ9.813 m/s2, the bubble critical diameter dcrZ3.44 mm.
commonly used in vacuum injection, this would expand
Therefore, a bubble of diameter lower than this critical
50 times if brought into solution.
value (e.g. from 1 mm down to dust like particles) will be as
rigid as can be theoretically accepted.
1.3. Imbibition and drainage
There is a need to explain what happens to the bubbles.
As they cannot pass through a woven cloth, the following
In studies of multiphase flow through porous media [12],
formula derived from the Young–Laplace equation should
it is found that capillarity governs most of the permeation
be able to verify the condition. Pressure P inside a bubble of
process. Bubbles in the fluid may be termed non-wetting
radius r is given by:
fluid while the resin mixture may be termed a wetting fluid.
Due to the complexity of a random configuration in a
naturally porous medium [12], a capillary tube has been 4s
PZ (2)
used in most experiments to ideally represent the actual r
mono-system. For a single bubble of non-wetting fluid to be
forced in to a capillary (to promote drainage), slightly The pressure inside a small bubble is greater than that
higher pressure needs to be induced compared to the process inside a large one. When small and large bubbles coalesce,
of imbibition by the wetting fluid that takes place naturally the smaller ones inflate the larger and collapse. Therefore,
due to the capillary pressure. This is clearly shown in Fig. 1 the result will be that the coalescing bubbles that cannot
below. Drainage starts at point A (Fig. 1), in unsaturated penetrate through the filter will increase in buoyancy, rise
flows, where Snwo indicates the amount of entrapped air that and diffuse at the surface.
M. Afendi et al. / Composites: Part A 36 (2005) 739–746 741

