Advanced Ceramics - Midlands Industrial Ceramics Group

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AdvancedCeramicsAn industry of the futureSector Profile for the Midlands (UK) - 2021

IntroductionThis sector profile evidences demand forthe rapid expansion of advanced ceramics,and the Midlands is well positioned togrow and create jobs in this industry.This report was commissioned by the Midlands IndustrialCeramics Group (MICG) (an academic and industrial consortium)in partnership with the Midlands Engine Observatory1 . Itspurpose is to raise awareness of the importance of advancedceramics to UK industry and highlight the opportunities forgrowth in the Midlands.Advanced ceramics, which are also referred to as technicalceramics, underpin many industries. They are embedded innumerous high-performing products owing to their highstrength, high operating temperatures, wear resistance andtailorable properties and are replacing metals in applicationswhere advantageous. They make an important contributionto the global competitiveness of the United Kingdom’s (UK’s)manufacturing sector.The sector is growing rapidly across the world. The Midlands has key strengths in advanced ceramicsowing to its growing advanced ceramics supply chains, large end user manufacturers and its leadingacademic institutions. These strengths provide the Midlands with a significant opportunity toincrease its global competitiveness and grow jobs.This sector profile answers the following key questions: What are advanced ceramics, why are they important, what key challenges are they solving? What is the size of the global market and its expected growth rates? What are the Midlands’ strengths in this sector and why do we propose it has comparative /competitive advantage? What are the challenges facing the sector and what are the proposals in the Midlands to tacklethese? What are the expected benefits of investing in advanced ceramics in the Midlands?This report has been informed by sixty in-depth consultations with industry representativesconducted in 2018 and 2020 by SQW and City-REDI (City-Region Economic Development Institute)at the University of Birmingham. It draws on qualitative analysis and quantitative data to summarisethe global opportunities and the strengths in the Midlands.1. The Midlands Engine Economic Observatory is a part of the Midlands Engine, providing comprehensive and contemporary data, analysis andintelligence on the whole Midlands economy. The Midlands Engine partnership brings together public sector partners and businesses to complementthe activity of local and combined authorities, LEPs, universities, businesses and others. We are generating added value for the whole of the Midlands, itscommunities and the wider UK.3

What are Advanced Ceramics?Introducing Advanced CeramicsAdvanced ceramics are inorganic, non-metallicmaterials which exhibit an extensive range ofhigh-performing properties and behaviours.They can be divided into two categories: Functional ceramics – which display specificelectrical, electronic, magnetic or opticalproperties and performanceStructural ceramics – which displayadvantageous mechanical and thermalproperties and behaviours.With the development of new ceramics theseboundaries are becoming increasingly blurred,as can be seen, for example, in bio-ceramicswhich exhibit both structural and functionalproperties.Materials are increasingly required to operatein ever more demanding environments. Theirunique set of properties make ceramics thematerial of choice in many applications.Ceramics are often used in hidden, niche orspecialist components but are hugely importantto the UK in that they unlock performance in awide range of high-tech industries, includingaerospace (jet engines) energy (fuel cells,batteries), automotive (brakes, sensors andengine components), telecommunications andIT (electronics), defence (rocket parts, antennasand armour), healthcare (artificial hips, teeth,etc.) and many other sectors where they areidentified as the ‘only material that will work’.Figure 1: Composition of Advanced CeramicsWhy Ceramics?Ceramics provide a combination of hardness,chemical resistance, strength and hightemperature operation not found in alternativematerials such as metal, alloys and polymers,(Figure 1).A good example of the benefits of ceramicsare ceramic matrix composites (CMCs). Thesecomprise a ceramic body reinforced by ceramicfibres, and typically exhibit significantlyenhanced toughness.4In addition, they have the attractive ceramicproperties of low density, good compressivestrength and excellent thermal and chemicalresistance.This makes CMCs ideal as lightweightreplacements for alloys in high temperatureaggressive environments, such as turbineengines and exhaust systems, where they canbring significant improvements in performance,emissions, and fuel consumption.5

