Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
  • C21D1/18—Hardening; Quenching with or without subsequent tempering
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
  • C21D1/26—Methods of annealing
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
  • C21D1/56—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
  • C21D1/58—Oils
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
  • C21D1/56—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
  • C21D1/60—Aqueous agents
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
  • C21D1/74—Methods of treatment in inert gas, controlled atmosphere, vacuum or pulverulent material
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D6/00—Heat treatment of ferrous alloys
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D6/00—Heat treatment of ferrous alloys
  • C21D6/02—Hardening by precipitation
• • C—CHEMISTRY; METALLURGY
  • C21—METALLURGY OF IRON
  • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
  • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
  • C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/002—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
  • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
  • C22F1/02—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working in inert or controlled atmosphere or vacuum

Definitions

• the present disclosure relates to methods of heat-treating gas turbine components that are made of multiphase superalloys.
• a gas turbine includes a compressor section, a combustor section, and a turbine section.
• the compressor and the turbine sections contain a rotor shaft, and disks (rotors) and seals mounted or otherwise carried by the shaft and blades mounted to and radially extending from the periphery of the disk.
• Components within the gas turbine are often formed of superalloy materials to achieve acceptable mechanical properties while at elevated temperatures. Suitable alloy compositions and microstructures for a given component are dependent on temperatures, stresses, and other conditions to which the component is subjected.
• airfoil components such as blades and vanes are often formed of equiaxed, directionally solidified (DS), or single crystal (SX) superalloys, whereas disks and seals are typically formed of polycrystalline superalloys that must undergo careful processing to produce a microstructure that leads to desirable mechanical properties.
• DS directionally solidified
• SX single crystal
• At least one of in the context of, e.g., "at least one of A, B, and C” refers to only A, only B, only C, or any combination of A, B, and C.
• turbomachine refers to a machine including one or more compressors, a heat generating section (e.g., a combustion section), and one or more turbines that together generate a torque output.
• gas turbine engine refers to an engine having a turbomachine as all or a portion of its power source.
• Example gas turbine engines include turbofan engines, turboprop engines, turbojet engines, turboshaft engines, etc., as well as hybrid-electric versions of one or more of these engines.
• superalloy refers to a high-performance alloy designed to withstand extreme temperatures and stresses. Key characteristics of superalloys for gas turbine components include heat resistance, oxidation resistance, creep resistance, fatigue resistance, corrosion resistance, high strength-to-weight ratio, thermal stability, etc. Exemplary superalloys suitable for use in gas turbine components include nickel-based alloys, cobalt-based alloys, or iron-based alloys.
• one or more of chromium, tungsten, molybdenum, iron, cobalt, or combinations thereof are principal alloying elements that combine with nickel to form a base matrix
• one or more of aluminum, titanium, tantalum, niobium, vanadium, or combinations thereof are principal alloying elements that combine with nickel to form desirable strengthening precipitates such as gamma-prime phase i.e., Ni 3 (Al, X) and/or gamma-double-prime phase i.e., Ni 3 (Nb, X), where X can be one or more of aluminum, titanium, tantalum, niobium and vanadium.
• creep refers to gradual time-dependent deformation that occurs under prolonged exposure to high temperatures and stresses.
• matrix refers to the continuous phase in the microstructure of a superalloy.
• precipitate refers to a discrete phase present in the matrix of a superalloy.
• solvus refers to the maximum temperature at which a precipitate can exist, prior to full dissolution, within the matrix for a given alloy.
• nucleation refers to the phenomenon when the precipitate phase first appears within the matrix while cooling from higher temperature.
• nucleation temperature refers to the temperature at which the precipitate phase first appears within the matrix while cooling from higher temperature.
• solution temperature refers to the temperature used to dissolve part or all of the precipitate phases into the matrix.
• solution time refers to the duration for which a component is held at the solution temperature.
• solution heat-treatment refers to the process of holding a component at the solution temperature for a specific solution time.
