This article takes an in depth look at water jet cutting.
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Water jet cutting is a manufacturing method that utilizes high-pressure water jets, powered by pressurizing pumps, to produce a supersonic stream capable of cutting and shaping a wide range of materials. The water used in water jet cutting is pressurized up to 392 MPa and passed through a precisely engineered small nozzle. Once the water exits the nozzle, it attains velocities three times faster than the speed of sound.
Pure water jet cutting, which employs only water as its medium, is designed for softer materials like wood, plastics, foam, paper, and rubber. When an abrasive is incorporated into the water stream, the cutting process is enhanced significantly, allowing the machine to cut through tougher materials such as titanium, stainless steel, aluminum, glass, ceramic, and concrete.
The water jet cutting process is a highly advanced precision manufacturing technology that utilizes a high-pressure stream of water, often combined with an abrasive, to cut virtually any material with exceptional accuracy. Most modern water jet cutting methods incorporate abrasive materials such as garnet or aluminum oxide into the water stream, significantly increasing the ability to cut hard substances including metals, stone, glass, and composites. This versatile manufacturing process enables manufacturers, fabricators, and engineers to cut, shape, and design workpieces to meet extremely precise specifications, without inducing thermal distortion or mechanical stress on the material.
The shaping method used in water jet cutting offers several advantages over other machining processes like plasma cutting, laser cutting, or EDM (electrical discharge machining). Water jet cutting provides superior edge quality and accuracy, can handle highly intricate and complex designs (such as those required in aerospace and automotive component manufacturing), and is particularly well-suited for thermally sensitive or heat-affected materials. The high-velocity abrasive, akin to sandpaper but far more powerful, erodes the material being cut while keeping the workpiece cold and free from any alteration in temper or metallurgical properties. As a result, the cut edges are exceptionally clean, minimizing the need for secondary processing like grinding or deburring and rendering them ideal for immediate welding or assembly.
Kerf width refers to the amount of material removed during a cutting process. In traditional machining, "kerf" described the width of material lost to a saw blade, but in the context of water jet cutting machines, kerf width denotes the width of the high-pressure water or abrasive jet, typically 0.04 inches or smaller. The kerf precision is critical when programming CNC water jet cutters, as the inside corners have a radius equivalent to the stream's width. Several factors influence the kerf, including material thickness, density, hardness, cutting speed, desired edge quality, and the specific characteristics of the waterjet nozzle and orifice.
The size of the kerf is a crucial engineering and design factor that must be considered when determining the cut path and final dimensions of the finished part. For example, if the kerf is 0.042 inches, compensation must be made within the CAD/CAM software to ensure components meet required tolerances. Failure to account for kerf can result in finished parts that are dimensionally inaccurate and potentially unusable in critical assemblies.
The initial cut made by a water jet cutter, known as the pierce, is typically wider and less precise than the main cutting kerf due to the initiation of the high-pressure stream. This first step in the water jet cutting process can be executed in various ways—stationary, linear, circular, and low-pressure piercing—all chosen based on the material's properties and the amount of waste (scrap) produced. Effective piercing minimizes delamination in composite materials and prevents cracking in brittle materials such as glass or ceramics, enhancing part quality and reducing material waste.
Tapering in water jet cutting refers to the difference in kerf width at the top and bottom of the cut. This phenomenon creates a V-shaped (standard) taper because the kinetic energy of the jet stream decreases as it penetrates deeper into the material, resulting in slightly wider removal at the surface than at the bottom. Managing taper is essential for parts requiring high-precision fits, such as those in aerospace, defense, electronics, and medical device manufacturing.
A slow cutting speed can result in a reverse taper, where the kerf width at the bottom is wider than at the top due to prolonged jet exposure. This is commonly observed when cutting soft, pliable materials like rubber or foam. Conversely, a "barrel taper" occurs when the cut is widest in the middle, usually when cutting extremely thick or multi-layered materials. Advanced water jet cutting systems often employ dynamic head compensation technology, which can significantly reduce or eliminate taper by automatically adjusting the cutting head angle.
While tapering is usually minimal and acceptable in most industrial applications, for parts requiring exact tolerances and precision fit, addressing and compensating for taper during the design and cutting stages is critical to achieve optimal part quality and performance.
