Sukhoi Su-57 / T-50 / PAK FA - flight testing and development Part II [2012-current]

I noticed something about the nozzle material. The black section looks like a textured composite, it looks like Saturn spared no expenses. The fitment looks very tight too and the exhaust flaps when opened are properly sealed off unlike the F-22 flaps that have the internals exposed. I do like the F-22 but this really pissed off many F-22 fanboys
You do know that the F-22 nozzles are in the shutdown maintenance position in the photo? The divergent flap sides are fully hidden by the sidewall when the engine is operating.
 
You do know that the F-22 nozzles are in the shutdown maintenance position in the photo? The divergent flap sides are fully hidden by the sidewall when the engine is operating.

Even the slightest movement of the horizontal stabilizer causes the nozzles to move, and even if they move just a little the side wall of the nozzle is visible and if its visible to a camera it’s visible to a radar
 

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You'd be really lucky to catch a moment and angle to see flaps in this position on your radar.

A stealth aircraft will always have a BVR advantage but dog fights will always exists, even during the Gulf war there were a lot of dog fights were Iraqis surprised NATO fighters

Here is a Rafale and F-22 during exercises. The Rafale indeed had the F-22 at very similar angles

View: https://youtu.be/KOswfrc7Xtg
 
Even the slightest movement of the horizontal stabilizer causes the nozzles to move, and even if they move just a little the side wall of the nozzle is visible and if its visible to a camera it’s visible to a radar
Those photos do show the nozzle full open at ground idle. They are not that open even in full AB (where the thermal image is highly visible), and are much further closed at Mil and below. And there is no vectoring at mid to high airspeeds, making the nozzle virtually invisible to radar in the aft sector.
 
A stealth aircraft will always have a BVR advantage but dog fights will always exists, even during the Gulf war there were a lot of dog fights were Iraqis surprised NATO fighters

Here is a Rafale and F-22 during exercises. The Rafale indeed had the F-22 at very similar angles

View: https://youtu.be/KOswfrc7Xtg
At close range, the RCS is large enough for a missile lock regardless (though pilots testimonies in the past have indicated that some 4th gen fighters couldn't even get a lock in visual range against f-22 but most likely very narrow range of angles) and most likely it's IR seeker you're worrying about more. Regardless I don't think it was a design requirement to be RCS stealthy in visual range dogfight.

The nozzle flaps actually move very little in regards to how the thrust vectoring is engaged in any scenario outside of close-in dogfight and airshow flight demos, mainly to limit flight control surfaces' movements and trim drags at certain speed so I don't think that side would ever be exposed. Testing probably led them to believe such scenario where RCS is relevant and the side of the flap exposed is so unrealistic they could do away to save weight.
 
Very strange and obviously incorrect title:

Su-57 Felon’s Two-Dimensional Thrust-Vectoring Engine Nozzle Breaks Cover​


''In the Su-57 and the Su-35, the AL-41F-1 features a thrust-vectoring nozzle of axisymmetric type. This is also known as three-dimensional thrust vectoring and provides pitch, yaw, and roll control.
In its initial form, the AL-51F-1 also retains a similar three-dimensional thrust vectoring nozzle, but what we see in the new imagery is an alternative nozzle, this time of the two-dimensional type, which provides pitch control as well as limited roll control if engaged asymmetrically. It isn’t clear if the angled installation of the nozzle is meant to provide extra control in the latter.''


As M. Strelets said it is a 3D TVC nozzle. Maybe the author did not know that nozzles can rotate in a longitudinal axis?


View: https://x.com/Fighterman_FFRC/status/1868421610388246553


On the other side this was one very clever thinking from 2017 ( translated):

''The feasibility of using flat nozzles in the PAK FA program. I assume that theoretically it is possible to get rid of the problem of non-all-aspect deviation of the thrust vector by integrating a motor nozzle into the design, which allows you to rotate the deflected plane around the engine( longitudinal) axis.''



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Screenshot 2024-12-16 135559.png I am assuming if Lockheed Martin and Chengdu had a choice, they would change their round serrated nozzles on their current 5th gen aircrafts to round flat nozzles for a better stealth choice?
 
