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Understanding the Difference Between Hot and Cold Extrusion Processes

Understanding the Difference Between Hot and Cold Extrusion Processes
Understanding the Difference Between Hot and Cold Extrusion Processes
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The world of extrusion processes is made up of ambitious and astonishing. In manufacturing, one must grasp the intricacies and differences among different methods. This post will look at a critical, almost unexplored area: hot and cold extrusion processes as some of the most potent forms of metal shaping. Irrespective of whether you’re a practitioner looking to enhance your understanding or a curious individual willing to learn about the intricacies of this manufacturing wonder, you’re at the perfect place. Come with us to discuss the specifics of the hot and cold extrusion difference and step into the details, including how each works out and their advantages, drawbacks, and uses. Buckle in for a flight through a technical understanding of extrusion methods to understand what drives their selection in different manufacturing campaigns. Join us as we open up a whole world of potential techno Mechanical engineering systems and examples in extrusion processes. The world of production techniques will be in your hands through the learnings we make available here.

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What is Cold Extrusion and How Does it Work?

What is Cold Extrusion and How Does it Work?

Cold extrusion is a forming process for fabricating metal or other material at room temperature. Rather than developing the material to hot temperatures, as in hot extrusion, where the material is heated, cold extrusion uses a mechanical force to affect the desired shape. Usually, this process includes putting the material in a specific cavity within the die and then using a punch or a press to apply force, which causes the material to flow and fill the die cavity. Cold extrusion is widely used to fabricate components that require close tolerances, high strength, and excellent surface finishes. It has benefits such as improved material properties, an economy, energy employed, and enhanced productivity. Cold extrusion also has the advantage of not requiring the process to be heated, which reduces thermal distortion and enables the processing of thermal-sensitive materials. As a result, it can be said that cold extrusion is a simple and cheap method that can be used in various fields, including the automotive industry, airplanes, and electronic devices.

Key Elements of the Cold Extrusion Process

Cold extrusion is a metalworking process in which room-temperature materials are shaped, and their internal structure is altered through high pressure. It uses a die and a punch to apply force to the material, causing it to take a specific shape. Below are the steps that are involved in the cold extrusion process:

  1. Material Selection: Metal characteristics such as flexibility and deformability must be present to prevent fracturing during cold extrusion. Copper, aluminum, and steel are most often used.
  2. Die Construction: The die used in the process is made of stainless steel, which creates the impression of the final product. The impression can be made using a specially made cold extrusion die, which has a cavity of the required size and allows the metal to be shaped by flow.
  3. Punching Process: The punch exerts high pressure on the material, which emerges out of the cavity at the end of the die and is made to pass through the die cavity structure. Consequently, the material is kept in a plastic deformation state, thus enabling it to take the shape of the die design.
  4. Cooling and Finishing: Cooled metal extruded undergoes some form of finishing after cutting, trimming, and other processes to achieve desired surfaces and dimensions. Additionally, some may require end machining, surface coating, and thermal treatment.

The cold extrusion process provides several benefits, such as enhanced properties of the material, reduced energy requirement, and increased efficiency. This is especially advantageous for heat-sensitive materials as it makes it unnecessary to heat the workpieces, thereby decreasing thermal distortion. Cold extrusion is employed in many industries like automotive, aerospace, and electronics, where close tolerances and accurate shaping and forming of metal parts are required.

Advantages of Cold Extrusion in Manufacturing

The cold extrusion method has several benefits in the industrial production sector, making it the preferred approach for shaping and forming metals. A few of these MERITS include:

  1. Enhanced Microstructural Properties: A cold extrusion process usually improves other mechanical properties of a material, such as tensile strength and even flexibility. The process also seems to positively impact grain structure and enhance material integrity, which ultimately improves the parts’ performance.
  2. Lower Heating Requirements: Unlike hot extrusion, which requires personnel heating to very high levels, cold extrusion is practical because it does not require the heating of materials. This also diminishes the heating consumption rate, reduces thermal distortion, and makes the method more energy efficient.
  3. Higher Production Output: The method’s work output is excellent mainly because it can produce solid and complicated shapes much quicker than other methods. This means that manufacturers can work at faster production speeds to fulfill strict deadlines.
  4. Relevance to Reheat-Proof Materials: Losses imposed by cold extrusion are greater in inflation, so heating is unnecessary, which helps the procedure. The problem of thermos in hot extrusion, which could harm the image or even ruin the component, was not a concern in this procedure, enabling the components to maintain an excellent position definition when completed.