Water can be pressurized using various types of industrial water jet pumps, such as linear intensifiers and rotary direct drive high-pressure pumps. Both designs incorporate powerful electric motors, water filtration systems, advanced control systems, and monitoring sensors to ensure safe and efficient operation.
Linear intensifier pumps utilize pressurized hydraulic oil at 3,000 psi. By applying low-pressure oil against a large-diameter piston, pressure is intensified through a much smaller high-pressure plunger that pressurizes the water up to 60,000 psi and beyond. State-of-the-art water jet systems may even reach operating pressures up to 90,000 psi (ultra-high-pressure water jets), increasing speed and cutting capability for demanding industrial applications.
A direct drive rotary pump, by contrast, operates without hydraulic oil. Instead, it uses a robust electric motor to spin a crankshaft, which drives multiple pistons that directly pressurize the water. These high-efficiency pumps are suited for light to medium-duty cutting tasks, typically powered by 30 hp motors with high-flow water inlets and optimized for lower maintenance and energy consumption. The choice between a linear intensifier and rotary direct drive system depends on required output pressure, duty cycle, and cost of ownership.
The pressurized water is transported from the pump to the cutting head via high-pressure tubing, an essential component engineered to withstand extreme pressures and prevent leaks. This tubing is manufactured for superior yield strength and tensile durability, often featuring a highly polished, smooth internal bore to minimize turbulence and energy loss. It is commonly fabricated from cold-worked stainless steel or reinforced thermoplastic pressure hose. Tubing is available in sizes ranging from 0.25 inches to 0.563 inches and in various lengths to suit the unique layouts of industrial water jet cutting systems. Routine inspection and preventative maintenance of this tubing are vital in high-production environments to ensure operator safety and equipment reliability.
The pressurized water exits through the precisely engineered orifice of the cutting head, which is usually constructed from diamond, ruby, or sapphire and features an aperture smaller than the tip of a pin. As water accelerates through this tiny opening, its velocity increases dramatically—exceeding 90,000 psi and reaching speeds over 2,500 mph. The cutting head’s design, including its mixing chamber and focusing tube, is critical in determining edge quality, cutting speed, and system longevity. With optimized operational parameters, high-precision water jet cutting heads can last 500 to 1,000 hours, reducing downtime and maximizing productivity.
The image below shows two types of cutting heads: one for pure water-only cutting—ideal for soft materials like plastics and food—and another designed for abrasive cutting—capable of slicing through hard metals, stone, and ceramics. The red tube present in the abrasive model transports grit into the mixing chamber, where it is entrained by the high-speed water jet for maximum cutting efficiency.
Pure water jet cutters represent the original type of water jet cutting machinery and remain essential in the fabrication of soft materials or specialty applications. These systems excel because they produce less residual moisture on the workpiece compared to traditional contact methods and provide an extremely fine, precise jet suitable for intricate geometries, minimal kerf, and high-yield production. Typical target materials include plastics, foam, textiles, soft composites, and paper products. Pure water jet cutters operate using a precision orifice—generally a jewel such as diamond or sapphire, as rubies are not compatible due to their rapid erosion when exposed to the high-velocity water stream. The supersonic water stream travels at Mach 2 for 40,000 psi and Mach 3 for 60,000 psi, facilitating high-speed, burr-free cuts without thermal distortion.
In an abrasive water jet cutting system—also called abrasive jet machining—an abrasive additive (often garnet, but sometimes aluminum oxide or silicon carbide) is precisely injected into the high-pressure water stream within the cutting head’s mixing chamber. This combination allows for the effective machining of hard and thick materials such as stainless steel, titanium, tool steel, ceramics, composites, stone, and glass. Abrasive water jet systems dramatically expand the capability of water jet machining, as they can cut materials up to ten inches thick with no heat-affected zone (HAZ) or mechanical stress, and produce edges suitable for direct joining or finishing.
An abrasive water jet cutter accelerates abrasive particles to extremely high velocities, enhancing the jet's abrasion and erosion force. Modern abrasive water jet machines are up to 1,000 times more effective than pure water systems for cutting dense or layered materials. Popular applications include custom metal fabrication, architectural glass cutting, granite countertop manufacturing, aerospace part production, and specialized component prototyping, where tight tolerances and clean cuts are essential.