Future Sector: the roleof Advanced Ceramics inSpaceThe Space sector is an important contributor to the UK Economy,delivering approximately 15 billion Gross Value Added (GVA) perannum with a strong rate of growth. Its importance is recognisedby the UK Government in the Industrial Strategy and the ambitionis to grow the sector to 40 billion per annum by 2030, capturing asignificant share of the global market and creating 100,000 new jobs.The Midlands has key strengths in the space sector with the ambitionsfor Space Park Leicester (aligned to Leicester University) and a numberof high-profile advanced manufacturers growing into the space sector.It is anticipated the growing advanced ceramics sector in the Midlandswill both benefit from the growing demand from the space sector, andhelp to reinforce the competitiveness of UK space companies throughthe development of innovative high-performing materials.The benefits of advanced ceramics for the space sector is their abilityto respond to the distinctive engineering challenges posed by the‘hostile’ outer space environment, intense pressure caused duringspace craft launch and collisions with ‘space junk’.Precision Ceramics based in Birmingham have designed andmanufactured a series of highly technical ceramic components usingShapal for the unmanned space-craft Cassini–Huygens sent to theplanet Saturn. Shapal Hi-M Soft is a ceramic which combines goodheat resistance, high mechanical strength and bending strengths of30 kg/mm2 giving a perfect combination of properties for spacecraft. Precision Ceramics is the principal UK distributor for Shapalwhich forms an important part of the company’s wide portfolio oftechnical ceramics available for an ever-increasing array of worldwideapplications.The Moog Space and Defence Group is another example of a businessexploring the use of advanced ceramics in the development of theirspace vehicles including high reliability cost effective spacecraft buses,and propulsive secondary payload adapters.67

SizeOpportunitySize ofof theOpportunityThe advanced ceramics sector is growingrapidly across the world. Grandview Researchestimated that the advanced ceramics sectorachieved annual global revenues of 42 billion in2015 and projected the sector would reach 143billion by 2025.The sector is rapidly growing in the UK:Grandview Research estimated that the UKmarket for advanced ceramics is expected togrow at 12.8% per annum until 2024 (Table 1).By comparison Grandview2 estimates the globalbiotechnology market will grow by 7.4% perannum to 2025.Advanced ceramics are used in a variety of keyUK strategic industrial sectors. Table 2 providesestimates of revenues generated by businessesproviding advanced ceramics and support in theiradoption by end user.Collectively, these sectors - such as Aerospace,Medicine and Energy - make a substantialcontribution to the national and regionaleconomy.In terms of revenue, the electronics end-userindustry segment is estimated to have thelargest share, with nearly 44% of the totalmarket (Figure 2), in 2020.However, the medical end-user segmentis expected to register the highest growthduring the forecast period. In the medicalindustry, advanced ceramics are used in allkinds of medical devices and equipment, suchas ultrasonic tools, infusion pumps, dialysismachines and diagnostic equipment.Table 1: Estimated advanced ceramics market revenue, by end user industries, 2013-2024 ( m US)Figure 2: Advanced Ceramics Market (Revenue share % by end-user)Table 2: Size of key sectors in 2018 where advanced ceramics enables product innovation (Total GVA millions)Source: Mordor Intelligence Analysis2 Grandview (2017). Biotechnology Market Size, Share & Trends Analysis Report By Application (Health, Food & Agriculture, Natural Resources & Environment, IndustrialProcessing Bioinformatics), By Technology, And Segment Forecasts, 2018 – 2025.89

International ExportOpportunitiesInternationally the export opportunities for UK advanced ceramics aresubstantial and are expected to grow. The major factors driving thegrowth of the advanced ceramics market are the growing demand inthe medical industry and the rise in use as an alternative to metals andplastics.The UK is competing with other major economies to supply productsand gain a share of the global advanced ceramics market. Theambition of many UK suppliers is to become not only a domesticleader but an international competitor.Measured by revenue, the Asia-Pacific region (predominantly madeup from China, Japan and South Korea) is estimated to have thelargest share of the global market, with 54% of the total market in2020, followed by the USA with 26%, compared to Europe’s shareof 17%. The markets that dominate advanced ceramics productionare generally characterised as developed economies with stronginnovation capabilities and a highly skilled workforce.The City-REDI and SQW consultation with UK businesses evidencedthe widely held view that for the UK to be internationally competitivewith the industry in the United States, Germany and the Far East, itneeds to embrace and support the innovation process and facilitateeffective R&D. Supporting R&D in the industry will break new groundand help to innovate new practices to enable the creation of productsfor the various sectors it supports.Alan McLelland of Morgan Advanced Materials said: ‘The advancedceramics sector is forecast to continue to grow globally at a rapid ratewhich provides the organisation with significant potential to createadditional jobs and exports, including at our key operational siteswithin the Midlands’.‘Midlands advanced ceramicsinnovation and production will helpus grow our supply chains locally andimprove the competitiveness of ourproducts, all of which would help thebalance of trade for the UK.’– Ian Edmonds, Rolls-Royce PLC1011