Thus, manufacturers can improve their production processes, obtain high-quality details, and meet the demanding requirements in several sectors, such as automotive, aircraft, and electronics manufacturing.

Standard Extrusion Methods Used in Cold Extrusion

Cold extrusion is a process used in manufacturing that allows the shaping of materials at room temperature without heating the material. It’s particularly beneficial because it improves the integrity and accuracy of the components and also cuts costs, as there’s no need for heaters. There are several standard methods used in cold extrusion, including:

  1. Forward Extrusion: This technique is widely used for extrusions requiring an extended barrel and is frequently referred to as tube extrusion. The process requires the above header tube to be forced through the die. It’s most widely used for paid industries involving rods, wires, and tubes extrusions.
  2. Backward Extrusion: Most people probably consider this conventional punching method. In this method, the punch presses the tube material forward and moves backward to form the desired tube shape. This method is used when the extrusion of confirmed parts is necessary.
  3. Combined Extrusion: This method helps form die-shaped components by retaining a central core of material, rotating two or more materials during the process, or injecting a liquid into a single core material. Hence, it is said to allow custom extrusion, offering both quality and precision.
  4. Hydrostatic Extrusion: It allows pipes to be extruded tightly. This makes the grain flow neck or deform because of more welding pressure. As a result, there are improved physical properties and mechanical homogeneities.

These techniques permit the creation of a broad array of components, from simple to more complex ones, with numerous variations in shapes and sizes. Hence, they are helpful to manufacturers. At the same time, by choosing the appropriate cold extrusion method, manufacturers can minimize costs and still provide high-quality components.

Exploring Hot Extrusion: The Process and Its Applications

Exploring Hot Extrusion: The Process and Its Applications

How Hot Extrusion Involves Heating the Material

Hot extrusion is a solid metal fabrication process in which the material is heated beyond its recrystallization temperature and forced through a die to work into desired shapes. Applying heat softens tough metal substances, allowing easy manipulation into various forms. This high temperature decreases the friction to plastic deformation, thereby allowing better control of the shaping process.

Hot extrusion commences with a heated material in a fitted container called a billet. The container is then transferred to a chamber with high temperatures induced by conductive means or other heating methods. After the composites are in the acceptable range, they are driven out by a ram or hydraulic press via the extrusion press. The resultant material acquires the nature of the die, which determines the shape of the extruded element.

The heating of the material in hot extrusion has its merits. It lowers the required efforts to deform the material to create dies with complicated and accurate geometries. The high temperature enhances material characteristics like flow rate, leading to a finer surface finish and improved mechanical characteristics of the extruded element.

The hot extrusion process can be implemented in several industries, such as the automotive, aerospace, and construction sectors. Such a technology is typically employed to manufacture various parts, including rods, tubes, profiles, and structural components. It allows the possibility to make different sizing, shapes, and structures out of various materials, which helps the manufacturers have a more extensive range of their production.

As explained, hot extrusion is formed by heating the material. This is important for the manufacturers to know since such a process may allow them to manufacture suitable components and, at the same time, be cost-effective in their production. However, success in hot extrusion and the anticipated properties of the obtained extruded products depend on temperature control, die design, and material selection.

Applications and Benefits of Hot Extrusion

Hot extrusion is a manufacturing method that applies to different sectors. It allows for accurate shaping and forming of components by heating the material to very high temperatures. Some of the applications and benefits of hot extrusion include:

  1. Automotive Industry: Hot extrusion lessens the cost of producing complex shapes and automotive structural components such as engine parts, transmission components, and other structural parts. High strength, aa, and excellent surface finish are guaranteed.
  2. Aerospace Industry: In aerospace manufacturing, hot extrusion is used to make integral parts at the structural level of the aircraft, such as the airplane’s landing gears and turbine blades. This method results in the formation of light parts with high strength.
  3. Construction Industry: In the construction industry, hot extrusion processes are integrated into manufacturing architectural profiles, window frames, door frames, and other structural components. This process’s shape stabilizes dimensions and provides corrosion stability.
  4. Energy Sector: In the energy industry, hot extrusion is needed to manufacture heat exchangers, gas turbines, and boiler components. Such technology allows for the formation of complex shapes with good mechanical characteristics.
  5. Medical Industry: Hot extrusion is used in the medical sector to produce surgical implants, surgical instruments, and parts of medical devices. The procedure guarantees high precision with biocompatible properties and dimensional accuracy.
  6. Consumer Goods: Hot extrusion produces aluminum cans, tubes, and kitchen appliances. The process suits cheaper large-scale production, superb surface finishing, and versatile design.