Industries choose water jet cutting for its numerous benefits over competing processes like laser cutting, EDM, plasma cutting, and traditional machining. Some of the key advantages include:
When selecting a water jet cutting service or machine for your application, consider the type of material, required tolerances, production volume, system capability (such as multi-axis or 5-axis CNC water jet machining), and operational costs. Partnering with an experienced water jet cutting manufacturer or supplier ensures access to advanced equipment, material expertise, and quality assurance systems that deliver consistent, reliable results for your projects.
Although cutting, in essence, involves severing material with a cutting tool, water jet cutting operates similarly to a band saw but with more precision. Modern manufacturing, however, involves far more complex and advanced cutting processes than the traditional band saw method.
Water jet cutting machines can be programmed for a diverse range of cuts, tailored to specific application needs. They can perform traditional single cuts as well as more complex multi-axis cuts, including 2, 3, 4, and 5-axis configurations.
One-dimensional water jet cuts are straightforward, involving a single pass of the workpiece through the cutting mechanism. These are the simplest cuts, typically used for trimming. During the process, the operator feeds the workpiece into the cutting tool, while debris and water are collected on the other side. A variation of this method is the slitter, which cuts pieces to specific widths. One dimensional cutters can operate with either pure water or water mixed with an abrasive.
Two-dimensional cutting involves using PC or CNC programming to control the process. These machines are equipped with a servo motor and closed-loop feedback systems to manage positioning and cutting velocity. The catcher tanks are water-filled and have slats to support the workpiece. Additionally, the Z-axis of an XY two-dimensional cutting machine adjusts the height of the cutting device to accommodate variations in the thickness of the workpiece.
Two-dimensional cutting is ideal for quickly and efficiently cutting various materials and parts, making it suitable for applications requiring speed and precision.
Three-dimensional cutting utilizes the X axis (left to right), Y axis (front to back), and Z axis (up and down) to achieve precise cuts. In this process, the workpiece stays stationary while the cutting tool moves along these three planes. This method is commonly used to produce complex mechanical components.
Four-dimensional cutting involves the XYZ axes for traditional three-dimensional movement, plus an additional rotary motion around the X axis, known as the A axis. This setup allows for cutting on multiple sides of a workpiece, including creating holes or openings. The A axis enables the automatic flipping of the workpiece, allowing the waterjet to access and cut from both sides.
A 5-axis system offers exceptional power and flexibility by allowing the workpiece to be manipulated along five different axes simultaneously. It combines traditional XYZ linear movements with rotational movements around these axes, specifically the A, B, and C axes, which enable 180° rotations around the X, Y, and Z axes, respectively. This advanced setup facilitates the fabrication of highly complex and intricate solid components.
Five-axis machining demands extensive CNC programming to manage the complex rotary movements involved. Its primary advantage is the capability to work on all five sides of a single workpiece in one operation. This method is particularly valuable for producing components with intricate details and high precision.
The principle of water jet cutting is straightforward, relying on pressure, velocity, and an abrasive. While the core concept is simple, its applications are diverse and highly specialized. Various techniques have been developed to address specific requirements across different industries and materials.
Water jet cutting can be categorized into two main types: pure water and abrasive water jet cutting. Each of these categories can be further subdivided based on specific factors, including the material being cut, the desired precision, and the complexity of the cut.
Abrasive flow machining (AFM) is used for interior surface finishing, particularly for deburring and honing parts that are difficult to reach with traditional methods. By using a mixture of water and abrasive, AFM effectively erodes raised surfaces inside a workpiece, similar to the action of a grinder or sandpaper, to remove unwanted particles and achieve a smooth finish.
The abrasive jet machining process is a key aspect of abrasive water jet cutting. It involves a high-pressure stream of water mixed with abrasive particles that blast and erode the workpiece, removing particulate matter, burrs, and other materials. This technique uses extremely fine particles applied at high velocity and is particularly effective for cutting and shaping brittle, thin, and hard materials. Abrasive jet machining excels in creating intricate shapes and achieving smooth, even edges.
Intensifiers are used to dramatically increase the pressure of pure water, allowing it to shape and form soft materials without leaving behind water residue. Hydraulic pumps play a crucial role in this process, converting the force of the water into mechanical energy to achieve the required high pressure.
