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. 2021 Apr 9;11:7823. doi: 10.1038/s41598-021-87077-2

Simultaneous tuning of the magnetic anisotropy and thermal stability of α-phase Fe16N2

D Odkhuu 1,, S C Hong 2,
PMCID: PMC8035402  PMID: 33837232

Abstract

Simultaneously enhancing the uniaxial magnetic anisotropy (Ku) and thermal stability of α-phase Fe16N2 without inclusion of heavy-metal or rare-earth (RE) elements has been a challenge over the years. Herein, through first-principles calculations and rigid-band analysis, significant enhancement of Ku is proposed to be achievable through excess valence electrons in the Fe16N2 unit cell. We demonstrate a persistent increase in Ku up to 1.8 MJ m-3, a value three times that of 0.6 MJ m-3 in α-Fe16N2, by simply replacing Fe with metal elements with more valence electrons (Co to Ga in the periodic table). A similar rigid-band argument is further adopted to reveal an extremely large Ku up to 2.4 MJ m-3 in (Fe0.5Co0.5)16N2 obtained by replacing Co with Ni to Ga. Such a strong Ku can also be achieved with the replacement by Al, which is isoelectronic to Ga, with simultaneous improvement of the phase stability. These results provide an instructive guideline for simultaneous manipulation of Ku and the thermal stability in 3d-only metals for RE-free permanent magnet applications.

Subject terms: Magnetic properties and materials, Electronic structure

Introduction

Alpha-phase iron has been known for its extraordinary magnetic properties, including high saturation magnetization (μ0Ms) and Curie temperature (Tc), in addition to its relatively simple fabrication and low price. These intriguing features make it a potential champion ever for high-performance permanent magnet applications14. However, the main drawback of α-Fe is its negligible uniaxial magnetic anisotropy (Ku) on the order of μeV per atom14. Two practical approaches to enhance Ku in α-Fe are (1) alloying with heavy-metal (HM) or rare-earth (RE) elements, with the most prominent examples being FePt5 and Nd2Fe14B6, 7, and (2) reducing the crystal symmetry from the cubic (c/a=1) to tetragonal phase (c/a1)810. In (1), 5d or 4f electrons possess inherently large spin-orbit coupling (SOC) and orbital angular momentum (L), but the inclusion of these HM and RE elements is not desirable in terms of price and is detrimental to μ0Ms and Tc. In (2), the energy levels of the 3d orbitals evolve in tetragonal symmetry, particularly around the Fermi level (EF), which in turn enhances Ku11.

The tetragonal phase of c/a1 is now accessible in epitaxial Fe films with a diverse choice of lattice-mismatched substrates. Nevertheless, such tetragonal distortion is feasible only for limited film thicknesses of a few nanometers12, 13. In contrast, a bulk-scale tetragonal structure of the α-phase (c/a = 1.1) is favored when 12.5 at.% N is embedded into the α-Fe structure with octahedral interstitial sites, forming a 16:2 (Fe16N2) stoichiometry14. Since a surprisingly large magnetic moment of 2.6−3 μB per Fe atom was reported1517, α-phase Fe16N2 has received enormous attention as a possible 3d-only permanent magnet. However, the practical implementation of α-Fe16N2 in obtaining monophasic samples is quite difficult as α-Fe16N2 decomposes into α-Fe and γ-Fe4N at a low temperature of approximately 500 K14. Numerous efforts have been made to improve the thermal stability of α-Fe16N2; the most successful approach is Ti addition but the magnetic properties are greatly suppressed18, 19. In addition to the weak thermal stability, another major obstacle that hampers practical applications is the still insufficient Ku, which ranges from 0.4 to 1 MJ m-3, depending on the sample preparation and film thickness2022. In the research community, search for enhancing Ku while improving the thermal stability of α-Fe16N2 in the bulk has been thus very intensive and remains unresolved.

In this article, we propose a possible mechanism of tuning the number of valence electrons to simultaneously enhance the thermal stability and Ku by a few times in Fe16N2 and (Fe0.5Co0.5)16N2 apart from the aforementioned approaches (1) and (2), using first-principles calculations and rigid-band model analysis. We predict a persistent increase in Ku up to 2.4 MJ m-3, which is four times that (0.6 MJ m-3) of Fe16N2, by replacing Fe with metal elements with more valence electrons (Co to Ga and Al in the periodic table). Such a supreme Ku is discussed in connection with the mutual mechanisms of the Jahn−Teller orbital splitting and excess electron-induced energy level changes in the electronic structure.