• active quench refers to forced cooling of a component using any gaseous or liquid media, such as fan air cooling, forced gas cooling, oil quenching, water quenching, etc.
• air transfer refers to the natural cooling of the component between solution heat-treatment and the onset of active quench, in the presence of air or a gas or a mixture of gases (e.g., argon, helium, nitrogen) at room temperature (i.e., 20 °C to 25 °C). It is to be understood that air transfer is a passive cooling process that does not include fan air cooling or forced gas cooling.
• gases e.g., argon, helium, nitrogen
• air transfer time refers to the duration of the natural cooling of the component between solution heat-treatment and the onset active quench.
• maximum quench temperature refers to a temperature that does not exceed the nucleation temperature by more than 10 °C at the start of active quench.
• minimum quench temperature refers to a temperature below which the precipitates coarsen beyond a desired limit. In most embodiments, the “minimum quench temperature” is 90% of the nucleation temperature.
• unitary denotes that the final component has a construction that is inseparable and is different from a component comprising a plurality of separate component pieces that have been joined together but remain distinct and the single component is not inseparable (i.e., the pieces may be re-separated).
• unitary components may comprise generally substantially continuous pieces of material.
• Gas-turbine components made of superalloys are required to meet mechanical property criteria at their relevant operating conditions.
• Such components may undergo a solution heat-treatment, where part or all of the strengthening precipitate phase dissolves in the superalloy matrix.
• the component undergoes natural cooling for an air transfer time before it is subjected to active quenching.
• the precipitates reappear in a fresh burst of nucleation during either or both the air transfer and the active quenching processes. Regions of the component that are above the nucleation temperature will be comparatively weaker than regions of the component that are below the nucleation temperature.
• a heat-treatment process is performed on the component that reduces quench plastic strain accumulation in any predetermined location (e.g., an interior location within the component that would normally accumulate high quench plastic strain) by introducing a geometry dependent and alloy-specific air transfer time. It has been found that when the active quench begins, the outer surface of the component can be colder than the precipitate nucleation temperature, leading to precipitate nucleation, and hence a locally stronger response to thermo-mechanical deformation. Conversely, the interior locations of the component (such as locations within the cross-sectional thickness of the component), which are still above the nucleation temperature, show a weaker resistance to plastic deformation. Rapid plastic strain accumulation occurs in the interior locations until the temperature at the interior location reaches the precipitate nucleation temperature. That is, it was found that the internal locations (particularly within thick regions of the component) cool at a slower rate than outer locations at the surface of the component.
• any predetermined location e.g., an interior location within the component that would normally accumulate high quench plastic strain
• the quench plastic strain accumulation is caused by a low dispersion or absence of strengthening precipitates at the predetermined internal location of the component.
• the air transfer time is too short, the precipitates will not appear sufficiently within the superalloy matrix, causing the quench plastic strain to accumulate during active quench, leading to a poor creep life.
• the air transfer period is too long, the precipitates may coarsen (i.e., grow) to be too large within the superalloy matrix, leading to a reduction in mechanical properties.
• the desired size of the precipitates depends on the alloy, and its application, and the operating temperature and stress conditions.
• an air transfer time exists as a function of alloy chemistry and component geometry that enables active quench to begin at the moment all predetermined internal locations in the component are at or below the maximum quench temperature of the superalloy (i.e., not exceeding the nucleation temperature by more than 10°C).
• the heat-treatment process may be a component specific model that incorporates the material data (e.g., the precipitate nucleation temperature for the particular superalloy within a window of relevant cooling rates) and the heat-treatment boundary conditions.
• the component-specific model may be used to predict a specific air transfer time that ensures all or specific locations enter active quench when their temperatures are within the bound defined by the maximum quench temperature and the minimum quench temperature.
• Empirical data may be developed in laboratory heat-treatment, if desired, to mimic the hardware heat-treat path to estimate the duration of the air transfer (i.e., an air transfer period). These experiments may involve assessment of (a) intra-grain microstructure and/or (b) cooling profiles, to identify the nucleation temperature for a specific superalloy, part geometry, or both.