This is only a fraction of hot extrusion’s wide range of applications. The procedure allows manufacturers to fabricate high-quality components requiring minimal shaping, greater structural stiffness, and optimized production speed.

Challenges in the Hot Extrusion Process

The hot extrusion process is associated with several benefits; however, it also has certain downsides that manufacturers must manage to achieve the desired results. These potential issues and their consequences for the hot extrusion process may be understood by gleaning information from literature and professional experience.

  • Temperature Control: During the extrusion manufacturing process, sufficient temperature control must be observed at every procedure stage. Increasing or lowering the temperature above the set threshold affects the product dimensions that involve flow and even alters material flow.
  • Die Design and Wear: The geometry and state of the extrusion die surfaces are critical elements that influence material flow during the extrusion and any material flow defects. Having the appropriate extrusion die geometry in combination with effective die cooling mechanisms helps to solve die sticking problems, die line problems, and die wear problems.
  • Metallurgical Considerations: Extruding at high temperatures and stresses can alter the material’s microstructure and cause other modifications to the selected material. It is important that the material selected can withstand softening and controlled grain growth, allowing the production to achieve the preset mechanical attributes.
  • Tooling and Lubrication: Proper tooling and lubrication systems cannot be overstated in decreasing friction (Callaghan, O. C. (2005), moderating the material flow behavior, and avoiding the formation of relevant surface defects. Effectively applying the right lubricant is very important in enhancing the extrusion quality while minimizing tool wear.
  • Process Optimization: Finding the best set of process parameters and conditions during extrusion requires due diligence and numerous trials. When properly controlled, time, ram speed, billet temperature, and extrusion ratio can help achieve the desired product characteristics while reducing waste and energy consumption.

To realize these and other benefits, tackling the identified problems and extending the possibilities offered by hot extrusion, particularly high-precision, energy-efficient, and low-cost component machining, is necessary.

The Difference Between Hot and Cold Extrusion Processes

The Difference Between Hot and Cold Extrusion Processes

Comparing Deformation Mechanisms

Understanding the basic underlying principles of deformation mechanisms is crucial when comparing hot and cold extrusion processes. In hot extrusion, work material is preheated to a specific temperature, that is, to a temperature that is somewhat higher than its heating temperature, to make the material pliable, and less force would be needed in the machining process. Since such a temperature is maintained, it enhances the deformation velocity and flexibility of the material, thus aiding in effortlessly deforming and reshaping the material.

In comparison, cold extrusion forms the material at or close to the room temperature. However, unlike the hot extrusion, warm material softening is not available; hence, a more significant force is required to cause plastically deform the material. However, cold extrusion has benefits over warm extrusion, such as better dimensional tolerance, surface quality, and mechanical properties due to strain hardening.

The selection of hot or cold extrusion cannot be arbitrary. Each technique has merits and demerits, which have to be weighed against various parameters such as the type of material, end component features, etc. Thus, the manufacturers must carefully consider these factors so that an appropriate extrusion process can be used for their projects.

To discuss the matter and uncover new trends in hot and cold extrusion, it would be helpful to seek the most recent information in this field and connect with professionals to enhance your knowledge and understanding of this topic.

Impact on Mechanical Properties and Surface Finish

The extrusion process focuses on temperature and its effects on components. Hot extrusion takes place above the recrystallization temperature, which increases the material’s ductility, once again reflecting the reason why extrusion is the preferred way to manufacture many items. But when the temperature in cold extrusion is taken below the recrystallization point, it gives out components with better results and improved strength. Cold extrusion is also preferable when alloys of aluminum and copper are used due to their drop in preferred temperature.

