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Influence of Mosaic Patterns on the Structural Integrity of Filament

Wound Composite Pressure Vessels

Article · March 2011

DOI: 10.1108/17579861111162932

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 International Journal of Structural Integrity
Influence of mosaic patterns on the structural integrity of filament wound composite
pressure vessels
Haris Hameed Mian, Hammad Rahman,
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Influence of
Influence of mosaic patterns mosaic patterns
on the structural integrity
of filament wound composite
345
pressure vessels
Haris Hameed Mian and Hammad Rahman
Department of Mechanical Engineering,
University of Engineering and Technology, Taxila, Pakistan
Downloaded by UNIVERSITY OF NOTTINGHAM At 00:46 20 March 2018 (PT)

Abstract
Purpose – Filament wound pressure vessels have a characteristic pattern observed in their helical
layers. These are mosaic-shaped patterns and affect the layer structural behavior. The present
research aims to focus on the influence of mosaic patterns on stress-strain field and structural design
of thin-walled internally pressurized filament wound pressure vessel. The widely used stress analysis
procedures and the commercially available finite element tools usually neglect the effect of the mosaic
patterns. The present work seeks to deal with the modeling and stress analysis of complete pressure
vessel, incorporating mosaic patterns.
Design/methodology/approach – The incorporation of the mosaic effect provides more realistic
modeling of the real stress distribution and the stress values compared to the conventional analyses
(the effect would depend on the shell structure, i.e. number of plies, relative thicknesses, etc.). The
structural analysis is performed using commercial finite element analysis (FEA) tools ANSYS.
Findings – The comparison of results of analytical solution and conventional FEA provides close
values of the stresses in the plies. As for the stress and strain distributions obtained by incorporating
the effect of mosaic patterns are considerably different. The distribution of the stress and strain fields
are not uniform along the length of the vessel and along its circumference and the maximum stresses
acting in the direction of the fibers are higher than those calculated using conventional FEA
techniques.
Originality/value – Previous work was limited to composite cylindrical shells, without
incorporating the end domes. The present work deals with the modeling and stress analysis of
complete pressure vessel, incorporating mosaic patterns.
Keywords Filament winding, Pressure vessels, Mosaic patterns, Stress analysis, Fatigue
Paper type Research paper

Introduction
The insistent passion of today’s modern industry and manufacturers’ to increase the
performance of their products is relentlessly driving the development of high performance
structural materials. Composite materials are one such category of materials that plays a
momentous role in current and future products. Composite materials are predominantly
attractive because of their exceptional strength-to-density and stiffness-to-density ratios
and better physical properties. To get such superior mechanical properties and economic
manufacturing necessitates better understanding of the manufacturing methods and International Journal of Structural
incorporating realistic features in the design and analysis phase. Integrity
Vol. 2 No. 3, 2011
Filament wound composite pressure vessels are an imperative type of high-pressure pp. 345-356
containers that are widely used in modern industries. Modeling and structural analysis of q Emerald Group Publishing Limited
1757-9864
these high performance pressure vessels are usually based on the mechanics of composite DOI 10.1108/17579861111162932
 IJSI laminates (Vasiliev and Morozov, 2007), considering only the fiber orientation, stacking
2,3 sequence and number of plies. But filament winding process creates a much more
complicated laminate geometry than does simple lamination methods. A simple laminated
composite consists of several plies and each ply has a unique fiber angle but a filament
wound composite has two fiber angles, þu and 2u, in each ply (Figure 1).
Furthermore, the filament wound composite has regions (Figure 2) where the fibers
346 cross each other (major crossover), where the fiber angle changes immediately (minor
crossover) and some regions similar to simple laminated composite (Barenberg, 1991).
All these regions unite to form a diamond shaped or triangular repeating mosaic
patterns with alternating ^u and 7u configurations. These alternating patterns
causes elastic coupling in the structure, influencing its mechanical response and
causing the structure to behave in an unconventional manner.
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Previously, the composite shells manufactured by filament winding were modeled as

laminated structure composed of orthotropic layers or separate plies having different
fiber orientation (Morozov, 2006). Both of these approaches are used in existing finite
element analysis (FEA) tools but these do not imitate the actual filament wound structure.
The present research is focused on how this manufacturing effect (mosaic patterns)
of filament winding process is incorporated in the modeling and analysis phase and
how these patterns influence the mechanical strength of filament wound composite
pressure vessels. The structural analysis incorporating the mosaic effect is first
performed on a cylindrical shell and the results of the analysis are compared with the
previous work (Morozov, 2006). The same modeling and analysis scheme is then