Would be interesting to know how much reduction in radar and heat signature these type of exhaust produce
 
Would be interesting to know how much reduction in radar and heat signature these type of exhaust produce

Both significantly when compared to the standard engines but of course it’s impossible to know since Sukhoi/Saturn are not providing data. Studies however, have shown up to a 20% reduction in heat but it looks like Saturn also added something that looks like cooling veins.


As for RCS, main thing is that the leading edge and base of the nozzles are shaped so as to scatter radar as apposed to the older design that would cause radar to bounce back in a perpendicular manner, so by shaping the nozzles the radar or electro magnetic energy is diffracted away, this should reduce the RCS significantly and from both the front as well as the back of the aircraft. The nozzles are also canted/flat as opposed to cylindrical which will also reduce RCS from the sides. IMG_2014.png
 
@paralay @QuadroFX I took an interest in this forum through taking an interest in your forum. Considering Russia is your home country do you have more information on their electronic production like how much of these circuits they will produce?
]In Russia, the production of unique communication equipment operating on photonic integrated circuits is launched. This is a new type of microelectronics, the speed of which is much higher than that of traditional silicon chips. It opens up good prospects for the creation of devices that are necessary, in particular, for the development of telecommunications networks, for example, 5G base stations and subsequent generations, known as pervasive networks. The development will also help establish quantum communications, experts believe.

Radio Electronics of the New Generation
St. Petersburg Electrotechnical University "LETI" and the Element Group of Companies have announced the launch of production of ultra-high frequency (microwave) generators with unique characteristics based on new elements - photonic integrated circuits (FIS).

The speed of photons in such FIS is equal to the speed of propagation of an electromagnetic wave in the material, in fact, this is the speed of light, the developers said. Therefore, the speed of action, and hence the frequency ranges of such integrated circuits, are much higher than those of electronic ones.
At the same time, the requirements for topological standards in production are much lower than in silicon electronics, which makes it possible to obtain a high percentage of yield of suitable crystals at the stage of industrial development of the technology, LETI noted.

"Radiophotonic devices allow you to work with ultra-wideband signals, which provides high speeds and large amounts of transmitted information. This is in demand in promising telecommunication systems, quantum communication systems. In addition to microwave signal generators, we are developing photonic integrated circuits, signal spectrum analyzers, analog-to-digital converters, signal processors," Viktor Tupik, Vice-Rector for Strategic Development of ETU "LETI", told Izvestia.

As the developers explained, the launch of industrial production of radio-electronic products using the principles of photonics opens up good prospects for the creation of new devices. In particular, those necessary for the development of telecommunications networks, for example, 5G base stations and subsequent ones, known as pervasive networks. They will also be in demand for the modernization of system devices in radar, radio navigation and other areas.

As Viktor Tupik explained, combining radio frequency and optical signals in one system makes it possible to detect what cannot be recorded in each range separately.

"Photonic and electronic integrated circuits have a common advantage - they are manufactured using integral, in other words, group technology. That is, not one circuit is processed in one operation, but dozens, hundreds or thousands of chip crystals, their number depends on the size of the single-crystal substrate," the expert said. "Their differences are in the physics of the processes on the basis of which information processing is built.


The line of the first devices will be supplemented with the latest products, including domestic developments of components for quantum communications, such as random signal generators, spectrum analyzers, and others.

Digital technologies Science 5G Nanotechnology Quantum Technologies
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In Russia, the production of unique communication equipment operating on photonic integrated circuits is launched. This is a new type of microelectronics, the speed of which is much higher than that of traditional silicon chips. It opens up good prospects for the creation of devices that are necessary, in particular, for the development of telecommunications networks, for example, 5G base stations and subsequent generations, known as pervasive networks. The development will also help establish quantum communications, experts believe.

Ultra-high-frequency generators based on FIS open up great opportunities for ultra-wideband communication systems, such as future 5G/6G networks and quantum communications, said Vyacheslav Begishev, associate professor of the Department of Probability Theory and Cybersecurity of the Institute of Computer Science and Telecommunications of the RUDN University.