AdvancedCeramics Assets in the MidlandsSize of OpportunityThe UK advanced ceramics industry has asignificant cluster in the Midlands, with aclear opportunity to grow. This is confirmed byresearch undertaken in 2020 by City-REDI andSQW. No other UK region has the equivalentmass of advanced ceramics specialist suppliers,end users and researchers.The Midlands is home to three world-classuniversities that are at the forefront of researchinto advanced ceramics and who are investingin research scientists of the future by supportingPhD students and post-doctoral studentssupported by leading academics in the field.The Midlands has the largest cluster ofadvanced ceramics producers in the UK.These producers form an integral part of theMidlands manufacturing supply chain, as well asexporting specialist products across the world.These companies include Morgan AdvancedMaterials, Mantec Technical Ceramics, PrinceMaterials, CDS group, Precision Ceramics, PCLCeramics, Foseco and Trelleborg who are allfounding members of the Midlands IndustrialCeramics Group (this is not an exhaustive list ofactive companies in the Midlands).The University of Birmingham has extensiveexperience of processing and characterisingceramics, including the use of techniques suchas additive manufacturing, green forming andsintering amongst many others. There areseveral research groups within the Universitywith interests in ceramics, including biomaterials,engineering ceramics, functional ceramics andelectronic ceramics - the latter with particularexpertise in battery technology. The groupsinteract with a wide range of organisations,including Rolls-Royce, BAE Systems, DSTL andmany others.In the Midlands there is a concentrationof manufacturers that will increasinglyuse advanced ceramics in their products,creating a critical mass of advanced ceramicscustomers. These include companies withinthe automotive and aerospace sectors; andcompanies within the rapidly growing energyand med-tech sectors, (Table 2). Three endusers, Rolls-Royce and JCB, and AEONEngineering are founding members of theMICG and have a keen interest in improvingtheir advanced ceramic supply chains andcollaborating to deliver ceramics technologyimprovements.The University of Leicester is home to theMechanics of Materials (MoM) Research Groupwhich has expertise in advanced ceramicsincluding biomaterials and medical devices,digital twin of ceramic processing (computerstimulations) and corrosion of engineeringsystems. Within MoM are located a numberof specialist centres and facilities includingthe Advanced Microscopy Facility which hasequipment and sophisticated software forimage analysis, image processing and X-raycharacterisation of materials, with facilities forrapid report generation.Lucideon is a private company based inStoke-on-Trent and is a gla global leadingdevelopment, testing and commercialisationbusiness. A subsidiary company of Lucideon,AMRICC, houses pilot lines that helps companiesexploit new advanced ceramics technologiesand commercialise new products. Its ambitionis to significantly grow these facilities. ThroughAMRICC, Lucideon is also leading on thevocational curriculum development for advancedceramicists with leading Midlands skillsproviders.12Figure 3: Location of members of the consortium within the region [Source MICG 2020]Loughborough University provides accessto research infrastructure, with particularstrengths in ceramics, which includes theLoughborough Materials Characterisation Centre(LMCC), Additive Manufacturing, Field AssistedProcessing, and the HPC-Midlands, a Tier-2 HighPerformance Computing centre with a focuson Engineering and Physical Sciences, fundedby EPSRC. The University is also host to theLoughborough University Science and EnterprisePark - a thriving and collaborative innovationcommunity of over 80 knowledge-basedcompanies and world-class research centres.13