To monitor the effect cold or hot extrusion has on the component in terms of strength and surface finish, other factors have to be polled, too, such as the properties of the material, parameters of the process, and the requirement of the component. By thoroughly checking these landmarks, the manufacturer can choose the method that best suits their project. Also, it is beneficial to talk to peer consultants from the extrusion segment or keep an eye on the latest cutting-edge innovations for hot and cold extrusion. As a cherry on top, this research will optimize the hand performance and quality component.

Considerations for Dimensional Accuracy and Tool Wear

Regarding the extrusion processes, bearing in mind dimensional control and the issue of tool wear are essential issues to think about. These are some basic aspects that you should note:

  1. Material Properties: Dimensional accuracy is achieved primarily through material selection. Different materials have different melt flow characteristics, thermal coefficients for expansion, and shrinkage, which all contribute to the final size of the extruded part.
  2. Die and Tooling: Proper and effective design of the dies and tooling will play a vital role in achieving dimensional control. Again, the die shape, length of land, and taper angle must also be considered to lessen the chances of distortion and solve the shape of the extruded product.
  3. Process Control and Monitoring: Having the proper process controls in place, such as extrusion at a constant temperature and speed, will promote the achievement of the dimensional requirements. It is common practice to follow up on the parameters of the melt temperature and extrusion pressure to allow for timely recognition of any discrepancies and rectification of any problems.
  4. Tool Maintenance and Replacement: Tool wear and dimensional accuracy are affected by lack of or poor inspection and maintenance, which are also frequent/regular tasks. Quality control of the extruded components can only be achieved by precision turnaround of the components through swapping old and damaged tools for effective ones.
  5. Quality Assurance Testing: These are the basic quality assurance checks that need to be carried out at the very least, such as dimensional inspection and tolerance checks of the extruded components. This assists in determining whether any discrepancies capping the extrusion process need to be corrected.

By paying attention to these issues and taking the proper measures, manufacturers can improve dimensional control and reduce tool wear, guaranteeing the quality of extruded components.

Choosing the Right Type of Extrusion for Your Project

Choosing the Right Type of Extrusion for Your Project

Factors Influencing the Choice of Extrusion Methods

Several important considerations exist for projects when selecting the most appropriate extrusion process. These include:

  1. Material characteristics: The temperature sensitivity, viscosity, and flow behavior of the extruded material are relevant factors in selecting the extrusion process.
  2. Heightened geometry: The chosen shape and geometry of the extruded section will also affect the method of extrusion employed, as some methods are not ideal for intricate designs.
  3. Production Quantity: The projected amount will determine the most effective extrusion method. For instance, continuous extrusion processes were better with high volume output.
  4. Cost factors: Cost factors, including equipment buying, servicing, and material wastage, would also affect the extrusion process. Some processes may require a lot of capital investment but will, over time, require less due to high efficiency.
  5. Material restriction: The extrusion process can significantly restrict a material. Aspects such as thermal sensitivity, melt temperature range, and degradation of material information must be present to guarantee successful extrusion.
  6. Specification Clauses: Categories of components specifying dimensional tolerances influence the method of choice in extrusion. Some methods, such as precision extrusion, may be more appropriate for applications with stringent tolerance specifications.

Considering these factors, it will be easier for them to select the most suitable extrusion technique for the project, the costs to be incurred, and the expected quality.

Cost and Efficiency in Different Extrusion Processes

Cost and economic efficiency are some of the considerations when assessing potential extrusion processes in the manufacturing industry. That being said, as a professional in the industry, I have observed that these two elements play a significant role. As per the needs of every particular project, manufacturers set their eyes on the most appropriate extrusion technique with maximum efficiency and cost concerning rate. Among all these aspects, construction includes material, shape complexity, extrusion rate, material features, and tolerances. Such a thorough analysis ensures that manufacturers make rational choices, which enhance productivity, reduce expense, and improve the quality of the extruded products.