"The production of such devices in Russia will reduce dependence on foreign technologies and create domestic components for 5G/6G networks and more advanced communication systems. The introduction of the FIS will make it possible to increase the production of high-tech products based on domestic production facilities," the specialist said.

Currently, the global market for integrated photonics for use in promising telecommunications systems and quantum communications systems is about $10 billion, while Russia's share in it is only about 2%, according to LETI. His work is mainly focused on the search for technological possibilities for combining microelectronic silicon technology and photonic technologies.
The production for the circuits started a month ago, do they usually prioritize circuits for radars on military equipment like ground radars and aircrafts over civilian related shit?
 
That's my point. It's working for both eyes.

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Actually it's like an EF-2000 helmet:

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It appears I was mistaken, I thought that it was a dropdown eyepiece from it's design, I didn't expect such compactness from a projection system using the the actual pilot face shield. Now that I've zoomed in fully, I do see the sunvisor over the faceshield.
 
That's my point. It's working for both eyes.

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Actually it's like an EF-2000 helmet:

View attachment 752617


This makes sense now, I didn’t notice the middle reflective mirror. Like everyone else at first I thought the piece of hexagonal glass was to look through but the angle coincided with how it would reflect onto the visor. I then questioned why use clear glass but then upon further research coated glass can reflect but also prevent excessive glare like you would get with a traditional mirror.

The concept does look the same to the Striker II where they use more efficient mirror projectors to display the image, where as the Striker I used ray projectors that consumed a lot of power, several thousand volts apparently.
 
what's the deal with all the triangular extrusions on the top of the helmet?

Probably a similar function to the Striker helmet sensors:

“The bumps (infra-red LED’s) are used to calculate the pilot’s head position and its angle. The LEDs on the helmet flash and the 3 sensors in the cockpit detect the flashing. The data is then used to calculate where the pilot is looking. As the pilot turns his head, the system continually re-configures to use the best sensor and LED combination to give the most accurate result. Accurate targeting is immediate; there’s no delay”

 
Su-57 modernization – three-coordinate flat nozzle and helmet-mounted target designation system, 12.17.2024.

The second stage engine with a flat nozzle and controlled thrust vector for the Su-57 fighter, known under the designation "product 30" or AL-51F1, is undergoing flight tests on an experimental aircraft with the tail number 052 (PAK FA T-50-2). At the same time, the second engine with an axisymmetric round nozzle remains the standard one - AL-41F1. This is described and shown in documentary film Channel One's "Lords of the Sky", dedicated to the 85th anniversary of the Pavel Sukhoi Experimental Design Bureau.

The engineering approach to the Su-57 involves the modularity of its design, which allows for the prompt replacement of various components, including the power plant. As noted by Mikhail Strelets, Director of the Sukhoi Design Bureau and Chief Designer of the Su-57, in the future, combat aircraft with first-stage engines installed may be equipped with a new engine with a flat nozzle, which will significantly improve their combat performance and reduce the fighter's visibility in the rear hemisphere.

The flat nozzle is a complex metal-composite structure. Unlike traditional axisymmetric nozzles, the flat nozzle is used on the aircraft to create new capabilities, including providing low visibility in the radar range due to the characteristic shape of the nozzle flaps, and allows it to be used in a wide range of altitudes and flight speeds. Due to this, the aircraft retains all its maneuverability.

"In essence, the flat nozzle complements the existing aerodynamic controls, allowing the creation of moments in three planes and thus - pitch, roll and yaw control. And since the nozzle installation angle remains axisymmetric, all the aircraft's super-maneuverability capabilities are also preserved," explained Mikhail Strelets.

One of the key advantages of the flat nozzle is that it reduces the aircraft's visibility in the infrared range as well. The flat nozzle narrows the high-temperature exhaust stream, reducing the Su-57's thermal signature, making it less vulnerable to missiles with infrared homing heads.

On the foreign market, the American F-22 fighter has similar solutions. However, its flat nozzles can only deflect in the vertical plane, which limits its maneuverability compared to the Su-57.