Results and discussion

Figure 1a displays the α-phase structure of Fe16N2. The optimized a and c/a are 5.69 Å and 1.1, respectively. The corresponding values in an experiment are 5.72 Å and 1.114. In the unit cell, 16 Fe atoms occupy 3 inequivalent sites at the Wyckoff positions of 4e, 8h, and 4d, while 2 N are at the octahedral interstices with the 4 Fe(8h) coordination14. These 4e, 8h, and 4d sites differ in magnetic moment (Table 1): 2.14 (2.33), 2.36 (2.45), and 2.82 (3.05) μB in the present theory (experiment17), respectively. The mechanism is associated with the nonidentical Fe–N bond lengths: Fe(4e)–N: 1.83, Fe(8h)–N: 1.95, and Fe(4d)–N: 3.24 Å. Furthermore, the energy levels of their 3d orbitals evolve near EF, particularly in the spin-down channel (Fig. 1b).

Figure 1.

Figure 1

(a) Crystal structure of α-phase Fe16N2. (b) Spin-down channel eigenvalues of the a1 and b2 orbitals of Fe(4e), Fe(8h), and Fe(4d) along the high-symmetry NΓZ line of the Brillouin zone. The size of the symbols is proportional to their weights. The Fermi level is set to zero. (c) Schematic phase diagram of the ternary Fe−Al−N system. (d) Enthalpy of formation Hf of Fe15M1N2 (M = Co−Ga and Al) for M(4e), M(8h), and M(4d).

Table 1.

Optimized tetragonal distortion c/a, magnetic moments (μB) of Fe(4e), Fe(8h), Fe(4d), and M-replacement elements, saturation magnetization μ0Ms (T), anisotropic field μ0Ha (T), hardness parameter κ, and Curie temperature Tc (K) of Fe15M1N2 for M = Fe−Ga and Al.

c/a Magnetic Moment (μB) μ0Ms (T) μ0Ha (T) κ Tc (K)
Fe(4e) Fe(8h) Fe(4d) M(4d)
Fe 1.10 2.14 2.36 2.82 2.82 2.24 0.65 0.38 925
Co 1.10 2.15 2.43 2.82 1.93 2.22 0.94 0.45 .
Ni 1.11 2.10 2.38 2.77 0.82 2.12 0.71 0.41 .
Cu 1.11 2.08 2.34 2.72 0.10 2.04 0.82 0.44 .
Zn 1.11 2.10 2.29 2.74  -0.08 2.01 1.58 0.62 760
Ga 1.11 2.11 2.22 2.76  -0.14 1.98 2.35 0.77 804
Al 1.11 2.11 2.21 2.76  -0.07 1.98 2.24 0.75 855

Only one Fe atom in the 16 Fe unit cell is replaced by a 3d-metal atom (M = Co−Ga and Al), which corresponds to approximately 5.5 at.% doping. For each M, we have considered three different substitution sites, i.e., M(4e), M(8h), and M(4d). The α-phase stability upon M replacement can be inspected by the enthalpy of formation: Hf=(H-iμiNi)NA/N, where μi and Ni are the chemical potential and number of decomposable components i, respectively. NA and N are the Avogadro constant and the number of atoms in the unit cell. The obtained Hf values of Fe16N2 are  -3.14 kJmol-1 against (α-Fe)+N2 and  -0.80 kJ mol-1 against (α-Fe)+(γ-Fe4N) decomposition. The small negative value of the latter implies that the α-Fe16N2 phase is stable at a low temperature but most likely decomposes into the α-Fe and γ-Fe4N phases at an elevated temperature, as observed experimentally14. From the ternary Fe−M−N phase diagram, as an example for M = Al in Fig. 1c, Fe4N and Fe3M phases are identified as the most competitive binary decomposable phases to Fe15M1N2. For M = Ni (Cu and Zn), Fe4N+FeNi(Cu/Zn)+Fe decomposition has been considered since Fe3Ni (Fe3Cu/Zn and FeCu/Zn) is unstable.