A significant advancement in high-pressure water jet cutting was the introduction of corundum elements in the cutting head, including varieties such as rubies and sapphires. Corundum is renowned for its hardness, toughness, and stability, being resistant to acids and the second hardest mineral on Earth.
CNC water jet cutting utilizes high-pressure water in a programmable manner to perform multiple operations in a single pass. It is particularly useful for materials that are sensitive to high-temperature processes. CNC water jet machines can handle various operations such as cutting, forming, deburring, reaming, and honing, making them ideal for tasks requiring precision and minimal thermal impact.
Most CNC water jet cutting machines operate on three axes: X (left to right), Y (front to back), and Z (up and down). Recent advancements include five-axis models that add rotational capabilities. The A axis allows rotation around the X axis, and the B axis provides rotation around the Y axis, offering greater flexibility and precision in cutting complex shapes.
The water jet cutting process has become popular for its precision and quick turnaround times. Its high-quality results and performance make it the preferred cutting method in industries that demand precise and accurate tolerances.
Since its inception in the 1950s and subsequent improvements in the 1970s, water jet cutting has steadily become a crucial component in industrial operations. Its widespread use is largely due to the absence of heat in the cutting process, which offers significant advantages.
In the aerospace industry, where complex and precise components are crucial, water jet cutting is indispensable. The strict tolerance requirements leave no room for error, making water jet cutting essential for producing everything from jet engines to custom-designed control panels.
Abrasive water jet cutting is employed in the aerospace industry to cut metals such as steel, brass, Inconel, and aluminum. This process is utilized for components like wing sections, turbine blades, brake parts, and landing gear, with the ability to cut materials up to eight inches thick.
A significant advantage of water jet cutting in the automotive industry is its compatibility with robotic systems. Pure water jet cutting is utilized for shaping interior components such as carpets, insulation, and head linings. This method minimizes material waste and reduces the need for extensive cleanup.
Water jet cutting avoids heat-affected zones (HAZ), does not produce noxious fumes, and minimizes stress on the workpiece. It creates smooth, burr-free surfaces, eliminating the need for secondary finishing.
In medicine, water jet cutting technology is being explored as a replacement for traditional surgical tools. High-pressure spiral water is used to crush and aspirate liver parenchymal cells during tumor treatment. This method is preferred because it avoids heat that could damage surrounding organs and reduces the risk of bleeding. By adjusting the pressure and flow rate, it is possible to dissect human tissue with less trauma, bleeding, and postoperative complications.
Similar to its use in medicine, water jet cutting is highly effective for glass due to its precision and adaptability. The process allows for detailed modifications and adjustments to the cutting stream, which is crucial for working with delicate glass materials. By avoiding damage to the glass's internal structure, water jet cutting ensures smooth and efficient cuts. Its omnidirectional stream can handle any shape, form, or configuration with pinpoint accuracy, making it ideal for cutting holes, notches, and intricate designs without causing distortions.
Industrial processes often generate unwanted materials, and storage tanks and conduits can accumulate flakes, scales, and rust over time. While highly caustic cleaners can be effective, they may not always be suitable for every situation. High-pressure water jet cutting provides a safe and efficient alternative, using its high-speed, pulsating blast to remove and clean industrial equipment, storage units, and piping without the need for harsh chemicals.
The energy generated by a water jet cutter far exceeds the energy required to remove scales, coatings, or contaminants from a surface. This makes it an exceptionally safe and efficient cold cutting method for industrial cleaning. Its high efficiency and speed minimize downtime and prevent work stoppages, making it a valuable tool for maintaining industrial equipment and surfaces.
Water jet cutting of food is a USDA-approved method that offers both productivity and sanitary benefits. Like its industrial applications, water jet cutting in the food industry is valued for its precision and effectiveness in portion control. It is capable of cutting meat, fish, poultry, pastries, and frozen foods into precise and uniform shapes.
The key feature of water jet cutting for foods is the use of pure, clean water, which is central to its operation. The high-speed operation of water jet cutters enables efficient and rapid processing of food products.
A major concern in electronics manufacturing is cost, as manufacturers strive to reduce expenses while boosting efficiency. Water jet cutting has become essential in this sector due to its cost-effectiveness and efficiency. It can cut circuit boards, whether populated or empty, and is also effective for stripping wires without causing damage.