• the predetermined air transfer time may be of a duration (e.g., sufficiently long) such that a predetermined internal location (or multiple predetermined internal locations) cools to a temperature below the maximum quench temperature of the superalloy before active quenching of the component.
• the predetermined air transfer time is constrained in duration by the minimum quench temperature to prevent coarsening of the gamma prime microstructure.
• gamma prime may have an average size that remains below a predetermined average particle size.
• the predetermined air transfer time may be of a duration (e.g., sufficiently short) to prevent the gamma prime particles from growing above the predetermined average particle size.
• the heat-treatment for the predetermined air transfer time is not likely to change grain related microstructural aspects since it doesn't alter the solution heat-treatment.
• the heat-treatment for the predetermined air transfer time does affect the intra-grain gamma-prime microstructure and the grain boundary phase prevalence, compared to a shorter air transfer time.
• particularly suitable superalloys may include a nickel-based superalloy, a cobalt-based superalloy, or an iron-based superalloy.
• the precipitate nucleation temperature depends on the particular superalloy composition.
• FIG. 1 is a perspective view of a turbine engine component 10 in accordance with an exemplary embodiment of the present disclosure
• FIG. 2 is a partial cross-sectional view of an exemplary turbine engine component 10, such as the embodiment shown in FIG. 1 .
• the turbine engine component 10 is a high-pressure turbine disk for a gas turbine engine.
• this disclosure refers to the component 10 as a turbine disk, those skilled in the art will appreciate that the teachings and benefits of this disclosure are also applicable to compressor disks, bladed disks, and other components that are subjected to stresses at high temperatures and therefore require a high temperature superalloy.
• the component 10 represented in FIG. 1 is a disk of a turbine engine that generally includes an outer rim 12, a central hub or bore 14, and a web 16 between the rim 12 and bore 14.
• the rim 12 is configured for the attachment of turbine blades (not shown) by including dovetail slots 13 along the outer periphery of the component 10 into which the turbine blades are inserted.
• a bore hole 18 in the form of a through-hole is centrally located in the bore 14 for mounting the component 10 on a shaft, and therefore the axis of the bore hole 18 coincides with the axis of rotation of the component 10.
• the component 10 is a unitary forging and representative of turbine disks used in aircraft engines, including but not limited to gas turbine engines.
• Components 10 of the type represented in FIG. 1 and FIG. 2 may be produced from a billet formed by powder metallurgy (PM), or a cast and wrought processing.
• the billet can be formed by consolidating a superalloy powder, such as by hot isostatic pressing (HIP) or compaction/extrusion consolidation.
• the billet is typically forged under superplastic forming conditions at a temperature at or near the recrystallization temperature of the alloy, but less than the solvus temperature of the alloy.
• a solution heat treatment is performed at a predetermined solution temperature for a predetermined solution time, during which grain growth may occur.
• the predetermined solution temperature and the predetermined solution time are determined based on the composition of the superalloy so as to recrystallize the worked grain structure and dissolve part or all of the precipitates in the alloy (e.g., gamma prime precipitates within a nickel-based superalloy).
• the component 10 is transferred through air or a gas or a mixture of gases, during which it cools naturally, for a predetermined air transfer time.
• the predetermined air transfer time is tailored for at least one predetermined internal location 20 within the construction of the component 10, as compared to a predetermined surface location 22. As stated above, it has been found that if the air transfer time (e.g., during transfer from the furnace to the active quenching medium) is too short, the precipitates will not appear sufficiently within the superalloy matrix, causing the quench plastic strain to accumulate, leading to loss of mechanical properties.
• the air transfer time should therefore be of a duration to enable precipitation of the strengthening particles at the predetermined internal location(s) 20 and surface location(s) 22, thereby minimizing or preventing the accumulation of plastic strain.