–q –q +q +q –q –q
+q –q +q

–q +q –q
Figure 1. +q +q –q –q +q +q
Fiber angles in filament ..... etc
wound composite
Layer 1 Layer 2 Layer 3

Major Minor
Figure 2. crossover crossover
(a) Filament wound tube
and (b) triangular mosaic
patterns of a wound
composite showing major (a) (b)
and minor crossovers
Source: www. carbonfibreexpress.com
 applied on a complete pressure vessel and the structural analysis highlighting the Influence of
strength characteristics is performed.
mosaic patterns
Mechanics of laminated structures
Composite structures are considered as a system of layers and are analytically modeled
using the classical laminated plate theory (Barenberg, 1991), sometimes modified to
include the edge effects, inter-laminar stresses or non linear effects. This theory 347
describes the elastic properties of a composite laminate but with certain assumptions
like the laminate consists of perfectly bonded lamina and the bonds are infinitesimally
thin, the laminate is thin and a straight line normal to the middle surface remains
straight and the strain perpendicular to the middle surface is ignored (Daniel and Ishai,
1994; Herakovich, 1998). The angle-ply layer is treated as an anti-symmetric
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balanced laminate consisting of þu and 2u unidirectional plies (Figure 3(a)) of same

thickness t/2.
The interface of the surface plies, which is the middle surface of the laminate,
is selected as a reference surface or reference plane. The strains at any point in the
laminate to the reference plane strains and the laminate curvatures are described by
the following relation (Daniel and Ishai, 1994; Herakovich, 1998):
2 3 2 03 2 3
1x 1x kx
6 7 6 7 6 7
6 1y 7 ¼ 6 1y 7
0
7 þ z6 ky 7 ð1Þ
4 5 6 4 5 4 5
gs 0 ks
gs

where 10x ; 10y ; g 0s and kx ; ky ; ks are the mid surface strains and curvatures, respectively,
and z is a general point through the laminate thickness.
The lamina compliance matrix in material coordinates (1, 2, 6) is given by:
2 3
S 11 S 12 0
6 7
½S
126 ¼ 6 S
4 12
S 22 0 7
5 ð2Þ
0 0 S 66

z y sy
ts = txy 1

2
t/2
sx sx
t/2 x
+q ts q Figure 3.
(a) Anti-symmetric
y x
–q angle-ply layers and
(b) stress components in
sy unidirectional lamina
(a) (b) referred to loading and
material axes
Sources: Daniel and Ishai (1994); Herakovich (1998)
 IJSI where:
1 y 21 y 12 1 1
2,3 S 11 ¼ ; S 12 ¼ 2 ; S 21 ¼ 2 ; S 22 ¼
; S 66 ¼
E1 E2 E1 E2 G12


E1
E 1 ; E 2 ; G12 and y 12 ; y 21 ¼ y 12 £
E2
348 are engineering constants of composite materials.
The lamina modulus matrix is calculated as:

½Q
126 ¼ ½S
21
126 ð3Þ
Generally, the lamina axes (1, 2) do not coincide with the loading or global axes (x, y)
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(Figure 3(b)). The modulus matrix is in the lamina coordinates and we have to
transform it into global coordinates, so the transformation matrix [T] is specified as
follows:
2 3 2 2 3
m2 n2 2mn m n2 22mn
6 2 7 6 2 7
½T
¼ 6
4 n m2 22mn 7 21
5 and ½T
¼ 4 n
6 m2 2mn 7 5 ð4Þ
2 2 2 2
2mn mn m 2 n mn 2mn m 2 n
where m ¼ cosu and n ¼ sinu:
The lamina global modulus matrix is specified as:
½Q
xys ¼ ½T
½Q
126 ½T 21
ð5Þ
The force and moment resultants are given as:
2 3 2 38 8 9 8 9 9
Nx Qxx Qxy Qxs > > >
> 10x >
> kx > > >
>Z > > Z zk >< >
> = >
6 7 X n 6 7 < zk < 0 = =
6 Ny 7 ¼ 6 Qyx Qyy Qys 7 1y dz þ ky zdz ð6Þ
4 5 4 5> > >
> zk21 >
> >
> zk21 >
: ks >
> ; >
Ns k¼1 Qsx Qsy Qss > : : g 0s >
> ; >
;
k8 8 9 9
2 3 2 3 8 9
Mx Qxx Qxy Qxs > > >
> 10x >> > k x > >
>
>Z > > Z zk <> = > >
6 7 X6 n 7 < zk < 0 = =
6 My 7 ¼ 6 Qyx Qyy Qys 7 1y zdz þ ky z dz
2
ð7Þ
4 5 4 5> > >
> zk21 >
> > zk21 >
: ks >
> > >
Ms k¼1 Qsx Qsy Qss > : : g 0s >
> ; ; >
;
k

where:
Qxx ¼ Q11 m 4 þ 2ðQ12 þ 2Q66 Þm 2 n 2 þ Q22 n 4

Qxy ¼ ðQ11 þ Q22 2 4Q66 Þm 2 n 2 þ Q12 ðn 4 þ m 4 Þ

Qyy ¼ Q11 n 4 þ 2ðQ12 þ 2Q66 Þm 2 n 2 þ Q22 m 4

ð8Þ
Qxs ¼ ðQ11 2 Q12 2 2Q66 Þm 3 n þ ðQ12 2 Q22 þ 2Q66 Þn 3 m

Qys ¼ ðQ11 2 Q12 2 2Q66 Þmn 3 þ ðQ12 2 Q22 þ 2Q66 Þnm 3

Qss ¼ ðQ11 þ Q22 2 2Q12 2 2Q66 Þm 2 n 2 þ Q66 ðn 4 þ m 4 Þ

 The above relations are expressed in terms of three laminate stiffness matrices [A], Influence of
[B] and [D], which are the functions of the geometry, material properties and stacking
sequence of the individual plies. These matrices are defined as follows:
mosaic patterns
X
N
½Aij
¼ ½Qij
K ðzk 2 zk21 Þ
k¼1
349
1X N  
½Bij
¼ ½Qij
K z2k 2 z2k21 ð9Þ
2 k¼1
  1X N  
Dij ¼ ½Qij
K z3k 2 z3k21
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3 k¼1

where:
Aij ¼ Laminate extensional stiffness or in-plane laminate moduli.
Bij ¼ Laminate coupled bending-extension stiffness.
Dij ¼ Laminate bending or flexural stiffness.
zk ¼ Distance of individual layer k from the laminate reference.
The overall load-deformation relations for this class of laminates are:
8 9 " #21 ( )
< 10xys = A B N
¼ ð10Þ
: kxys ; B D M

where: 10xys and kxys are the mid surface strains and curvatures. The plane stress
constitutive equation is given by:
{sxys } ¼ ½Qxys
{1xys } ð11Þ
Though the above approach do not take into account the real structure of filament
winding process, still it reflects the anisotropy of the angle-ply layer. This analytical
model works well for the laminated composite plates but does not consider the
alternating triangular shaped mosaic patterns (Figure 4).

