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Kaščák Ľ, Varga J, Bidulská J, Bidulský R. Simulation of 316L Stainless Steel Produced the Laser Powder Bed Fusion Process. Materials (Basel) 2023; 16:7653. [PMID: 38138795 PMCID: PMC10744782 DOI: 10.3390/ma16247653] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/26/2023] [Revised: 12/06/2023] [Accepted: 12/08/2023] [Indexed: 12/24/2023]
Abstract
Additive manufacturing is increasingly being used in the production of parts of simple as well as complex shapes designed for various areas of industry. Prevention of errors in the production process is currently enabled using simulation tools that have the function of predicting possible errors and, at the same time, providing a set of information about the behaviour of the material in the metal additive manufacturing process. This paper discusses the simulation processes of 316L stainless steel produced using the laser powder bed fusion (L-PBF) process. Simulation of the printing process in the Simufact Additive simulation program made it possible to predict possible deformations and errors that could occur in the process of producing test samples. After analysing the final distortion already with compensation, the simulation values of maximum deviation -0.01 mm and minimum -0.13 mm were achieved.
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Affiliation(s)
- Ľuboš Kaščák
- Department of Technology, Materials and Computer-Aided Production, Faculty of Mechanical Engineering, Technical University of Košice, Letná 9, 04002 Košice, Slovakia;
| | - Ján Varga
- Department of Technology, Materials and Computer-Aided Production, Faculty of Mechanical Engineering, Technical University of Košice, Letná 9, 04002 Košice, Slovakia;
| | - Jana Bidulská
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, Vysokoškolská 4, 04200 Košice, Slovakia
| | - Róbert Bidulský
- Bodva Industry and Innovation Cluster, Budulov 174, 04501 Moldava and Bodvou, Slovakia;
- Advanced Research and Innovation Hub, Budulov 174, 04501 Moldava and Bodvou, Slovakia
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Petroušek P, Kvačkaj T, Bidulská J, Bidulský R, Grande MA, Manfredi D, Weiss KP, Kočiško R, Lupták M, Pokorný I. Investigation of the Properties of 316L Stainless Steel after AM and Heat Treatment. Materials (Basel) 2023; 16:ma16113935. [PMID: 37297069 DOI: 10.3390/ma16113935] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/20/2023] [Revised: 05/12/2023] [Accepted: 05/22/2023] [Indexed: 06/12/2023]
Abstract
Additive manufacturing, including laser powder bed fusion, offers possibilities for the production of materials with properties comparable to conventional technologies. The main aim of this paper is to describe the specific microstructure of 316L stainless steel prepared using additive manufacturing. The as-built state and the material after heat treatment (solution annealing at 1050 °C and 60 min soaking time, followed by artificial aging at 700 °C and 3000 min soaking time) were analyzed. A static tensile test at ambient temperature, 77 K, and 8 K was performed to evaluate the mechanical properties. The characteristics of the specific microstructure were examined using optical microscopy, scanning electron microscopy, and transmission electron microscopy. The stainless steel 316L prepared using laser powder bed fusion consisted of a hierarchical austenitic microstructure, with a grain size of 25 µm as-built up to 35 µm after heat treatment. The grains predominantly contained fine 300-700 nm subgrains with a cellular structure. It was concluded that after the selected heat treatment there was a significant reduction in dislocations. An increase in precipitates was observed after heat treatment, from the original amount of approximately 20 nm to 150 nm.
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Affiliation(s)
- Patrik Petroušek
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Tibor Kvačkaj
- Bodva Industry and Innovation Cluster, Budulov 174, 04501 Moldava nad Bodvou, Slovakia
| | - Jana Bidulská
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Róbert Bidulský
- Bodva Industry and Innovation Cluster, Budulov 174, 04501 Moldava nad Bodvou, Slovakia
| | - Marco Actis Grande
- Department of Applied Science and Technology (DISAT), Politecnico di Torino, Viale T. Michel 5, 15121 Alessandria, Italy
| | - Diego Manfredi
- Department of Applied Science and Technology (DISAT), Polythecnic of Turin, Corso Duca degli Abruzzi 24, 10129 Torino, Italy
| | - Klaus-Peter Weiss
- Institute for Technical Physics, Karlsruhe Institute of Technology (KIT), 76344 Eggenstein-Leopoldshafen, Germany
| | - Róbert Kočiško
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Miloslav Lupták
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Imrich Pokorný
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
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Mulidrán P, Spišák E, Tomáš M, Majerníková J, Bidulská J, Bidulský R. Impact of Blank Holding Force and Friction on Springback and Its Prediction of a Hat-Shaped Part Made of Dual-Phase Steel. Materials (Basel) 2023; 16:811. [PMID: 36676548 PMCID: PMC9860678 DOI: 10.3390/ma16020811] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 12/22/2022] [Revised: 01/10/2023] [Accepted: 01/12/2023] [Indexed: 06/17/2023]
Abstract
Formability and its prediction of high-strength steels is an important research subject for forming specialists and researchers in this field. Springback and its accurate prediction of high-strength steels are very common issues in metal forming processes. In this article, the impact of blank holding force and friction on the parts springback made of dual-phase steel was studied. Numerical predictions of the springback effect were conducted using nine combinations of yield criteria and hardening rules. Results from experiments were evaluated and compared with results from numerical simulations. The use of lower blank holding forces and PE foil can reduce springback by a significant amount. Numerical simulations where the Yoshida-Uemori hardening rule was applied produced more accurate springback prediction results compared to simulations that used Krupkowski and Hollomon's isotropic hardening rules in number of cases.