Safety is a primary concern when handling fiberglass, which demands precision and efficiency. Water jet cutting addresses these needs by shaping and forming fiberglass without producing dust or waste. The process delivers cuts quickly and to the exact dimensions required for the application.
Water jet cutting handles fiberglass with minimal limitations on rigidity, making it suitable for applications ranging from shaping insulation to forming boat components. The precision of water jet cutting ensures that fiberglass is delivered in accurately cut shapes, meeting exact specifications for various uses.
Water jet cutting machines feature a comprehensive setup that includes a high-pressure pump, controller, catch tank, an XY movement system, and either an abrasive or pure water nozzle. A crucial element of these machines is the motion control system, which not only directs the movement of the cutter but also securely holds the workpiece in place during the cutting process.
Water jet cutting machines come in various types, sizes, designs, and processes. Many of these machines are equipped with CNC controllers, which significantly enhance the precision and capabilities of the cutting process.
A staple in modern manufacturing is the computer numerical control (CNC) machine, which can be programmed to perform multiple tasks in a single pass over a workpiece. The integration of CNC programming with water jet cutting has been widely adopted for years, combining precision control with advanced cutting capabilities.
CNC water jet cutting is primarily used for materials sensitive to high temperature processes. It excels in tasks such as cutting, forming, deburring, reaming, and honing, which are well-suited to the water jet cutting method.
A CNC water jet cutting machine incorporates all the features of traditional water jet cutting. Typically, these machines are flatbed setups equipped with CNC programming that interfaces with the machine’s components. Their flexibility and versatility allow them to be customized to meet various production requirements.
Flatbed water jet cutting machines feature a large working table designed for cutting sizable pieces. This design facilitates easy loading and unloading of materials. A key advantage of flatbed machines is their ability to collect water and waste from the cutting process. These machines are valued for their cost-effectiveness, ability to cut various materials, and lack of heat generation. As a result, parts retain their heat treatment throughout the cutting process, eliminating the need for post-cutting heat treatment.
CNC machines are integral to modern manufacturing, enabling the programming of multiple tasks to be performed in a single pass over a workpiece. The integration of CNC programming with water jet cutting has been established for many years, combining advanced cutting techniques with precise control to achieve exceptional results.
A CNC water jet cutting machine incorporates all the features of traditional water jet cutting but is enhanced with CNC programming. Typically designed as flatbed machines, these CNC water jet cutters offer the flexibility and versatility needed to adapt to various production requirements, making them customizable to meet specific manufacturing needs.
Portable water jet cutting machines offer a cost-effective, environmentally friendly, and adaptable solution for tasks such as cleaning contaminated surfaces, removing burrs, and cutting off rust. Designed for use in hazardous conditions like the oil industry, construction tunnels, and pipelines, these machines deliver high-pressure water and velocity, making them capable of cutting through any type of material.
Portable water jet cutting machines can be classified into two types based on how the abrasive is introduced into the water stream. The first type inserts the abrasive directly into the water stream at the nozzle, providing a more effective cutting action. The second type premixes the abrasive with the water before it is pressurized, which is generally less effective.
Water jet cutting is employed to shape and machine a vast array of products, parts, components, and materials. From precision parts for the aerospace industry to intricate decorative ornaments for the home, water jet cutting is valued for its ability to deliver precise cuts and maintain dimensional accuracy across a wide range of applications.
The list below highlights just a few examples of items produced using water jet cutting. This versatile process is used not only for crafting various products but also for applying logos and designs on both final products and the surfaces of hard materials.
Using a CAD drawing, the outline of a guitar body is marked on the workpiece. The piece of wood is then fed into the water jet cutter. Because water jet cutting does not apply significant pressure to the workpiece, it can cut delicate wood without damaging the grain.
Gears are commonly manufactured using water jet cutting because the process provides the precision and accuracy needed for their complex shapes and tight tolerances.
Water jet cutting is well-suited for manufacturing cams, as it allows for precise shaping based on the desired design. By loading the CAD rendering into the machine, the water jet cutter can quickly and accurately produce the cam with the specified shape.
Chains produced with water jet cutting are designed to handle extremely heavy loads, often several tons. The links are precisely cut using water jet technology and then assembled into chains capable of lifting exceptionally heavy weights.