Filament wound structure modeling and FEA

As discussed above the actual filament wound layer is composed of triangular-shaped
repeating units placed around the circumference and along the axis of rotation
(Morozov, 2006). One triangular unit consists of two plies that are either (þu /2u) or
(2u /þu) and equations (5) and (6) are applicable to these alternating units. The
conventional procedures available for the analysis of filament wound structures do not
take into account the effect of alternating units. Morozov (2006) developed the model
which takes into account these effects (Vasiliev and Morozov, 2007) and the model was
implemented in combination with FEA so as to investigate the mechanical behavior of
filament wound composite shells structures.
Depending on the numbered sequences of the fiber band placing order onto a
mandrel filament wound shells with 2-, 4-, 8- and 16-triangular-shaped units around the
 IJSI E1, E2, G12, V12 Engineering constants of unidirectional layer
2,3

[S]12
Compliance matrix
350

[Q]12 Modulus matrix/principal layer stiffness

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[Q]12 Fiber orientation

[Q]xy Transformed layer stiffness

hk, hk–1 Location of layer k surfaces

[A]x,y, [B]x,y, [D]x,y Laminate stiffness matrix

[N], [M] Mechanical loading

[eo]x,y, [k]x,y Reference plane strains and curvatures

z Location of point of interest in layer

[e]kx,y Layer strains

Figure 4.
Flow chart for analytical
model [s]kx,y Layer stresses

circumference are obtained (Vasiliev and Morozov, 2007). This model was justified by
observing similar effect for the physically tested thin-walled filament wound
composite cylinders with these manufacturing effects (Vorobey et al., 1992).
In order to study the effect of filament winding mosaic pattern same modeling technique,
geometric details, material properties and boundary conditions, as discussed above, was
followed and stress analysis of the cylindrical shell with different winding patterns was
performed. The solid model of the shell structure was developed using Autodesk Inventorw
and finite element analyses were performed using ANSYS 11.0w. Actual filament
wound cylindrical shell and the corresponding FEA model is shown in Figure 5.
 Elements Influence of
mosaic patterns

351

Figure 5.
(a) Actual filament wound
cylindrical shell and
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(a) (b) (b) rinite element model

of cylindrical shell
Source: Vasiliev and Morozov (2007)

The shells under study were composed of one filament-wound ^u angle ply and
internal pressure loading is applied. The cylindrical shell was modeled with winding
angle of ^608, length equal to 140 and 60 mm in diameter with a total thickness of
1.4 mm, with the thickness of each ply t ¼ 0.7 mm. Both the ends of the shell were fixed
and an internal pressure of 1 MPa is applied. The shell is constructed from
unidirectional glass epoxy having following mechanical properties: E1 ¼ 60 GPa,
E2 ¼ 13 GPa, G12 ¼ 3.4 GPa, n21 ¼ 0.3 (Vasiliev and Morozov, 2007).
The cylindrical shell was analyzed using the above obtained analytical approach and
conventional finite element approach utilizing the available elements for modeling
composite materials within ANSYS 11.0w. The cylindrical shells (2-, 4- and 8-unit)
incorporating the triangular shaped mosaic patterns were analyzed using the FEA tool. An
8-node linear-layered structural shell element “SHELL99” has been used in the analysis.
Both the undeformed and deformed models are shown in Figure 6. It can be seen
from the results that the deformation developed in the shell is quite different from the
deformation in conventional FEA technique. Also the contours are not uniform along
the axis of the cylinder and the deformation plots clearly display the effect of mosaic
patterns.
The stress values along the fibers s1 and s2 and shear stress t21 are shown in
Table I. The results of the stress analysis are very much similar to those obtained
in reference analysis (Morozov, 2006). The analytical solution results of stress values
are close to the conventional FEA results and the stress values for 2-unit cylinder are
higher as compared to the conventional results. This shows that increasing the number
of triangular units decreases the stress values along the fibers (Morozov, 2006).
The same modeling technique is applied to a filament wound composite pressure
vessel. The winding patterns must be carefully selected to avoid fiber slippage and shear
loads on the filament. The fiber slippage on the mandrel surface is affected by
parameters like temperature, mandrel shape, fiber-resin combination, surface treatment,
etc. (Madhavi et al., 2009). The ideal dome shape is an isotensoid or geodesic dome and its
shape is dependent on the diameter of pressure vessel and its polar openings. Geodesic
lines connect two points along the shortest distance over the surface (Murphy, 2002).
Non-geodesic domes are considered for vessels with unequal openings.
 IJSI
2,3