Figure 1d presents the calculated Hf of Fe15M1N2 (M = Co−Ga and Al) for M(4e), M(8h), and M(4d). All the M elements prefer 4d-site replacement, which in turn splits the neighboring Fe(4d) sites into Fe(4d)c along the c axis and Fe(4d)ab on the ab plane with dissimilar magnetic properties, as addressed in the following paragraphs. The α-phase becomes unstable upon Co to Cu replacements. In contrast, the replacement of Zn, Ga, and Al improves the α-phase stability with Hf enhanced by 0.04−0.8 kJ mol-1 in magnitude, as their nitrides (ZnN, GaN, and AlN) have higher standard enthalpies of formation, in the range of  -100 to  -320 kJ mol-12325, than FeN (-47 kJ mol-1)25. The completely filled d-orbitals of the Zn and Ga elements provide extra stability to the system, as these elements have a symmetrical distribution of electrons and larger exchange energies than Fe26.

We further investigate the structural stability at an elevated temperature using ab initio molecular dynamic (AIMD) simulation. Figure 2a,b present the fluctuations of the total free energy of the selected Fe16N2 and Fe15Al1N2 phases for given temperatures 300, 500, and 600 K, respectively. The total energy of Fe16N2 decreases immediately within a few fs by 1.3 (at 300 K)−2.2 eV/f.u. (at 600 K), which is associated with the thermal motion and relocation of atomic coordinates. Furthermore, the energy variation during the AIMD simulation increases with temperature and reaches 3.2 eV/f.u. at 600 K, where the α-phase structure is largely distorted, as indicated in the insets in Fig. 2a. On the other hand, the energy fluctuation of Fe15Al1N2 phase is rather small within 1.5 eV/f.u. even at 600 K (Fig. 2b). In particular, the α phase tends to maintain up to 600 K (insets in Fig. 2b), although marginal phonon vibrations and atomic coordinate distortions occur during the AIMD simulation.

Figure 2.

Figure 2

AIMD simulation of the free energy fluctuation of (a) Fe16N2 and (b) Fe15Al1N2 for given temperatures 300, 500, and 600 K. The insets show the side views of the corresponding atomic structures before (0 K) and after the AIMD simulation period of 10 ps. The atomic symbols are the same as used in Fig. 1a. Green sphere in b is the Al atom.

In Fig. 3a, an even more notable finding is the persistent increase in Ku as M changes from Ni to Ga, reaching the largest value of 1.85 MJ m-3 for Ga replacement. This value is more than 3 times the enhancement attained for α-Fe16N2. The present Ku of Fe16N2 is 0.6 MJ m-3, which is within the range of experimental values of 0.4−1 MJ m-32022. The enhanced Ku of the α-phase is associated with tetragonal distortion. The Jahn−Teller-like d-orbital level splitting when αα offers more electronic energy level degrees of freedom10. More specifically, the tetragonal distortion splits the cubic eg and t2g levels around EF: singlets a1 (dx2-y2) and b1 (d3r2-z2), and singlet b2 (dxy) and doublet e (dyz,xz), respectively. Evidently, the energy levels near EF of the spin-down electrons, especially the a1 and b2 states, differ at the 4e, 8h, and 4d sites (Fig. 1b). Further analyses indicate that the difference comes from their dissimilar hybridization with N-2p orbitals.

Figure 3.

Figure 3

Predicted uniaxial magnetic anisotropy Ku of (a) Fe16N2 and (b) (Fe0.5Co0.5)16N2 with M replacement (M = Co−Ga and Al). (c,e) Atom-decomposed (open symbols) and total (filled star) magnetocrystalline anisotropy energy MAE, (d,f) M (Cu−Ga and Al)-induced enhancement in MAE (ΔMAE) of Fe16N2 and (Fe0.5Co0.5)16N2.