1.4. Vacuum infusion After infusion, voids can also be formed as a result of resin
shrinkage. Labordus and Soderlund [26] suggest that one
Vacuum infusion is one of the manufacturing techniques way to reduce the void content is to use degassed resin.
suitable for large load carrying composite and sandwich Labordus [1] reported that some reinforcement materials
structures. Resin infusion shares many of the characteristics (e.g. Unifiloe) cause more bubble nucleation than other
of vacuum bag moulding and resin transfer moulding materials, and thus result in laminates with a higher void
(RTM). All these techniques reduce emission of volatile content. Labordus reported resin degassing procedures
components into the workplace by wetting out and curing using bubble nucleation material and air sparging showing
the laminate in a closed system. very good results in reducing the void formation during
In comparison with traditional hand lay-up, the infusion vacuum infusion.
process has obvious health and safety advantages, through The aim of the current studies on the process of vacuum
reductions in human contact with liquid resin and in reduced infusion is to fully understand the specific sources of voids
emissions to the environment. Additionally, laminate and to reduce void formation. Even though it is not
mechanical properties are improved by higher fibre content imperative to eliminate all the voids, it is essential to
and lower voidage. In comparison with conventional minimize the void content as well as assuring the
(matched mould) resin transfer moulding, the process can homogeneity of the laminates. Investigations throughout
offer a substantial reduction in tooling cost, especially for the process have been taken to identify the sources of voids
large parts. These processes are most suitable for making in order to control the void formation during production.
large structures as they minimise mould and laminate Lower resin viscosity, achieved by heat treatment can
deformation during the process as the tooling is uniformly improve the degassing process as well as the wetting profile
subjected to external atmospheric pressure. Petrie [14] and infusion rate but this action also shortens the pot life of
strongly emphasized that the vacuum infusion process the resin solution, resulting in limiting the time the process
virtually eliminates styrene emissions, making for a cleaner has to completely infuse. For the infusion of large
and healthier workplace. This process not only improved the structures, the quantities of resin and hardener to be
air quality, but also reduced non-construction solid waste mixed can make the process very vulnerable to exothermic
products significantly. reaction. Therefore, it is preferable for the manufacturer to
The generic form of resin infusion itself can be traced to have a continuous supply of resin to maintain productivity
the use of the Marco method [15] in 1950, where the dry and minimise quality concerns.
reinforcement was placed onto a solid male tool and then Two issues have been given special attention in this
encapsulated by a semi-flexible female tool used for research; one is to seek an appropriate method of degassing
compaction, and vacuum sealing. The use of a silicone suitable for a continuous process and the other the
rubber bag as one of the tool halves can be traced to the production of bubble free resin.
development by Gotch [16] in 1985 in response to the need
for lower styrene emissions. Le Compte [17] extended these
methods to the fabrication of large structural components 2. Experimental
including hulls for surface effect ships up to 50 m length.
The development of various vacuum bagging materials for 2.1. Degassing dissolved gas
low cost, better compaction, and flow development was
conducted by a number of researchers including Brittles In the case of dissolved gas, it is quite difficult to know
[18], Marcus [19] and Shepheard [20]. the extent to which a solution is effectively degassed. The
The process is often practiced with one of the solid gas concentration at equilibrium, generally increases
mould faces replaced by a polymeric film. This is known by linearly with respect to the absolute pressure (Henry’s
a confusing array of acronyms. In the United Kingdom, it is Law), whereas the gas concentration at absolute vacuum is
commonly referred to as Resin Infusion under Flexible zero. Thus, for manufacturing methods, where the mould is
Tooling (RIFT) [21]. In the United States of America, it is evacuated (vacuum injection, resin transfer moulding, etc.),
known as Vacuum Assisted Resin Transfer Moulding it is likely that the resin will become over-saturated with gas
(VARTM) [22]. The use of a high permeability distribution when exposed to lower absolute pressure.
medium adjacent to the preformed reinforcement has been Dalton’s law states that the total pressure exerted by a
patented and is known as SCRIMPe [23–25]. mixture of gases is equal to the sum of the pressures that
Labordus [1,26] investigated void formation in the would be exerted by each of the gases. For a container filled
vacuum infusion process and verified that voids may be by three gases, the gases together would have a partial
due to local variation in permeability of the reinforcement at pressure of 1 and each alone would have a partial pressure
the resin flow front, leakage, boiling of volatile components relative to its percentage of the whole. For normal air, the
in the resin or gas dissolved in the resin coming out of the partial pressure of each gas would be as shown in Table 1.
solution. In the case of dissolved gas, it is quite difficult to Henry’s law states that the amount of any given gas that
know the extent to which a solution is effectively degassed. will dissolve in a liquid at a given temperature is a function
742 M. Afendi et al. / Composites: Part A 36 (2005) 739–746

Table 1 Table 3
Gas component fraction and partial pressure in normal air Percentage of oxygen content in degassed resin by various methods