352
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(a)

(b)

(c)

Figure 6.
(d)
Deformed and undeformed
models Notes: (a) Conventional FEA; (b) 2-unit cylinder; (c) 4-unit cylinder; (d) 8-unit cylinder
 To investigate the influence of filament winding mosaic pattern, the stress analysis of Influence of
the composite pressure vessel with different mosaic structures was performed. mosaic patterns
The geometry of cylindrical portion of the vessel is same as in cylindrical shell case
and spherical domes are attached at both ends of the cylinder having same polar
opening diameter of 20 mm. The solid modeling of the vessel was developed using
Autodesk Inventorw and the FEA was performed using the ANSYS 11.0w techniques.
The actual filament wound pressure vessel and its equivalent FEA model are shown in 353
(Figure 7).
Each vessel was divided into triangular shaped mosaic units according to a specific
filament winding pattern. The geometric and material properties are same as
in previous case of cylindrical shell. The ends of the vessel were clamped (fixed) and
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the internal pressure of 1 MPa is applied. The stress analysis of the pressure vessel
have been performed first by conventional FEA and then by changing the size of the
mosaic triangles for three vessels.
The results of the stress analysis of pressure vessel showing both the undeformed
and deformed models are shown in Figure 8. The first vessel (Figure 8(a)) was analyzed
using the conventional FEA utilizing finite element models available in ANSYS 11.0w.
The other three vessels were partitioned to have 12-, 20- and 28-triangular units around
the circumference, respectively, and were analyzed using finite element modeling. The
mosaic pattern influence can be seen from the deformed results and the deformation
plot clearly indicates the influence of mosaic pattern.

Filament winding pattern s1 (MPa) s2 (MPa) t21 (MPa)

Table I.
Analytical solution 23.5 14.5 2.2 Stress analysis result
Conventional FEA 25.4 13.3 2.8 for analytical solution,
Two-unit filament wound cylinder 14.2-43.3 12-25 0.5-11 conventional FEA
Four-unit filament wound cylinder 12.5-36.4 10-20 2-9.5 and 2-, 4- and 8-unit
Eight-unit filament wound cylinder 10.6-28.2 9-15.4 2.6-4.8 cylinder

Elements

Figure 7.
(a) Actual filament wound
pressure vessel and
(b) finite element model
(a) (b) of filament wound
pressure vessel
Source: http://jkamc.com
 IJSI
2,3

354

(a)
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(b)

(c)

Figure 8.
Deformed and undeformed (d)
models Notes: (a) Conventional FEA; (b) 12-unit cylinder; (c) 20-unit cylinder; (d) 28-unit cylinder
 The calculated values of the stresses along the fibers s1 and s2 and shear stress t21 are Influence of
shown in Table II. The results of the stress analysis of pressure vessel show a similar mosaic patterns
trend as in the case of cylindrical shell. The distribution of stresses in the vessel is not
uniform along the axis and around the circumference. Also the stress values for 12-unit
vessel are higher compared to those of the conventional analysis. This indicates that
increasing the number of triangular units, correspondingly decreasing their size,
decreases values of stresses acting along the fibers. This is in accordance with the 355
physical testing of thin-walled composite cylinders with different filament winding
patterns (Vorobey et al., 1992).
The above results indicate that the stress values in filament wound composite shells
of revolution could be underrated in some cases when analyzing them by conventional
means. This shows that the mosaic patterns have great influence on the mechanical
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behavior of thin walled shell structures. Figure 9 shows a comparison of the results for
the stress analysis. The fiber stress values for the cylindrical shell are close to the
reference results (Morozov, 2006), also the pressure vessel analysis shows a similar trend
of stress values.

Conclusion
The stress analysis of filament wound composite shells of revolution incorporating the
mosaic patterns is presented in this study. It was found that these manufacturing
effects (mosaic patterns) have a pronounced effect on the mechanical behavior of thin
walled composite shells. The stress contours are not uniform along the axis and
circumference of shell and in some cases maximum stresses acting in the direction

Filament winding pattern s1 (MPa) s2 (MPa) t21 (MPa)

Conventional FEA 21.5 11.8 3.4 Table II.