Our analysis of atom resolved magnetocrystalline anisotropy energy (MAE) in Fig. 3c indicates that MAE in this α-phase distributes unequally over the unit cell: -0.14, 0.18, and -0.03 meV at the 4e, 8h, and 4d sites, respectively. Here, MAE is scaled down to the microscopic atomic level (meV/atom), rather than the macroscopic energy density (MJ m-3). From the k-resolved (minority-spin) eigenvalue analysis in Fig. 1b, featured bands with cone-like shapes occur: the minimum of a1 (parabolic) and maximum of b2 (reverse parabolic) dispersions touch at the Γ point. In particular, for Fe(8h), such a conical a1-b2 pair appears right at EF. In association with their reduced eigenvalue difference across EF, the SOC matrix term in the Hamiltonian can thus increase the positive contribution to MAE, according to the perturbation theory11.

According to Fig. 3d, the Fe(4d)c site plays a major role in the M(Cu to Ga)-induced enhancement in MAE (ΔMAE) rather than the Fe(4d)ab site. The contributions to MAE from the other 4e and 8h sites cannot be ignored although minor. Meanwhile, the conical a1-b2 pair of the Fe(4d)c site moves gradually toward EF with the Cu to Ga replacement (Fig. 4a), which reflects the rigid-band model. A similar phenomenon is not present for the Fe(4d)ab site because of its longer separation (4 Å) from M than Fe(4d)c (3.1 Å). We therefore attribute MAE in Fe15M1N2 to the joint effects of the Jahn−Teller level splitting and the supplied-electron-induced level changes of the d-orbitals.

Figure 4.

Figure 4

Spin-down channel eigenvalues of a1 (blue) and b2 (red) orbitals of the (a) Fe(4d)c atom in M-replaced Fe16N2 and (b) Coc atom in M-replaced (Fe0.5Co0.5)16N2 along the high-symmetry NΓZ line of the Brillouin zone for M = Cu−Ga and Al. The size of the symbols is proportional to their weights. The Fermi level is set to zero.

In the rigid-band picture, the shift of the electronic states is related to the change in the energy of the Bloch state with M (Δεk), as ρ(ε)=ρ0(ε)-[ρ0(εk)/εk]Δεk27, where ρ(ε) and ρ0(ε) are the density of states (DOS) of Fe(4d)c in Fe15M1N2 and Fe16N2, respectively. For a small amount of M, Δεk is also small and thus independent of k, where the shape of the band structure remains the same but displaced by Δεk. Eventually, for the Ga replacement, the conical a1-b2 pair of the Fe(4d)c site shifts down and appears near EF, which in turn enhances MAE. Here, the Jahn−Teller argument is not applicable, as the c/a (1.1) of α-Fe16N2 remains almost the same upon M replacement (Table 1).

In accordance with the a1-b2 shift (Fig. 4a), the replacement element that can maximize MAE is Ga, in line with the obtained Ku in Fig. 3a. To support this scenario, we explore the replacement element Al, which is isoelectronic to Ga. Remarkably, we find Ku value of 1.80 MJ m-3 for the Al replacement (Fig. 3a), similar to that (1.85 MJ m-3) for the Ga replacement. Accordingly, similar electronic features of the a1-b2 bands and Δεk at the Fe(4d)c site are identified in Fig. 4a for the same group elements, Al and Ga. Furthermore, as mentioned early in Fig. 1d, the inclusion of Al in Fe16N2 greatly improves the α-phase stability beyond the other M-replacements. From a practical viewpoint, the Ga and Al replacements (particularly, Al) for Fe are desirable for RE-free permanent magnets because of their abundances on earth.

In line with the argument we outlined thus far, an even larger Ku may be achieved if more Fe in Fe16N2 are replaced with metal elements with more valence electrons. To test this scenario, we replace half of the Fe in Fe16N2 with Co. From the total energy minimization, all the 4d and 4e sites are occupied by Co, forming the B2-phase, while 2 N prefer the 4 Fe(8h) coordinated octahedral interstices on the same ab plane. As Co has 1 more electron and stronger SOC than Fe, we find that the Ku in (Fe0.5Co0.5)16N2 is 1.65 MJ m-3. This value is more than double that (0.6 MJ m-3) of α-Fe16N2. A similar argument can be applied for other replacements such as Ni and Zn (not shown here). Furthermore, the enhanced c/a (1.17) of (Fe0.5Co0.5)16N2, compared with 1.1 in Fe16N2, is clearly an additional cause of the large Ku8.