SizeCeramics in the MidlandsSize ofof AdvancedOpportunityThe Midlands has a significant share of nationalemployment in both traditional and advancedceramics. Table 3 shows the number of jobs thatgeneral and technical (advanced) ceramics employsacross the region’s Local Enterprise Partnershipgeographies. The 7,050 advanced ceramics jobs arehelping to support 176,975 jobs in sectors that useceramics.In Stoke-on-Trent and Staffordshire, the historicalheart of the ceramics industry in the UK, there arenearly 8,000 jobs in the ceramics industry and anestimated 670 jobs in technical ceramics.Employment concentration is an indicator of acluster’s strength. This is measured using locationquotients (LQ) which summarises a sector’s share ofemployment in an area against national employmentfigures for that sector.Figure 4: Midlands share of national employment in the ceramic industry (2018)A LQ score less than 1 means that sector hasa smaller share of employment than nationallyand a score greater than 1 occurs where a sectorcontributes a larger share to local employment.Table 3 shows both the number of employees in theMidlands and is shaded to show LQs for sectors byLocal Enterprise Partnership (LEP).Industry users of advanced ceramics are prominentin the LEP areas with above national employmentlevels in general manufacturing, ceramic consumingmanufacturing3 and automotive and transportmanufacturing.The region has successfully attracted largeamounts of Foreign Direct Investment (FDI)in some of the region’s high productivity prioritysectors that use advanced ceramics. An example isGeely investment in London Taxis in Coventry for thedevelopment of electric taxis, which are dependenton improved battery technology that relies onadvanced ceramics.Source: ONS, (2019)Table 3: Size of key sectors in 2018 where advanced ceramics enable product innovation (Total GVA millions)The Midlands Industrial Ceramics Group (MICG) is a collaborative partnership that draws togetherthe advanced ceramics suppliers, users, professional services and academic base from acrossthe Midlands. The MICG has been established to ensure advanced ceramics help drive thecompetitiveness and success of Midlands advanced manufacturing by tackling key innovationchallenges.Its aims are to: Make the Midlands the go-to location for global R&D and production of advanced ceramics Increase the competitiveness of the Midlands industrial base Enhance industrial ability to develop innovative ceramic technologies with speedy marketplaceadoption Deliver a multi-sectoral approach with rapid translation of new technologies for the advantageof a whole range of industrial sectors Strengthen the UK advanced ceramics supply chain for the benefit of the Midlands’ advancedmanufacturing sector.3 Ceramic Consuming Manufacturing is a composite classification of sectors we consider to be prominent consumers of advanced ceramics and includes the SIC codes: 23,26, 27, 28, 29, and 30.1415

Case Study: LucideonLucideon is an independent, international materials technologycompany that focuses on innovation, sustainability and qualityassurance of materials. It is a global company with operations inJapan, USA and the UK with its global headquarters in Stoke-on-Trent.It is a development and commercialisation organisation (DCO),specialising in materials technologies and processes. Its applicationof cross-industry insight, materials science expertise and innovativethinking allows industry to develop and implement disruptivetechnology platforms more quickly, providing cost and / or productperformance benefits and enabling real market differentiation.In addition to a multi-disciplinary team of scientists, engineersand commercial analysts, Lucideon has world-leading testing andcharacterisation laboratories and a combination of pilot and feasibilityplant to enable the rapid commercialisation of new products as well asa management and certification division.Lucideon works in all markets where ceramics are applied (Healthcare,Construction, Aerospace, Energy) with expertise in a range of materials(e.g. metals, polymers), advanced technical ceramics are central towhat the organisation does.Lucideon’s current advanced ceramics development work includes: Ceramic thermal barrier coatings for aircraft engines so that bothenergy and emissions are reduced by allowing metals to operateabove their melting temperature. A world leading ceramic sintering (firing) technology that will helpmanufacturers to significantly reduce firing temperature and time(and thereby energy and emissions), saving energy for the world. Sintering of novel ceramic electrodes that could be crucial in thedevelopment of a sodium based alternative to Lithium batteries – ascarce and dangerously produced raw material. A ceramic-based technology to prevent the abuse of opioids andother addictive substances.161617