Water jet cutting is employed to create durable name plates from heavy metals. It is ideal for producing name plates, signage, and company logos due to its precision, elimination of the need for additional finishing, and the smooth, clean edges it provides.
Water jet cutting of rubber is highly efficient and versatile, capable of cutting through any thickness. It streamlines the manufacturing process by cutting through rubber and backing metals without the need for specialized tooling or dies. This method ensures precision, speed, and optimal material use.
A unique feature of water jet cutting rubber is stack cutting, where multiple layers of workpieces are stacked and cut in a single pass. This method increases efficiency and throughput by allowing simultaneous cutting of several pieces at once.
The six items listed above represent just a tiny fraction of the diverse products, parts, components, and materials fabricated using water jet cutting. Thanks to ongoing technological advancements and innovations in cutting techniques, water jet cutting has become a vital tool for efficient and streamlined industrial operations.
There are countless methods for cutting, shaping, and forming industrial products, each capable of performing various cuts and dimensions. However, a significant disadvantage of these methods is the heat generated during the cutting process. Even shearing, for example, produces friction that results in heat.
Water jet cutting maintains the workpiece at a cool temperature during the cutting process, ensuring accuracy and precision. It is a cold cutting method that preserves the molecular structure of the material and prevents thermal stress.
Water jet cutting offers remarkable precision and accuracy, with a tolerance range of ± 0.003 inch to ± 0.005 inch. Additionally, the ability to adjust cutting speed mid-process allows for the creation of parts with multiple edges.
Water jet cutting avoids creating rough surfaces, burrs, or imperfections, eliminating the need for secondary finishing. It produces minimal kerfs and smooth finishes due to its erosion-based material removal process, rather than relying on heat or shearing.
Water jet cutting has limitless applications because it can cut any material, regardless of its hardness, without altering its mechanical properties or weakening its integrity. For enhanced efficiency, thin materials can be stacked and cut simultaneously to boost productivity and reduce costs. Moreover, water jet cutting machines are available in various table sizes to accommodate different workpiece dimensions.
Environmental sustainability is a key concern for manufacturers and industries, and water jet cutting stands out in this regard. Unlike many traditional cutting methods that generate waste, particulate matter, and pollutants, water jet cutting is a cleaner process. It does not produce hazardous byproducts, making it an environmentally friendly choice for cutting and shaping materials.
Water jet cutting is an environmentally friendly process as it generates no toxic gases, harmful waste materials, or poisonous contaminants. It operates using pure water combined with natural abrasive materials. The leftover material from the cutting process can be safely disposed of, minimizing environmental impact.
The process of water jet cutting involves utilizing a water pump and cutting tool to generate a high-velocity water stream, which travels at speeds up to three times the speed of sound. This technology enables precise and versatile cutting across various materials using the same core components.
This simplicity in the water jet cutting process makes it a cost-effective and economical method for producing both 2D and 3D cuts.
The programmed shape from engineering software is seamlessly transferred into the water jet cutting machine's controls. This data dictates precise positioning, cutting speed, and cutting angle. Once the material specifics are entered, the machine efficiently completes the cutting process.
Among the numerous advantages of water jet cutting, cost savings is the most significant and prominent. Running a water jet cutting machine is considerably less expensive compared to other cutting processes. Additionally, the benefits include fast transition times, high cutting speed, and ease of setup.
The only fluids used in water jet cutting are water and an abrasive that erodes the material. The water jet stream cools any heat produced, preventing warping, distortion, and hardening, which minimizes the need for secondary processing. Additionally, water jet cutting is safer for workers and operators, as it does not produce harmful vapors.
Water jet cutting is the most efficient cutting method due to its power and versatility with materials. Its efficiency is highlighted by its ability to recycle the water used and eliminate the need for secondary processing. Additionally, because it can cut through any material, there is no need to change tooling when transitioning from one product to another.
Precision water jet cutting offers superior control over the cutting process, allowing workpieces to be cut to exact sizes and dimensions. This method is more manageable compared to traditional cutting methods like blades or saws, providing greater accuracy and flexibility in production.
Water jet cutting is ideal for the food industry because it avoids the use of chemicals, cutting tools, or any materials that might come into contact with food. Given the stringent cleanliness and sanitation requirements in food processing, water jet cutting meets the standards for zero cross-contamination, ensuring a safe and hygienic cutting process.
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