Remarkably, the M-replaced (Fe0.5Co0.5)16N2 compounds exhibit a trend similar to, but with notably enhanced numerical values, that in Fe16N2: a nearly linear increase in Ku from Cu to Ga (Fig. 3b). Eventually, Ga replacement leads to a Ku as high as 2.44 MJ m-3. Such supreme value of Ku can also be achieved for Al (2.41 MJ m-3). These values are more than 4 times that of Fe16N2 and more than half the value of 4.5 MJ m-3 of the typical RE-magnet Nd2Fe14B28. Similar to in Fe16N2, Co next to M on the c axis (denoted Coc) produces the largest ΔMAE compared with other sites (Fig. 3f), although MAE is larger for Fe than for Co (Fig. 3e). At this Coc site, it is manifested that the main mechanism of enhancing Ku is the displacement of the (unoccupied) a1 band toward EF as M changes from Cu to Ga and Al in Fig. 4b.

We believe that the present argument is rather general and can be applied to other magnetic materials. To better justify the excess-electron-induced enhancement in Ku, we forcibly increase the number of valence electrons in Fe16N2 and (Fe0.5Co0.5)16N2. This approach reflects an excess electron that is uniformly accumulated over all Fe rather than at a specific site neighboring the M replacement. For both Fe16N2 and (Fe0.5Co0.5)16N2, Ku increases linearly as the number of excess electrons (ΔΩ) increases (Fig. 5a). Nearly the same values of Ku of 1.3 MJ m-3 in Zn-replaced Fe16N2 and 2.4 MJ m-3 in Ga-replaced (Fe0.5Co0.5)16N2 are reproduced at ΔΩ = 0.2 e/atom. From the simplified DOS analyses in Fig. 5b for Fe16N2, the unoccupied a1 bands of all the Fe sites displace toward EF upon an increase in ΔΩ, while the occupied b2 state is rather insensitive. This result again reveals that the d-orbital level change induced by supplied electrons is the main mechanism of the Ku enhancement.

Figure 5.

Figure 5

(a) Predicted Ku of Fe16N2 (circle) and (Fe0.5Co0.5)16N2 (square) as a function of the number of excess valence electrons, ΔΩ, in a unit cell. (b) ΔΩ-dependent DOS of the a1 (blue) and b2 (black) orbitals of Fe(4e), Fe(8h), and Fe(4d) of Fe16N2. The color-scale from light to dark in the DOS corresponds to the enhancement of ΔΩ from 0 to 0.2 e/atom. The Fermi level is set to zero.

We now would like to highlight the intrinsic hard magnetic properties, including maximum theoretical energy product (BH)max, anisotropic field μ0Ha, and hardness parameter κ, of the present compounds. The sufficiently large μ0Ms and thus (BH)max, defined as (BH)max = (1/4)μ0Ms229, are worth noting. In Table 1, Fe15M1N2 exhibits μ0Ms of 2.24−1.98 T, while the (Fe0.5Co0.5)16N2-based compounds have a slightly lower magnetization of 1.96−1.80 T. These values are far beyond those of the best high-performance permanent magnets, for example, 1.61 T for Nd2Fe14B28. The predicted μ0Ha (=2Ku/Ms)29 increases from 0.65 T for Fe16N2 to more than 2 (3) T for the Ga/Al-replaced Fe16N2 ((Fe0.5Co0.5)16N2), as shown in Table 1. Additionally, typical permanent magnets possess a hardness parameter κ (= (Ku/μ0Ms2)1/2) close to or greater than 129. The calculated κ of the M-replaced (Fe0.5Co0.5)16N2 (M-replaced Fe16N2) ranges within 0.75−1.10 (0.41−0.78), values which are 2−3 times that (0.38) of Fe16N2. We finally explore the magnetization dynamics of α-Fe and Fe15M1N2 for the selected M = Fe, Zn, Ga, and Al. From the temperature dependent magnetization in Fig. 6, the absolute value of Tc can be estimated by fitting the magnetization data to the function M(T) = (1-T/Tc)β30. We find that the calculated Tc values of α-Fe and α-Fe16N2 are 1026 and 925 K, respectively, which are in reasonable agreement with the experimental ones (1044 and 813 K)31, 32. Furthermore, as listed in Table 1, the obtained Tc values (804−855 K) of the stable compounds (M = Zn, Ga, and Al) are sufficient to fulfill the basic requirement (no less than 550 K) of permanent magnets33.