Case Study: Rolls-RoyceRolls-Royce has invested more than 15m in R&D related to oxideceramic composites and has 40 staff in the UK and 120 worldwidespecialising in advanced ceramics. The use of advanced ceramics,such as oxide-oxide composites instead of nickel superalloys in itsaerospace products provides a competitive advantage through thecreation of lighter-engines.The company faces commercial pressures in terms of its UK-basedactivities, including the cost of some advanced ceramic materialsbeing higher in the UK because there is not a critical mass of otherindustrial users in other sectors for UK production.There are also potential concerns around security of supply shouldexport controls on materials with potential military uses currentlysourced from North America be introduced.A more significant challenge Rolls-Royce faces is the availability ofskills it needs to incorporate advanced ceramics in its products. Theproposed Advanced Ceramics Campus and services proposed by MIGCare seen as a timely intervention to address these challenges which iswhy Rolls-Royce is supporting the proposed MICG interventions.If the proposal takes too long to materialise, Rolls-Royce will need togrow this activity in Germany, Singapore or North America to serviceits demand.1819

Case Study: PrecisionCeramicsPrecision Ceramics is a company dedicated to the engineeringof technical ceramics that grew out of McGeoch Technology. Itis based in Birmingham with a subsidiary in Florida. McGeochfirst introduced technical ceramics into their product range whenit became the principal UK distributor for Macor , a uniqueglass ceramic that can be machined. It has since become the UKdistributor for a wider range of advanced ceramic products whichhas afforded the company a detailed understanding of theirtechnical properties and potential applications.Technical ceramics account for half the parent company’sturnover of 17m and the company’s investment in R&D issignificantly above the government target. It sees itself ‘in thebusiness of solving problems by creating products that meetspecific needs rather than pushing specific technology’ andis therefore an example of a Midlands business that supportscommercialisation and the adoption of new advanced ceramictechnologies by other sectors. It does this by providing its clientswith solutions at the right price point across a range of sectorsand the ability to produce custom units within a short time scale.Because they provide bespoke products they do not seethemselves as competing with other companies operating inadvanced ceramics but competing against more establishedtechnologies. Non-lubricated advanced ceramic pistonsis an example of one of their products. These help reducecontamination in food and pharmaceutical sectors from abrasion.They are also more durable helping to derive benefits associatedwith the circular economy (reducing replacement costs andmachine down-time).2021

Case Study: MorganAdvanced MaterialsMorgan Advanced Materials has been identified as one of thetop five global companies in the advanced ceramics sector withseveral sites across the Midlands, including at Stourport-onSevern and Rugby.Morgan can trace its heritage back to the mid-19th century.It has world-leading competencies in materials science,specialist manufacturing and applications engineering. It isa diversified supplier of high performance structural ceramicmaterial components and sub-assemblies to the semiconductor,automotive, aerospace, industrial, medical, energy, renewable andtransport sectors.Morgan’s breadth of market capabilities underscores the sheerdiversity of sectors in which advanced ceramics can play animportant role. Morgan focuses on differentiating itself byengineering solutions to meet demanding customer-specifictechnical challenges and ever more stringent performancerequirements, through advanced material formulations andmaterial joining technologies.Morgan undertakes R&D in the Midlands (including the TechnicalCeramics division at Stourport-on-Severn) and at several locationsin the USA.Accessing skills in the UK is an issue that Morgan faces giventhat there are few specialist degrees in ceramics and whereceramics comprise only a small part of materials science degrees.To address this, and in addition to the new MICG designedundergraduate program in Materials, Morgan Advanced Materialsworks closely with undergraduate and postgraduate studentsand staff at universities such as Loughborough and Birmingham.It believes that the Advanced Ceramics Campus could be afocal point of a pipeline for skills development while helping toraise awareness of the potential of advanced ceramics amongstmanufacturers and users across the supply chain.Morgan is a founding member of the MICG and foresees theadvances made through its collaborative research as having thepower to enhance its own materials and manufacturing processeswithin the Midlands and more widely across its global business.2223