In the USSR, a flat two-coordinate nozzle was designed in the second half of the 1970s for the Yak-41 carrier-based vertical takeoff and landing (VTOL) fighter. An original solution was used to rotate it: the nozzle was divided into three segments, which, rotating in opposite directions relative to each other, provided a thrust vector deviation in the vertical plane up to an angle of 95° (with VTOL). To perform a short takeoff, the nozzle was set to a position of 62°. This solution made it possible to use afterburner both in horizontal flight and in vertical mode.

In addition to upgrading the Su-57 with the second-stage engine, Sukhoi Design Bureau is working on improving the information display system. Data from the onboard computer will be displayed not only on the cockpit displays, but also on the visor of the flight helmet. The helmet is equipped with an optical-electronic positioning system and a video information display system. The image is displayed on the protective shield.

Such a helmet replaces several devices at once and is equipped with a large number of sensors. They detect the movements of the pilot's head and, depending on where he turns his head, project the information he needs at the moment onto the shield, for example, the function of selecting and capturing a target. The helmet-mounted target designation system is being developed specifically for the Su-57 and will allow the pilot to receive information about the aircraft's condition, combat situation, speed, flight altitude and distance to the target.

According to Dmitry Korzinin, head of the optical-electronic systems department at the Sukhoi Design Bureau, if a missile with an infrared homing head has acquired a target, the pilot's helmet shield will change the aiming marker. He will know that the target has been acquired and will then see whether the launch is permitted or not. The direction in which the pilot looks is in which direction the missile's homing head will deviate. The helmet with the target designation system is currently undergoing flight tests.

"We view the aircraft as a platform that can effectively solve its problems for at least 50 years. Including the gradual introduction of next-generation technologies, essentially transforming the aircraft from generation 5 to 5 plus. This is the generation in which individual sixth-generation technologies are already being introduced," added Mikhail Strelets.
 

"In essence, the flat nozzle complements the existing aerodynamic controls, allowing the creation of moments in three planes and thus - pitch, roll and yaw control. And since the nozzle installation angle remains axisymmetric, all the aircraft's super-maneuverability capabilities are also preserved," explained Mikhail Strelets.
I'm confused. Does it mean the whole flat nozzle moves up/down and left/right?!...
ezgif-5-1ae0d48aec.gif

I always assumed pitch, roll and yaw control is achieved by canted installation of the two 2D nozzles... Kind of how a V-tail works.
 
By the way, the latest published information about the PAK FA program suggests an interesting development not only of the Su-57 itself, but also of other programs such as LTS, PAK DA and in the future, perhaps PAK DP or PMKI, if the issue of a new aircraft carrier is finally resolved (the fall of Syria may fundamentally change the position on this issue).
 
It states that the maximum operational load factor below Mach 0.85 is 9G, the same as the F-15, but the maximum load factor above Mach 0.85 is 7.5G (if I remember correctly, the real G load for the F-15 in the transonic region is 7.33, as indicated on the chart). So, we can see that the transonic G limit differs from the limit in the chart you have posted, which is 7G and 139000kg.
Rather than using Soviet tables estimating the F-15C, the actual manual is available. The F-15 with the OWS is clearly able to pull 9g without any placard limit underneath. Only without OWS, F-15 is placard limit to 7.33g.
F-15 load limit.PNG

Note for the OWS, there are no "peacetime" g-limits. I don't know where the Soviets got the numbers for their tables, but the F-15 with OWS can pull 9g up to a certain weight

Let us take, for example, the Su-27, which is the most classical example of a fighter with large strakes and a wide lifting body (blended wing body), and the F-15C, which is a classical example of a fighter with a conventional configuration without strakes. The F-15C actually has a superior thrust-to-weight ratio and superior wing loading, and despite that, the Su-27 has considerably superior instantaneous turn rate (ITR) and superior sustained turn rate (STR) at sea level.
For example, at 600 km/h, the Su-27 can pull around 9G while having around 30 deg/s ITR, or it can sustain slightly more than 20 deg/s at that speed. On the other hand, the F-15C can pull around 6.4G and have "just" 21 deg/s ITR, and around 18 deg/s at the same speed.
This only shows the aerodynamic efficiency of the LERX - wide lifting body layout, even if the plane in question has an inferior thrust-to-weight ratio and worse wing loading. The Su-57 patent claims that they have managed to increase the lift coefficient and reduce drag in both, subsonic and supersonic range of speed, which is absolutely unquestionable when looking at what the plane has been capable of doing thus far.
F-15 flight manual does not have any ITR charts, only STR charts so don't know where you're getting those turn numbers from. There are no published E-M diagrams that shows max turn rate for different Ps like seen for F-16C. Especially if numbers are from the Soviet estimates, those charts are again estimates which are off. This is F-15C turn rate with original F100-PW-100, which is actually weaker than the F100-PW-220 that most are equipped with (the F100-PW-220 usually have dynamic thrust equal to 102% engine trim for F100-PW-100).
iQ3nC.png