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Affiliation(s)
- Peter Mulidrán
- Institute of Technology and Materials Engineering, Faculty of Mechanical Engineering, Technical University of Košice, Mäsiarska 74, 040 01 Kosice, Slovakia
| | - Emil Spišák
- Institute of Technology and Materials Engineering, Faculty of Mechanical Engineering, Technical University of Košice, Mäsiarska 74, 040 01 Kosice, Slovakia
| | - Miroslav Tomáš
- Institute of Technology and Materials Engineering, Faculty of Mechanical Engineering, Technical University of Košice, Mäsiarska 74, 040 01 Kosice, Slovakia
| | - Janka Majerníková
- Institute of Technology and Materials Engineering, Faculty of Mechanical Engineering, Technical University of Košice, Mäsiarska 74, 040 01 Kosice, Slovakia
| | - Jana Bidulská
- Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenskeho 10, 040 01 Kosice, Slovakia
| | - Róbert Bidulský
- Bodva Industry and Innovation Cluster, Budulov 174, 045 01 Moldava nad Bodvou, Slovakia
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Kočiško R, Kvačkaj T, Bidulská J, Bidulský R, Petroušek P, Pokorný I, Lupták M, Actis Grande M. Evaluation of Powder Metallurgy Workpiece Prepared by Equal Channel Angular Rolling. Materials (Basel) 2023; 16:ma16020601. [PMID: 36676337 PMCID: PMC9860864 DOI: 10.3390/ma16020601] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/15/2022] [Revised: 01/03/2023] [Accepted: 01/05/2023] [Indexed: 06/12/2023]
Abstract
The aim of the article is to examine the workability of sintered powder material of aluminum alloy (Alumix 321) through severe plastic deformations under the conditions of the equal channel angular rolling (ECAR) process. Accordingly, the stress-strain analysis of the ECAR was carried out through a computer simulation using the finite element method (FEM) by Deform 3D software. Additionally, the formability of the ALUMIX 321 was investigated using the diametrical compression (DC) test, which was measured and analyzed by digital image correlation and finite element simulation. The relationship between failure mode and stress state in the ECAR process and the DC test was quantified using stress triaxiality and Lode angle parameter. It is concluded that the sintered powder material during the ECAR processing failure by a shearing fracture because in the fracture location the stress conditions were close to the pure shear (η and θ¯ ≈ 0). Moreover, the DC test revealed the potential role as the method of calibration of the fracture locus for stress conditions between the pure shear and the axial symmetry compression.
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Affiliation(s)
- Róbert Kočiško
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Tibor Kvačkaj
- Bodva Industry and Innovation Cluster, Budulov 174, 04501 Moldava nad Bodvou, Slovakia
| | - Jana Bidulská
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Róbert Bidulský
- Bodva Industry and Innovation Cluster, Budulov 174, 04501 Moldava nad Bodvou, Slovakia
| | - Patrik Petroušek
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Imrich Pokorný
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Miloslav Lupták
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenského 11, 04001 Kosice, Slovakia
| | - Marco Actis Grande
- Department of Applied Science and Technology (DISAT), Politecnico di Torino, Viale T. Michel 5, 15121 Alessandria, Italy
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Fracchia E, Bidulská J, Bidulský R, Actis Grande M. MIG and TIG Joining of AA1070 Aluminium Sheets with Different Surface Preparations. Materials (Basel) 2022; 15:ma15020412. [PMID: 35057129 PMCID: PMC8781138 DOI: 10.3390/ma15020412] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/28/2021] [Revised: 01/02/2022] [Accepted: 01/04/2022] [Indexed: 02/01/2023]
Abstract
In this work, AA1070 aluminium alloy sheets are joined using TIG and MIG welding after three different edge preparations. Shearing, water jet and plasma-cut processes were used to cut sheets, subsequently welded using ER5356 and ER4043 filler metals for TIG and MIG, respectively. Mechanical properties of the obtained sheets were assessed through tensile tests obtaining a relation between sheet preparation and welding tightness. Micro-hardness measures were performed to evaluate the effects of both welding and cutting processes on the micro-hardness of the alloy, highlighting that TIG welding gives rise to inhomogeneous micro-hardness behaviour. After tensile tests, surface fractures were observed employing scanning electron microscopy to highlight the relation between tensile properties and edge preparations. Fractures show severe oxidation in the water jet cut specimens, ductile fractures and gas porosities.