The Needsof Advanced Ceramics in theSizeof OpportunityMidlandsThe MICG came together to work collaborativelyon promoting and improving the Midlands’competitiveness in advanced ceramics. Itcommissioned SQW and City-REDI to extensivelyconsult key industrialists and academics in thesector, not just those based in the Midlands, butalso those who have a significant presence inthe sector internationally. Through this researcha strong consensus on critical challenges andopportunities facing the Midlands’ advancedceramics businesses was established. Keyfindings were: The UK is well placed to compete in thissector – the advanced ceramics sectoris specialist and global. The competitorcountries are industrialised nations whocompete on the quality and innovativeproperties in their products. The UK shouldbe well positioned to compete, but mustensure it keeps pace, or better leads, ininnovation in this sector.The Midlands is the right place to focuson advanced ceramics – those consultedunderstood the Midlands’ strengths inthis sector, and there was consensus thatthe Midlands would be the perfect homefor national research facilities and alignedactivity.The speed and pace of innovation isparticularly important in this sector - in anincreasingly competitive international marketplace the pace at which new products andprocesses can be brought to the market iscritical. Currently the development of newadvanced ceramics products is expensiveand needs to follow iterative trial and errortechniques. Anything that could improve thecosts and speed of developing new productswould significantly lower barriers of firmsinvesting in innovation. Costs of production in advanced ceramicsis critical and needs to improve – advancedceramics can currently be expensiveto produce relative to other materials.Advanced ceramics can have higher failurerates in production resulting in wastage andcosts. Improved processes that lower costswould not only make the businesses thatadopt these techniques more competitive, itwould also result in an increase in take-up ofadvanced ceramics products (which wouldboost the performance of products acrossmany industrial sectors owing to the higherperforming characteristics of advancedceramics).A dedicated research programmeis needed – many advanced ceramicsbusinesses are facing common challengesassociated with production costs and pace ofinnovation. A collaborative programme ledby business, alongside the Midlands’ leadingUniversities, would be the most effective andcost efficient means of tackling these.Increasing the adoption of newtechnologies and techniques requiresdedicated facilities and promotion – thereis currently a lag in the adoption of newtechniques and products across the industry.Dedicated pilot line facilities would helpspeed up and de-risk this process. Thereis also a need to better communicate newtechnologies and processes across theindustry to increase take-up. The MICGfounding companies recognised the need forleadership and so came together to createthe Group.Proposalsto Grow the Advanced CeramicsSizeof OpportunitySector in the MidlandsIn order to capture the opportunities in advancedceramics and respond to the challenges facinglocal companies the MICG and partners areworking to create a holistic programme tofacilitate growth. This includes: MICG led collaborative R&D – the MICGis working together on a five-year researchprogramme that would see 30m ofpublic and private investment dedicated toovercoming some of the critical challengesfacing the advanced ceramics sector. Commercialisation and pilot-line facilities– Lucideon, via their subsidiary companyAMRICC, is seeking to establish an R&Dfacility in North Staffordshire. This wouldprovide pilot line facilities to enable thecommercialisation of the innovation createdin the region to be more easily pulledthrough by industry. Advanced ceramics campus – Partnersin North Staffordshire are promoting thevision of an advanced ceramics campus,which would be the UK home for R&D inadvanced ceramics as well as a commercialbusiness park for firms wanting to expandin the Midlands. This would create over120,000 sqft of dedicated R&D facilities andcommercial floorspace in a first phase. Skills development – the MICG led R&Dprogramme will create a legacy of skilledresearchers. In addition, Lucideon is workingon technical levels skills to support the sector.A degree apprenticeship in Materials Sciencehas been approved and is being rolled out viaSheffield Hallam University and the Universityof Derby. Promoting the Midlands – the MICG andLEPs are working together to promotethe Midlands as a destination for globalinvestment. The ambition is for an annualsymposium for the sector to be held in theregion. Proactive marketing of investmentopportunities across the Midlands will beput to the global sector (whilst not exclusiveto these areas, the promotion is expected tohighlight opportunities across Science Parksaligned to the Universities of Birmingham,Loughborough and Leicester, the CeramicValley Enterprise Zone and Infinity ParkDerby).Figure 5:Artist’s impression of proposed Advanced Ceramics Campus in the Midlands3 Ceramic Consuming Manufacturing is a composite classification of sectors we consider to be prominent consumers of advanced ceramics and includes the SIC codes: 23,26, 27, 28, 29, and 30.2425

Benefitsof Public Investment in theSizeof OpportunityAdvanced Ceramics SectorThe growth in advanced ceramics builds on thehistoric industrial strengths of the Midlands,and in particular North Staffordshire. It offersthe opportunity to create highly skilled jo

use advanced ceramics in their products, creating a critical mass of advanced ceramics customers. These include companies within the automotive and aerospace sectors; and companies within the rapidly growing energy and med-tech sectors, (Table 2). Three end users, Rolls-Royce and JCB, and AEON Engineering are founding members of the

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