But the F-15 aerodynamic configuration only has superficial similarities to F-22, it may look similar but there are no sharp LERX to generate strong vortices, so this kind of comparison not useful they have quite different Cd and Cl curves and characteristics. So not going to take these numbers as indications of anything.
They also state that this is not possible with the F-22 in the case of TVC malfunction.

So, the use of the LEVCONs is extremly beneficial from the point of decreasing the aircraft's longitudinal relaxed stability, and they can bassicaly "unload" the horizontal and vertical tails, (while reducing trim drag) so that you can make them smaller, increasing L/D ratio in the procces.
I hear the argument from patent about able to recover from TVC malfunction but that's not even relevant failure mode of F-22, the nozzle when in failure mode always forces itself in neutral position and F-22 control surfaces are specifically sized to recover from any condition TVC puts it in. Maybe if F119 has gimbal TVC like AL-41F1 that can lock at a certain position it would be more relevant but that's not how the nozzle is designed.
A design feature useful for one aircraft is not always applicable to another.

Papers from Song Wencong can explain about design rationale behind J-20, not useful to extrapolate the performance of other aircraft with different geometries and shapes.

And I don't have time for further debate about the weight unless you can explain where all that excess weight is coming from. The F-22 is the size of the F-15C, and it is more than 7 tons heavier, while the F-35, which is a small single-engine fighter (with the same S duct - weapons bay layout as the F-22), is actually heavier than the F-15C!
Also, there is no data of any kind suggesting that the Su-57 is heavier, or as heavy as the F-22. On the contrary, it seems that the plane is lighter while being slightly bigger.
To me, it is obvious that the excess weight comes from the significant strengthening of the airframe, but I'm happy to hear your explanation.
Just to be clear, I don't think that the operational Su-57 is as light as Su-27, far from it! Felon also needs structural strenghtening for various reasons.
Reasoning is clear, because your argument seems to be that because of Su-57's wide fuselage, the lift distribution is less on the wings and more from the centroplane to reduce peak bending moment. Yet the overlay of the planforms between F-22 and Su-57 aren't dramatically different from each other.
0sh5v90ugdgc1.jpeg


And whatever differences in spanwise lift distribution, does not come close to making up for difference in structural depth. Because, tensile stresses scale inversely with area moment of inertia, which increases with the square of structural depth, and there is no denying the Su-57 structural depth is much thinner, especially in the area of peak loads at the wings.

Even considering all this, yes it's perfect possible Su-57 weighs less than F-22. Yet highly doubt it can weigh significantly less without certain compromises, for instance, max overload at allowable weights.

As far as airshow performance, F-22 usually ends their demo with more than half fuel, while Sukhoi demos generally start their demos at 56% fuel or less.
 
I think you just described disruptive camouflage...

It’s not like that camouflage does anything to make the aircraft more difficult to see, it just distracts from the elagant lines of the aircraft. Light grey aircraft are always more difficult to see as opposed to dark grey hense why 95% of all aircraft are light grey, while Sukhoi uses large blocky dark grey patterns and fugly ones at that. Like I said it’s a waste of time, money and resources and the end result = rice/crap.

No one besides some ricer kids would put silly decals, stickers or strange paints schemes on their cars. Yet when it’s done to aircraft some people applaud it. It’s a piece of military equipment not some graffiti wall.