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Affiliation(s)
- Elisa Fracchia
- Department of Management and Production Engineering (DIGEP), Polytechnic of Turin, Corso Duca degli Abruzzi 24, 10129 Torino, Italy;
| | - Jana Bidulská
- EPMA PM R&D Centre, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Park Komenskeho 10, 040 01 Kosice, Slovakia
- Correspondence:
| | - Róbert Bidulský
- Asian Innovation Hub, Budulov 174, 045 01 Moldava nad Bodvou, Slovakia;
| | - Marco Actis Grande
- Department of Applied Science and Technology (DISAT), Polytechnic of Turin, Viale T. Michel 5, 15121 Alessandria, Italy;
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Kvackaj T, Bidulská J, Bidulský R. Overview of HSS Steel Grades Development and Study of Reheating Condition Effects on Austenite Grain Size Changes. Materials (Basel) 2021; 14:ma14081988. [PMID: 33921092 PMCID: PMC8071465 DOI: 10.3390/ma14081988] [Citation(s) in RCA: 12] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/08/2021] [Revised: 04/09/2021] [Accepted: 04/11/2021] [Indexed: 11/16/2022]
Abstract
This review paper concerns the development of the chemical compositions and controlled processes of rolling and cooling steels to increase their mechanical properties and reduce weight and production costs. The paper analyzes the basic differences among high-strength steel (HSS), advanced high-strength steel (AHSS) and ultra-high-strength steel (UHSS) depending on differences in their final microstructural components, chemical composition, alloying elements and strengthening contributions to determine strength and mechanical properties. HSS is characterized by a final single-phase structure with reduced perlite content, while AHSS has a final structure of two-phase to multiphase. UHSS is characterized by a single-phase or multiphase structure. The yield strength of the steels have the following value intervals: HSS, 180–550 MPa; AHSS, 260–900 MPa; UHSS, 600–960 MPa. In addition to strength properties, the ductility of these steel grades is also an important parameter. AHSS steel has the best ductility, followed by HSS and UHSS. Within the HSS steel group, high-strength low-alloy (HSLA) steel represents a special subgroup characterized by the use of microalloying elements for special strength and plastic properties. An important parameter determining the strength properties of these steels is the grain-size diameter of the final structure, which depends on the processing conditions of the previous austenitic structure. The influence of reheating temperatures (TReh) and the holding time at the reheating temperature (tReh) of C–Mn–Nb–V HSLA steel was investigated in detail. Mathematical equations describing changes in the diameter of austenite grain size (dγ), depending on reheating temperature and holding time, were derived by the authors. The coordinates of the point where normal grain growth turned abnormal was determined. These coordinates for testing steel are the reheating conditions TReh = 1060 °C, tReh = 1800 s at the diameter of austenite grain size dγ = 100 μm.
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Affiliation(s)
- Tibor Kvackaj
- Department of Plastic Deformation and Simulation Processes, Faculty of Materials, Metallurgy and Recycling, Institute of Materials and Quality Engineering, Technical University of Kosice, Vysokoskolska 4, 04200 Kosice, Slovakia;
- Correspondence:
| | - Jana Bidulská
- Department of Plastic Deformation and Simulation Processes, Faculty of Materials, Metallurgy and Recycling, Institute of Materials and Quality Engineering, Technical University of Kosice, Vysokoskolska 4, 04200 Kosice, Slovakia;
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Kapoor G, Kvackaj T, Heczel A, Bidulská J, Kočiško R, Fogarassy Z, Simcak D, Gubicza J. The Influence of Severe Plastic Deformation and Subsequent Annealing on the Microstructure and Hardness of a Cu-Cr-Zr Alloy. Materials (Basel) 2020; 13:ma13102241. [PMID: 32414095 PMCID: PMC7288192 DOI: 10.3390/ma13102241] [Citation(s) in RCA: 9] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/22/2020] [Revised: 05/08/2020] [Accepted: 05/11/2020] [Indexed: 11/16/2022]
Abstract
A Cu–1.1%Cr–0.04%Zr (wt.%) alloy was processed by severe plastic deformation (SPD) using the equal channel angular pressing (ECAP) technique at room temperature (RT). It was found that when the number of passes increased from one to four, the dislocation density significantly increased by 35% while the crystallite size decreased by 32%. Subsequent rolling at RT did not influence considerably the crystallite size and dislocation density. At the same time, cryorolling at liquid nitrogen temperature yielded a much higher dislocation density. All the samples contained Cr particles with an average size of 1 µm. Both the size and fraction of the Cr particles did not change during the increase in ECAP passes and the application of rolling after ECAP. The hardness of the severely deformed Cu alloy samples can be well correlated to the dislocation density using the Taylor equation. Heat treatment at 430 °C for 30 min in air caused a significant reduction in the dislocation density for all the deformed samples, while the hardness considerably increased. This apparent contradiction can be explained by the solute oxygen hardening, but the annihilation of mobile dislocations during annealing may also contribute to hardening.