Percent of component (%) Partial pressure Epoxy resin mixture Oxygen content (%)
Nitrogen 78.08 0.7808 After mixing 85–96
Oxygen 20.95 0.2095 Fully saturated with air bubble 100
Carbon dioxide 0.03 0.0003 After 15 min degassing with bubble nucleation 53–63
Other 0.94 0.0094 After 60 min degassing with bubble nucleation 50–60
Total 100 1.0000 After 120 min degassing with bubble nucleation 50–60
After 15 min degassing with air sparging 50–60
After 60 min degassing with air sparging 50–60
of the partial pressure of the gas that is in contact with the After 120 min degassing with air sparging 50–60
liquid and of the solubility coefficient of the gas in the Degassing Thin filament through 1 mm orifice 65–75
Degassing thin film through narrow passage 68–78
particular liquid.
(1 mm)
Two epoxy resin systems were used in the experiments Degassing of thin film on spinning disc 55–65
(Table 2). The PRF resin system is very much less viscous (1000 rpm)
than the Vantico system. The PRF resin is about 100 times Degassing of thin film on spinning disc 55–65
more viscous than water, and hence the Vantico resin is (3000 rpm)
around 1000 times more viscous than water. Both resins are
Newtonian fluids. bubbles develop in the mixture. When using bubble
The resin and the hardener were mixed in the proportions nucleation agent, the bubbling activity diminished after
recommended by the respective supplier. Some air bubbles 15 min. A sample was taken and tested with the dissolved
were found to be suspended in the solution. The solution was oxygen meter (Rank Brothers Ltd, Digital Model 10). The
degassed under vacuum at 90 mbar absolute, with a piece of dissolved oxygen meter gives an unstable reading (for
‘Scotch–Brite’ to act as a bubble nucleation agent. Bubble reasons which are not fully understood) resulting in the
nucleation had usually stopped after degassing for 15 min. range of values quoted above. The variation may result from
The viscosity has a very significant effect on the out- non-uniform diffusion of oxygen due to the resin viscosity
gassing process. The PRF resin system took a shorter time and the permeation behavior through the Teflon membrane
for degassing than the Vantico resin system. In the highly of the oxygen meter.
viscous liquid, bubble nucleation was seen to be very slow The oxygen content of the degassed resin dropped from
although detailed timing was not measured. After the the range of 85–96% down to a range of 53–64% after 15 min
degassing process, it was found that the mixture contained a degassing with bubble nucleation agent (Table 3). However,
lot of micro-bubbles in suspension. These micro-bubbles the test equipment does show significant reduction of oxygen
take a long time to travel up to the surface of the resin: about content. The same procedure of testing has been carried out
4 h for the PRF resin mixture and much longer for the on different samples with variation of prolonged exposure to
Vantico resin. vacuum and different methods of degassing.
To measure how much dissolved gas has been extracted
from a resin solution after being degassed, the resin needs to 2.2. Micro-bubble analysis
be analyzed for its chemical content, especially, the amount
of gas still remaining in the solution. One standard method After degassing using bubble nucleation, it is found that
is the dissolved oxygen meter, normally used for measuring the resin mixture contains a lot of micro-bubbles in
water-based solution. Oxygen is much easier to measure suspension. Degassing (by one of our industrial partners)
than nitrogen and the relationship between the level of air with lower vacuum pressure of 5 mbar gave the same result.
and that of oxygen is well correlated. Therefore, the oxygen Mass-spectral analysis of the bubble showed that the content
content should be able to give an approximate represen-
tation of the effectiveness of dissolved gas removal in any
degassing method.
All degassing processes were done at 90 mbar absolute.
Degassing at lower vacuum pressure should give lower
readings of oxygen content. When degassing starts, a lot of
Table 2
Resins and hardeners: supplier, type and viscosities in mPa s

Supplier Resin Resin Hardener Hardener Mix


viscosity viscosity viscosity
PRF RSL 135i 1100 RSH 137i 50 200
Vantico LY 3505 7218 XB 3403 20 400
Fig. 2. Micro-bubbles (white dots) during degassing.
M. Afendi et al. / Composites: Part A 36 (2005) 739–746 743