This is what the aircraft should look like, clean, professional, efficient and sexy especially with the new nozzles, end of rant:

IMG_1997.jpeg
 
It’s not like that camouflage does anything to make the aircraft more difficult to see, it just distracts from the elagant lines of the aircraft. Light grey aircraft are always more difficult to see as opposed to dark grey hense why 95% of all aircraft are light grey, while Sukhoi uses large blocky dark grey patterns and fugly ones at that. Like I said it’s a waste of time, money and resources and the end result = rice/crap.

No one besides some ricer kids would put silly decals, stickers or strange paints schemes on their cars. Yet when it’s done to aircraft some people applaud it. It’s a piece of military equipment not some graffiti wall.

This is what the aircraft should look like, clean, professional, efficient and sexy especially with the new nozzles, end of rant:

View attachment 752779
I strongly disagree with you, sukhoi He perfectly understands how to make camouflage on airplanes and uses it on all his planes. Here is an example
View: https://youtu.be/YcAHH9OJUDs
 
I strongly disagree with you, sukhoi He perfectly understands how to make camouflage on airplanes and uses it on all his planes. Here is an example
View: https://youtu.be/YcAHH9OJUDs


Gloss black, bright green and bright white is an effective camouflage? Or bright white and grey like on SU-24s? Sukhoi might as well put a disco ball on their aircraft and paint them pink. I have seen Sukhois in real life and I have seen F-15s, Mirages, F-16s, F-18s, ect Russian aircraft are much easier to see. I have also always been into art so I understand perfectly well how colors work against backgrounds.

Which one of these two aircraft blend in better with the sky, the bright green/white/black SU-34 or the grey Rafale. Sukhoi does NOT use naturally occurring colors for their paint schemes nor does Sukhoi use any soft blending or natural texturing. Every one of Sukhois paint schemes (besides the SU-30SM) uses bright, glossy, not naturally occurring colors with rough edges and too much contrast.
 

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Supposedly the Su-57's IMA BK main multiprocessor computer, and the advanced HUD for the Su-57E:

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Detail of the new stealth nozzle:

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I find it strange Sukhoi is still using a HUD when they have apparently build a HUD into the visor of the helmet. I understand the need of a HUD on prototype aircraft and the serial models when the helmet is still in development but it would be strange if they keep the HUD after the helmet is ready. Seems like it would be very confusing and messy for the pilot when two HUDs are overlapping plus the cost and weight is unnecessary. Plus removing the HUD gives a better field of view as it takes up a lot of cockpit real estate.
 
Gloss black, bright green and bright white is an effective camouflage? Or bright white and grey like on SU-24s? Sukhoi might as well put a disco ball on their aircraft and paint them pink.
Do you know the story behind eggplant camo and who proposed it, to start with? I believe you don't.
 
Do you know the story behind eggplant camo and who proposed it, to start with? I believe you don't.

I don’t care about history of any camo, that is completely irrelevant nor do I care about outdated and flawed studies. What matters is function, no one with a strait face can tell me a bright black, green and white aircraft with hard lines will somehow blend in against the sky better than a light grey aircraft. Why does no one else use these magnificent “camouflage” colors if they are so effective? And yes, I know there are rare examples of western aircraft that are black for instance like the F-117 but that is because they have traditionally flown at night.

And I am Russian and have had pilots in my family….
 
Self-explaining.

Elaborate, as someone that has been around aircraft my entire life and as someone that understands how color blending works I just don’t understand the colors from Sukhoi. The early SU-27s were good and the SU-30SM and the similar colored SU-35s is good but everything else does not blend. BTW off topic but I painted this camouflage so as you can see im passionate about the topic.
 

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In his 63rd, he managed to withstand 9G for 20 sec. Man hard like a rock.

''Bogdan Sergey Leonidovich. Honored Test Pilot of the Russian Federation, Reserve Colonel, Hero of Russia (2011). Since 2000 - Head of the Flight Service of the Sukhoi Design Bureau. Born in 1962 in the city of Volsk, Saratov region. He served in a number of regions of Russia, in Mongolia, and took part in the operation in Syria.He likes to joke that he has been afraid of heights since childhood. Regularly goes to the fitness club, swimming pool and gym. Plays hockey and football. Climbed on Elbrus.''


Sergey Bogdan in T-50-4.jpg
 

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