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Affiliation(s)
- Garima Kapoor
- Department of Materials Physics, Eötvös Loránd University, P.O.B.32, H-1518 Budapest, Hungary; (G.K.); (A.H.)
| | - Tibor Kvackaj
- Department of Plastic Deformation and Simulation Processes, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, 042 00 Košice, Slovakia; (T.K.); (J.B.); (R.K.); (D.S.)
| | - Anita Heczel
- Department of Materials Physics, Eötvös Loránd University, P.O.B.32, H-1518 Budapest, Hungary; (G.K.); (A.H.)
| | - Jana Bidulská
- Department of Plastic Deformation and Simulation Processes, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, 042 00 Košice, Slovakia; (T.K.); (J.B.); (R.K.); (D.S.)
| | - Róbert Kočiško
- Department of Plastic Deformation and Simulation Processes, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, 042 00 Košice, Slovakia; (T.K.); (J.B.); (R.K.); (D.S.)
| | - Zsolt Fogarassy
- Institute for Technical Physics and Materials Science, Centre for Energy Research, Konkoly-Thege út 29-33, H-1121 Budapest, Hungary;
| | - Dusan Simcak
- Department of Plastic Deformation and Simulation Processes, Faculty of Materials, Metallurgy and Recycling, Technical University of Košice, 042 00 Košice, Slovakia; (T.K.); (J.B.); (R.K.); (D.S.)
| | - Jenő Gubicza
- Department of Materials Physics, Eötvös Loránd University, P.O.B.32, H-1518 Budapest, Hungary; (G.K.); (A.H.)
- Correspondence: ; Tel.: +36-1-372-2876
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Fracchia E, Gobber FS, Rosso M, Actis Grande M, Bidulská J, Bidulský R. Junction Characterization in a Functionally Graded Aluminum Part. Materials (Basel) 2019; 12:ma12213475. [PMID: 31652888 PMCID: PMC6861949 DOI: 10.3390/ma12213475] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/11/2019] [Revised: 10/19/2019] [Accepted: 10/22/2019] [Indexed: 11/16/2022]
Abstract
Aluminum alloys are widely used to produce automotive components, thanks to their great mechanical properties-to-density ratio. Engine components such as pistons are conventionally produced by casting of Al-Si eutectic alloys (Silumin alloys) such as EN AC 48000. Due to the harsh working conditions and the lower ductility if compared to aluminum-silicon alloys with lower silicon content, pistons made of this alloy are prone to fatigue failures in the skirt region. In order to overcome such limits, the use of a Functionally Graded Material (FGM) in the production of a piston is proposed. The adoption of a functionally graded architecture can maximize the properties of the component in specific areas. A higher level of thermal resistance in the crown of the piston can be achieved with EN AC 48000 (AlSi12CuNiMg), while higher elongation at rupture in the skirt region would be conferred by an EN AC 42100 (AlSi9Mg0.3). The FGM properties are strictly related to the metallurgical bonding between the alloys as well as to the presence of intermetallic phases in the alloys junction. In the present article, the characterization of gravity casted FGM samples based on Al-Si alloys with respect to microstructure and mechanical testing is presented, with a specific focus on the characterization by impact testing of the joint between the two alloys.
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Affiliation(s)
- Elisa Fracchia
- Politecnico di Torino, Department of Applied Science and Technology (DISAT), Viale T. Michel 5, 15121 Alessandria, Italy.
| | - Federico Simone Gobber
- Politecnico di Torino, Department of Applied Science and Technology (DISAT), Viale T. Michel 5, 15121 Alessandria, Italy.
| | - Mario Rosso
- Politecnico di Torino, Department of Applied Science and Technology (DISAT), Viale T. Michel 5, 15121 Alessandria, Italy.
| | - Marco Actis Grande
- Politecnico di Torino, Department of Applied Science and Technology (DISAT), Viale T. Michel 5, 15121 Alessandria, Italy.
| | - Jana Bidulská
- Department of Plastic Deformation and Simulation Processes, Institute of Materials and Quality Engineering, Faculty of Materials, Metallurgy and Recycling, Technical University of Kosice, Vysokoskolska 4, 04200 Kosice, Slovakia.
| | - Róbert Bidulský
- Agency for the Support of Regional Development Kosice, Kosice Self-Governing Region, Strojarenská 3, 04001 Kosice, Slovakia.
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