Evaluating Desired Shape and Material Compatibility

When considering the shape and necessary characteristics of extrusion, I find it critically important to gauge the requirements of the projects in such a way that the specific process will be productively usable. This encompasses aspects such as the material being used, how intricate the shape is being aimed for, the extrusion speed, the material compatibility, and the tolerance limits. With a keen eye on such items, manufacturers can thus pick the most appropriate extrusion method where cost and efficiency are optimal. This entire evaluation leads to active decision-making, where productivity is enhanced along with a drop in costs and better quality of the products. Being an expert in the field, I have seen how that alternative decision has a very pronounced effect on the production processes of extruded parts, thus benefitting manufacturers in the manufacturing sector.

Insights from Extrusion Industry Experts

Insights from Extrusion Industry Experts

Latest Innovations in Hot and Cold Extrusion

As an extrusion professional, I have seen significant improvements in hot and cold extrusion.  In hot extrusion, innovations focus on temperature control systems, which drive the accuracy and efficiency of the processes to the extent that manufacturers can achieve complex shapes with tight tolerances. Moreover, the superiority of Hot extrusion techniques has also been enhanced by the progress noted in die design and lubrication methods, which have contributed to better surface finish and less material wastage. On the contrary, cold extrusion has been enhanced by advancing the tooling materials and designs to manufacture more robust and complicated products. Incorporating computer simulations and process monitoring systems has also contributed to the advancement of cold extrusion technology, thus enhancing productivity and lowering production costs. These innovations in hot and cold extrusion techniques have transformed the manufacturing sector, enabling manufacturers to produce top-quality components at lower costs and with higher efficiency.

Expert Opinions: The Future of Extrusion is a Manufacturing Process

However, before diving into the specific innovations that allow us to sculpt this material, let’s first understand the general trends surrounding the extrusion processes, as some tendencies are bound to be consistent across boundaries. Such changes become apparent through the strategic forecasting of the industry experts based on their research and analysis. We turn our attention to the opinions of professionals in the field concerning the future of extrusion:

  1. Expansion of Material Science: According to professionals in the field, as new alloys and composite materials are created for extrusion, further development in material science is anticipated. These materials will have advanced capabilities of greater strength, heat, and corrosion resistance, thus making it possible to create more intricate components through extrusion in more industries.
  2. Implementing Industry 4.0 technologies: The next phase of extrusion development shall involve introducing Industry 4.0 technology, which includes automation, robotics, data, and AI, as a single holistic unit. Their synthesis will permit monitoring of extrusion parameters in real-time, equipment maintenance before a breakdown occurs, and increase the efficiency of production processes. Further combining digital twins and simulating instruments into the package will enable more efficient production processes, forcing manufacturers to reoptimize extrusion tools and settings on the production line.
  3. Circular Economy and Sustainability Orientation: Given the climate worries, specialists expect a greater emphasis on sustainability in extrusion processes. This implies ensuring eco-friendly materials, lowering waste, and utilizing less energy during production. Introducing a closed-loop recycling system will allow using post-consumer and post-industrial waste, increase participation in the circular economy, and protect nature.
  4. Personalization and Mass-Bespoke Production: In the next decade, extrusion is highly likely to witness changes in trends about focusing on personalization and on-demand manufacturing. So, as technologies like digital design and additive manufacturing develop, producers will be able to produce more intricate and individualized objects than ever – and do so in considerably shorter periods. This is in step with the tendency of consumers to request more personalized products and the shift towards just-in-time manufacturing.
  5. Quality and Trust will Remain Critical Factors in the Future: Technology will enlarge the extent of techniques available to rotary extruders for rotational skinning experts worldwide. However, they have stated without additional respect that quality and trust will remain hugely critical for the extrusion processes. This will mean spending on effective quality control processes, which include non-destructive test methods and real-time monitoring systems that maintain the validity and uniformity of extruded parts.

Expert opinions assist in predicting the future of extrusion as a manufacturing process. If these trends are followed and new technologies are adopted, manufacturers will be set for success in a fast-changing environment.

Frequently Asked Questions (FAQs)

Q: What is extrusion, and how does it operate?

A: Extrusion is a manufacturing process in which an object with a defined cross-sectional profile is shaped by being forced through a die. This technique is widely employed in metal forming, plastics, and food production. Depending on the outcome and material, the process can be done at high temperatures (hot extrusion) or lower temperatures (cold extrusion).

Q: How do hot and cold extrusions differ from each other?