• the predetermined air transfer time should be of a duration to prevent the precipitates from growing above a predetermined average particle size at the predetermined internal location(s) 20, at the predetermined surface location(s) 22, or both.
• the predetermined cooling period may be determined by many variables, including the composition, size, shape, and design of the component 10.
• the predetermined cooling period may be less than or greater than 1 minute (e.g., 30 seconds to 180 seconds). In embodiments, the predetermined cooling period may be 30 seconds to less than 60 seconds (e.g., 45 seconds to 60 seconds. In other embodiments, the predetermined cooling period may be 60 seconds to 180 seconds (e.g., greater than 60 seconds to 120 seconds).
• the gamma prime nickel-based superalloy is thermo-mechanically processed, including a solution heat treatment, air transfer, and quench, to have a microstructure that contains strengthening precipitates (e.g., of gamma prime in a nickel based superalloy) throughout the alloy matrix that leads to the desired properties.
• the temperature at the predetermined surface location(s) 22 may cross gamma prime nucleation temperature during air transfer, resulting in somewhat coarser gamma prime microstructure.
• the predetermined internal location(s) 20 are close to gamma prime nucleation temperature at the end of air transfer, causing the precipitates to nucleate during active quench and hence likely be finer in nature.
• an exemplary method 30 is shown for heat treating a component comprised of a superalloy.
• the component is heat treated at a predetermined solution temperature for a predetermined solution time.
• the predetermined solution temperature and the predetermined solution time may be sufficient such that a predetermined internal location is heated to an internal temperature that is above the solvus or the nucleation temperature of the superalloy.
• the component experiences air transfer from the furnace to the active quenching station and is air transfer cooled from the predetermined solution temperature for a predetermined air transfer time.
• the predetermined air transfer time is of a duration such that the predetermined internal location cools to a temperature below the maximum quench temperature but not lower than the minimum quench temperature.
• the component is actively quenched upon completion of the predetermined air transfer time.
• FIG. 4A is a chart 40A tracking the changing internal temperature at a predetermined internal location compared to the changing surface temperature at a predetermined surface location according to an exemplary method of the present disclosure, such as the method of FIG. 3 .
• both the predetermined internal location and the predetermined surface location start at a predetermined solution temperature 41 for a predetermined solution time 42 (e.g., corresponding to step 32 in FIG. 3 ).
• the component is cooled in the presence of air or a gas or a mixture of gases from the predetermined solution temperature 41 for a predetermined air transfer time 44.
• the changing internal temperature 45 at a predetermined internal location e.g., at least one of the predetermined internal locations 20 shown in FIG.
• the component is actively quenched at the quenching initiation point 47.
• a temperature differential 48 exists from the internal temperature at the predetermined internal location to the surface temperature at the predetermined surface location.
• the changing surface temperature 49 at a predetermined surface location decreases faster than the internal temperature.
• FIG. 4B is a chart 40B showing the amount of plastic strain formed in the resulting component at the predetermined internal location compared to the predetermined surface location according to the exemplary method of FIG. 4A . That is, FIG. 4B shows the differential in plastic strain between the predetermined internal location and predetermined surface location is relatively small (especially compared to the differential shown in the comparative Fig. 5B . Thus, the amount of plastic strain in both the predetermined internal location and predetermined surface location is minimized via the exemplary method of FIG. 4A .
• FIG. 5A is a chart 50A tracking the changing internal temperature at a predetermined internal location compared to the changing surface temperature at a predetermined surface location according to a comparative method as a comparison to what is shown in FIG. 4A .
• both the predetermined internal location and the predetermined surface location start at a predetermined solution temperature 41 for a predetermined solution time 42 (e.g., corresponding to step 32 in FIG. 3 ).
• the component is cooled from the predetermined solution temperature 41 for a predetermined air transfer time 54.
• the changing internal temperature 55 at a predetermined internal location e.g., at least one of the predetermined internal locations 20 shown in FIG.