Table 4 interface and help it to diffuse easily. Unfortunately, bubble


Void content analysis using loss ignition method (BS EN ISO 7822:1999— rupture time is mostly dependent on the resin viscosity and
average values from four sample of each variation)
surface tension [27]. As the thin film and filament is
Lamination sample 25!25 mm Void content (%) continuously flowing, the undiffused bubbles were carried
With no visible voids 0.53 along with the resin.
Containing dispersed voids 15.75 Another experiment using a spinning disc to break the
Containing localized micro-bubbles 8.30 bubbles also does not give a very satisfactory result. It could
not be verified whether the spinning disc managed to break
is mainly air components with a few traces of aromatic the bubble. Droplet formation, where the edge of the
compounds. The size of these micro-bubbles varied from spinning disc impinged on the vacuum container side wall
500 mm to dust like particles. These micro-bubbles (Fig. 2) developed finer bubbles. Degassing with the spinning disc
take a long time to travel up to the surface of the resin. showed a 55–65% oxygen content (Table 3).
Degassing with the air sparging method on the other hand,
shows less micro-bubble development. In fact, the bubble 2.3. The filtering medium
size developed during degassing is much larger. Based on
the results of the degassing experiments, it is assumed that The filtering medium used in this experiment is made of
the quality of the bubble produced also plays an important fine woven (50% polyester: 50% polyamide) fibre. It is
role (Table 4). supplied in sheet form and the pore size is fine (an estimated
The small bubbles (less than 1 mm in diameter) as shown range from 50 to 100 mm) and distributed randomly. The
in Fig. 2, moved very slowly to the surface. Theoretically, the woven cloth thickness is about 2 mm. Each fibre is so thin
terminal velocity U of the rising bubble can be represented as that it can only be seen in a microscope, which can magnify
at least 1000 times. Just 1 g of the cloth contains 39 km of
2 rgr 2
UZ (3) fibre. The cloth feels smoother and softer than the finest
9 m terry. Rather than using fine mesh, this woven micro fibre
Taking resin dynamic viscosity mZ200 mPa s (0.2 N s cloth was seen to be appropriate since the bubble size
/m2), resin density rZ1102.8 kg/m3, gZ9.8134 m/s and r is developed in the experiment varies from dust like particle.
the radius of the bubble, the terminal velocity for the rising
bubble of 1.0 mm diameter would be 12 mm/s and for 2.4. Bubble filtering experiment
bubbles of 0.01 mm diameter would be 12 mm/s. By
calculation, for the depth of 50 mm the 0.01 mm bubble An experiment was done incorporating degassing with
will take 11 h to rise to the surface. Due to the dynamic the nucleation agent and capillary separation. The vacuum
behaviour of these micro-bubbles (coalescing into larger chamber is made of 150 mm glass cylinder with 5 mm
bubbles), it is found that the bubble clearing time was thickness. A cylindrical filter was formed by wrapping the
reduced to 4 h. woven fine fibre cloth around a 100 mm diameter PVC tube
Several experiments were done in an effort to eliminate to form in which about 100 holes (10 mm) were drilled to
bubbles after degassing with either bubble nucleation or allow the resin to be in contact with the filter. The PVC
bubble sparging, such as forming thin film and thin filament tubing is closed at the bottom with a thick aluminium plate.
in vacuum. Theoretically, using these methods should be All the components were placed in the vacuum chamber as
able to position any bubble closer to the liquid–vacuum shown in Fig. 3.

Fig. 3. Schematic diagram of experimental equipment setup.