12-Unit filament wound vessel 11.5-35.8 14-28 1.8-15 Stress analysis result for
20-Unit filament wound vessel 10.3-29.5 11-25 2.8-13.8 conventional FEA and
28-Unit filament wound vessel 9.8-24.6 8.4-13.6 2.1-6.5 12-, 20- and 28-unit vessel

Plot of stress vs filament winding pattern Plot of stress vs filament winding pattern
45 Reference results
45
Vessel results
Cylinder results
40 40
Stress along fibers (σ1) – MPa

Stress along fibers (σ1) – MPa

35 35
30 30
25 25

20 20

15 15

10 10

5 5
0 0 Figure 9.
Conventional FEA 2-Unit 4-Unit 8-Unit Conventional FEA 12-Unit 20-Unit 28-Unit Plot of fiber stress (s1)
(a) (b) with different filament
winding patterns
Notes: (a) Cylinder results Morozov (2006); (b) Pressure vessel results
 IJSI of the fibers are higher than those calculated using conventional FEA techniques. This
indicates that the stress values in filament wound composite shells (cylindrical and
2,3 pressure vessel) could be underestimated if the mosaic effect is not incorporated
in the analysis and there could be significant disparity in the stress values at the ply
level calculated for single-layered filament wound shells with different mosaic
patterns.
356
References
Barenberg, B.J. (1991), Effect of Interweaving on the Axial Compressive Strength and Modulus of
Filament-Wound Composite Cylinders, MIT, Cambridge, MA.
Daniel, I.M. and Ishai, O. (1994), Engineering Mechanics of Composite Materials,
Oxford University Press, Oxford.
Downloaded by UNIVERSITY OF NOTTINGHAM At 00:46 20 March 2018 (PT)

Herakovich, C.T. (1998), Mechanics of Fibrous Composites, Wiley, New York, NY.
Madhavi, M., Rao, K.V.J. and Narayana Rao, K. (2009), “Design and analysis of filament wound
composite pressure vessel with integrated-end domes”, Defence Science Journal, Vol. 59
No. 1.
Morozov, E.V. (2006), “The effect of filament-winding mosaic patterns on the strength of
thin-walled composite shells”, Elsevier Composite Structures, Vol. 76, pp. 123-9.
Murphy, J.C. (2002), “Filament-wound isotensoid pressure vessels having geodesic domes”,
European Patent EP0714753.
Vasiliev, V.V. and Morozov, E.V. (2007), Advanced Mechanics of Composite Materials, Elsevier,
Boston, MA.
Vorobey, V.V., Morozov, E.V. and Tatarnikov, O.V. (1992), Analysis of Thermostressed
Composite Structures, Mashinostroenie, Moscow (in Russian).

Further reading
Dong-xia, L., Liang, L. and Ming, L. (2010), “Nonlinear finite element analysis of mechanical
characteristics on CFRP composite pressure vessels”, IOP Conference Series: Materials
Science and Engineering, Vol. 10.
Jensen, D.W. and Pai, S.P. (1993), “Theoretical sensitivity of composite cylinders in compression
to filament-winding pattern”, Proceedings of the 9th International Conference on
Composite Materials (ICCM-9), Madrid, Vol. 3, pp. 447-54.
Radulović, J. (2009), “Filament wound composite tubes: experimental and numerical simulations
results”, Scientific Technical Review, Vol. LIX No. 2.
Velosa, J.C., Nunes, J.P., Antunes, P.J., Silva, J.F. and Marques, A.T. (2007), “Development of a
new generation of filament wound composite pressure cylinders”, Ciência e Tecnologia dos
Materiais, Vol. 19.

Corresponding author
Haris Hameed Mian can be contacted at: [email protected]

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 This article has been cited by:

1. Md. Sayem Uddin, Evgeny V. Morozov, Krishnakumar Shankar. 2014. The effect of filament winding
mosaic pattern on the stress state of filament wound composite flywheel disk. Composite Structures 107,
260-275. [CrossRef]
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