Figure 6.

Figure 6

Calculated temperature dependent magnetization of Fe15M1N2 for M = Fe, Zn, Ga, and Al. The same for α-Fe is shown in open circles for reference. The lines are the fitted curves for the magnetization data points. The vertical dotted lines indicate the experimental Tc values of α-Fe (1044 K)31 and α-Fe16N2 (813 K)32.

Conclusion

In summary, we show, using first-principles calculations and rigid-band model analysis of α-phase Fe16N2, that Ku can be scaled up by a few times upon the substitution of metal elements with more valence electrons than Fe, from Co to Ga, without the inclusion of RE and HM elements. More remarkably, the replacement by simple metals (Al and Ga) has potential for simultaneous enhancements of Ku and the thermal stability, which would make α-Fe16N2 a possibly RE-free permanent magnet, along with its high Curie temperature and low materials price. Furthermore, we demonstrate that a similar argument, as a general rule, is applicable to suitable systems to achieve enhanced intrinsic hard magnetic properties and improved thermal stability. We hope that our results can be used as a guideline for subsequent experimental investigations of RE-free high-performance permanent magnetic materials.

Methods

The density-functional theory (DFT) calculations were performed using the projector augmented wave (PAW) method34, as implemented in the Vienna ab initio simulation package (VASP)35. The exchange-correlation interactions are treated with the generalized gradient approximation of Perdew, Burke, and Ernzerhof (PBE)36. We used an energy cutoff of 500 eV and a 11×11×11 Brillouin zone (BZ) k-point mesh to relax the lattice parameters and atomic coordinates until the largest force decreased to below 10-2 eV/Å. The total energy method is applied to obtain Ku, which is expressed as Ku=(Ea-Ec)/volume, where Ea and Ec are the total energies with magnetization along the a and c axes, respectively. To obtain well-converged Ku, we impose a denser k-point mesh of 15×15×15 with a smaller smearing of 0.05 in the Gaussian method, where the convergence of Ku with respect to the number of k points and smearing parameter is ensured. In tetragonal symmetry, Ku is expressed as KuK1sin2θ+K2sin4θ, where K1 and K2 are the magnetic anisotropy constants and θ is the polar angle between the magnetization vector and the easy axis (c axis in the present system). For θ=π/2, Ku=K1+K2. It is a formidable task to ensure numerical results of Ku with all electron methods, if we start from scratch. To this end, we have also performed full-potential calculations using the WIEN2K package37, adopting the optimized lattice constants and ionic positions obtained from the VASP calculations. The two methods produce consistent results. In the AIMD simulation, we adopted the Nosé-thermostat algorithm to model a canonical ensemble38. A time step of 1 fs and 10000 ionic steps were used for the total simulation time of 10 ps with the Γ-point BZ integration, where the lattice parameters and atomic coordinates are allowed to relax at constant volume. The numerical calculations for magnetization dynamics and Tc were carried out using Monte Carlo simulation based on the Heisenberg model in the VAMPIRE package30. Here, the Heisenberg spin Hamiltonian is defined by

H=-12ijJijSi·Sj-Kui(Si·e)2 1

where Jij is the exchange interaction between two spins Si at the i site and Sj at the j site. The exchange interaction parameters, from the first to the third nearest neighbor atoms, were estimated by the constrained local moment approach in the VASP calculations. More detailed methodology is provided in Ref.9.

Acknowledgements

This research was supported by Future Materials Discovery Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Science and ICT (Grant No. 2016M3D1A1027831), the Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korean government (MOTIE) (Grant No. 20192010106850, development of magnetic materials for IE4 class motor), and the Incheon National University Research Grant in 20180438.

Author contributions

D.O. and S.C.H conceived the study and wrote the manuscript. D.O. performed the calculations.

Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

Competing Interests

The authors declare no competing interests.

Footnotes

Publisher's note

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Contributor Information

D. Odkhuu, Email: odkhuu@inu.ac.kr

S. C. Hong, Email: schong@ulsan.ac.kr

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Associated Data

This section collects any data citations, data availability statements, or supplementary materials included in this article.

Data Availability Statement

The data that support the findings of this study are available from the corresponding author upon reasonable request.


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