744 M. Afendi et al. / Composites: Part A 36 (2005) 739–746

The vacuum chamber was firstly decompressed to


90 mbar. As the resin was mixed there were some bubbles
present in the mixture. After reaching a stable vacuum
pressure, the resin inlet valve was opened to feed in the
resin. As the resin came into contact with the nucleation
agent (Scotch–Brite) the nucleation begun. After approxi-
mately 1 min the resin started wetting the filter and clear
resin started to ooze from the filter outer surface. After
15 min, about 500 ml were estimated to have passed
through the filter and collected at the bottom of the vacuum
chamber.
The collected resin was found to be free of any bubbles,
although a few dust likes particles were present at the
surface of the resin. These particles, located towards the Fig. 5. Localized micro-bubbles under !40 magnification (scale
outer circumference of the filter, rise with the resin level. 0.1 mm/division at random orientation).
When the vacuum pressure was released to one atmosphere,
these particles disappeared. As a rise in temperature reduces the epoxy resin viscosity
The capability of bubble nucleation and air sparging it can help the bubbles to rise to the surface. This action also
methods for removal of dissolved gas and volatile reduces the resin pot life. Some manufacturers prefer to heat
components, as observed during the experiments, led into the resin during infusion as this may help the resin to flow by
further analysis of bubble behaviour in the degassing reducing the viscosity albeit while shortening the curing
process. time. Temperature elevation during curing also helps to
Howell [27] states that bubble film eventually becomes localize the bubble, otherwise the bubble will disperse in
thin enough (around 0.1 mm) before rapid rupture. In the between the fibres due to the shrinkage process.
case of the bubble nucleation process, it is found that the In the experimental work, infusion (in-plane flow with no
shear thinning criteria and rupture that occur during flow medium) with degassed and non-degassed (PRF) resins
the coalescing of two or more bubbles gives a significant was used to distinguish the differences in void formation
contribution in molecular diffusion. In relation to degassing along the impregnation route. A layer of twill woven E-glass
process, this method is capable of removing 40–50% roving (600 g/m2) and a layer of glass tissue were used to
dissolved oxygen. Besides the nucleation of bubbles, the make a 300!400 mm sample (Fig. 4). The degassing
shear thinning process plays an important role in providing process using bubble nucleation agent was conducted at
diffusion surface area for gas molecules and volatile 90 mbar for 15 min. The resin was left for approximately
component liberation. This evidence is well proven as 1 h, to let the bubbles produced during mixing and
degassing with air sparging is also showing the same result degassing diffuse to the surface, then the infusion process
as degassing with bubble nucleation method. was done at 110 mbar.
During the infusion of both samples, the first 150 mm
2.5. Infusion from the resin inlet point eventually became totally clear of
any bubbles. Bubbles were present beyond 150 mm.
It is essential to have bubble free resin before vacuum Beyond this point and in both samples, some bubbles
infusion can start. If the infusion starts immediately after were formed by air-entrapment at the crossover between
degassing, any unreleased bubble may migrate into the
lamination. During curing, the shrinkage of the resin will
pull the bubble surface in between the fibre tow creating
higher void content. Therefore, the degassing time needs to
be extended to allow for the bubbles to clear the resin.

Fig. 6. Diffused micro-bubbles under !40 magnification (scale 0.1 mm/di-


Fig. 4. Sample schematic diagram. vision at random orientation).
M. Afendi et al. / Composites: Part A 36 (2005) 739–746 745

in the effort of reducing voids when non-degassed resin is


used.

3. Conclusions

In the best interests of designing of a continuous system,


bubble nucleation and sparging removes 40–50% dissolved
gasses and leaves micro-bubbles (500 mm to dust like
particles). These bubbles in a viscous resin are very difficult
to eliminate. Immediate infusion after degassing of a resin
with bubble nucleation or an air sparging method may result
in inconsistency of void content along the lamination and
Fig. 7. Localized micro-bubbles under !100 magnification can in fact increase void content. Bubble thin films, rupture
(0.1 mm/division). in bubble nucleation and sparging methods are the main
elements that can assist degassing and removal of dissolved
gas molecules and volatile components from viscous liquid.
the weave fibre bundles. In the room-temperature cured
The experiments reported here show that separating micro-
plate made with degassed resin, the first 150 mm from the bubbles can be done using a fine fibre medium. The
inlet point was found to be totally clear of bubbles and capillary effect of the porous medium acting as a micro-
visible void formation. From this 150 mm point to the resin suction pump is capable of removing the resin from the
outlet point most of the bubbles were diffused in between bubbly medium. As the system used in the experiment is
the fibre tows (Figs. 6 and 8). In the case of using non- capable of degassing and filtering the bubble, a continuous
degassed resin, the whole laminate was full of voids. feeding system might be developed from this simple
Other samples were made and then cured at an elevated experimental configuration.
temperature (60 8C). After curing, both the samples were
found to have the same distribution of bubbles. The first
150 mm area from the inlet point was found to be clear of
any visible bubble and void formation. The bubbles found in Acknowledgements
the region beyond 150 mm from the inlet point, seem to be
localized (i.e. not associated with a fibre tow). They do not The authors would like to thank an industrial partner for
diffuse in between the fibre tows (Figs. 5 and 7). undertaking the high vacuum degassing. Further, we
Therefore, from these experiments it is found that appreciate the assistance of the referees and guest editor
degassed resin has a significant effect in the reduction of in refining the text of this paper.
void formation especially when elevated temperature is not
available during the curing process. On the other hand,
curing at elevated temperature also gives a beneficial result
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