• the predetermined air transfer time 54 is shorter than the predetermined air transfer time 44 of the exemplary method of FIG. 4A . Thereafter, the component is actively quenched at the quenching initiation point 57 while the internal temperature 55 at the predetermined internal location is significantly higher than the precipitate nucleation temperature 46 of the superalloy.
• a positive temperature differential 58 exists from the internal temperature at the predetermined internal location to the precipitate nucleation temperature 46 of the superalloy in that the internal temperature is still above the maximum quench temperature at that location.
• the component forms increased amounts of plastic strain at the predetermined internal location, as shown in FIG. 5B .
• the changing surface temperature 59 at a predetermined surface location e.g., at least one of the predetermined surface locations 22 shown in FIG. 2 ) decreases faster than the internal temperature.
• FIG. 5B is a chart 50B showing the amount of plastic strain formed in the resulting component at the predetermined internal location compared to the predetermined surface location according to the comparative method of FIG. 5A . That is, FIG. 5B shows the differential in plastic strain between the predetermined internal location and predetermined surface location is relatively large (especially compared to the differential shown in the exemplary embodiment of FIG. 4B .
• a method of heat treating a component comprised of a multiphase superalloy comprising: heat treating the component at a predetermined solution temperature for a predetermined solution time; thereafter, cooling the component from the predetermined solution temperature for a predetermined air transfer time in the presence of air, a gas, or a mixture of gases; and thereafter, actively quenching the component, wherein the predetermined air transfer time is of a duration such that a predetermined internal location cools to a temperature that is below the maximum quench temperature of the multiphase superalloy before actively quenching the component.
• the predetermined internal location includes one or more predetermined internal locations.
• the predetermined air transfer time is of a duration such that the one or more predetermined internal locations cool below the maximum quench temperature of the multiphase superalloy before actively quenching the component.
• the predetermined air transfer time is of a duration such that the predetermined internal location does not cool past the minimum quench temperature.
• the predetermined solution temperature and the predetermined solution time are determined by a component specific model based on the multiphase superalloy's composition, the component's geometry, or a combination thereof.
• the predetermined solution temperature and the predetermined solution time are determined by a component specific model based on the multiphase superalloy's composition, the component's geometry, at least one desired property of the component, or combinations thereof.
• the predetermined air transfer time is determined by a component specific model based on the multiphase superalloy's composition, the component's geometry, the predetermined solution temperature, the predetermined solution time, at least one desired property of the component, or combinations thereof.
• the predetermined air transfer time is determined by empirical data developed in a laboratory furnace.
• the multiphase superalloy comprises a nickel-based superalloy.
• the multiphase superalloy comprises a cobalt-based superalloy.
• the multiphase superalloy comprises an iron-based superalloy.
• liquid media comprises an oil quench bath.
• liquid media comprises a water quench bath.
• the predetermined air transfer time is of a duration such that the predetermined internal location does not cool past a minimum quench temperature of the multiphase superalloy.
• the predetermined solution temperature and the predetermined solution time are determined by a component specific model based on the multiphase superalloy's composition, the component's geometry, or a combination thereof.
• the predetermined solution temperature and the predetermined solution time are determined by a component specific model based on the multiphase superalloy's composition, the component's geometry, at least one desired property of the component, or combinations thereof.
• the predetermined air transfer time is determined by a component specific model based on the multiphase superalloy's composition, the component's geometry, the predetermined solution temperature, the predetermined solution time, at least one desired property of the component, or combinations thereof.
• the predetermined air transfer time is determined by empirical data developed in a laboratory furnace.
• the multiphase superalloy comprises a nickel-based superalloy.
• the multiphase superalloy comprises a cobalt-based superalloy.
• the multiphase superalloy comprises an iron-based superalloy.
• liquid media comprises an oil quench bath.
• liquid media comprises a water quench bath.
• the predetermined air transfer time is 30 seconds to 180 seconds.

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  • 2025-03-12 CN CN202510290068.6A patent/CN120818770A/zh active Pending

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