A: Hot extrusion and cold extrusion aren’t the same; they are different. Hot extrusion is a good process if it is above recrystallization temperature because the metal is more malleable. Cold extrusion mainly occurs at room temperature or slightly higher jump in temperature and below the recrystallization temperature. Hot extrusion is mostly done for softer metals, while cold extrusion is more effective when high tolerances need to be achieved on more rigid components.

Q: What materials can be cold extruded?

A: Room-temperature ductile material, including soft metals such as aluminum, copper, lead, and some steel, is ideal for cold extrusion. This technique is also useful in molding different plastics and processing food such as pasta and cereals.

Q: In what capacity do extruders function during the extrusion process?

A: An extruder can be defined as the machine which is responsible for executing the extrusion process. It consists of the following components: a barrel, a screw or ram, and a die. The material, known as a billet in metal extrusion, is placed into the barrel and pushed through by a screw or ram. The dimensions of the die determine the shape of the material exiting through the die. The extruder also contains parts for heating in case of hot extrusion during the process.

Q: Based on your experience, what are some common uses of hot extrusion vs. cold extrusion?

A: Aluminum profiles accommodate most building trades, auto parts, and heat sinks. Hot extrusion does aluminum profiles for construction trades. Cold extrusion is used in the molder or in manufacturing small and more accurate components such as gears or bolts and other minor electronic components. Because they are still made this way, pasta and pet food are made by cold extrusion, while hot extrusion is used on cereals and snack foods.

Q: What’s the effect on the product quality and tolerance from the decision to utilize hot vs cold extrusion?

A: Cold extrusion tends to provide enhanced dimensional accuracy and surface smoothness, making it suitable for parts where tolerances are closely adhered to. Hot extrusion will not be as precise, yet it can be used for more significant components with more complicated geometry shapes. The two processes can be used interchangeably, but the requirements of the end product, such as the material characteristics, shape, and degree of tolerance, will determine which pair will be used.

Q: Are there any hybrid or specialized extrusion processes?

A: Yes, there are several specialized extrusion processes. These include warm extrusion, which operates at temperatures between hot and cold extrusion; hydrostatic extrusion, which uses a fluid medium to apply pressure; and impact extrusion, which involves high-speed forming. Each process has specific advantages and is used for particular industry applications.

Reference Sources

1. “Comparative analysis of the specific mechanical energy, specific thermal energy, and functional properties of cold and hot extruded pea protein isolate” By Harrison Helmick et al. (2023)(Helmick et al., 2023, p. 113603):

  • Key Findings: The study compares the specific mechanical energy, thermal energy, and functional properties of pea protein isolate when subjected to hot and cold extrusion processes. Such research draws attention to energy consumption and its impact on the functional properties of extruded products.
  • Methodologies: The study uses an experimental method of extruding pea protein isolate using hot and cold extrusion processes. During the experiments, the researchers note each process’s mechanical and thermal energy requirements and the functional properties of the produced extrudates.

2. “Elongational Deformation Induced by Pins in Pin-Barrel Cold-Feed Extrusion: Investigations” by Zhilin Wang et al. (2022)(Wang et al., 2022):

  • Key Findings: The paper’s central focus was on the deformation caused by the pins in the extruder. It determines the quantitative values of deformation and the way or the ways it is determined quantitatively with consideration of specific parameters such as the diameter of the screw etc.
  • Methodologies: The presented work deals with mathematical modeling and applying the finite element method to simulate the flow in and the elongational deformation of cold-feed extruders. The theoretical outcomes are then used to compare and thus validate the model being established.

3. “Comparative analysis of the transformation behavior of Ni50.3Ti29.7Hf20 high-temperature shape memory alloy processed by cold rolling with aging and hot extrusion with aging” by H. O. Tugrul et al. (2019)(Tugrul et al., 2019).

  • Key Findings: This paper compares the transformation behavior of two processes developed for NiTiHf high-temperature shape memory alloys: hot extrusion with aging and cold rolling with aging. The two methods appear to differ in the actuation strain and dimensional stability, highlighting the unique characteristics of each type of extrusion process.
  • Methodologies: The alloy is subjected to a combination of cold rolling and hot extrusion followed by aging. Differential scanning calorimetry and heating-cooling tests help determine the transformation temperatures and some mechanical properties.

4. UDTECH’s Laboratory Extruders Solution

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