Литье и металлургия

Currently JSC “BMZ” carries out an active innovation and investment work directed at the development of new production capacity and creating of new energy saving productions. The large projects concerning steel, section rolling, hardware productions are considered.

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It is shown that foamed slag in arc electric steel-making furnaces provides decrease of power- and material-capacity of melting, increases the speed of steel melting due to more stable burning of electric arcs and enlargement of portion of the heat energy transferred to the bath.

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It is shown that application of the alternating steel conducting technology in casting ladles at JSC “BMZ” has increased the degree of metal desulphurization by 5% as compared to the melting of standard technology.

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The experience of design and construction of micro factory which is focused on production of building bar is briefly stated.

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The statistical analysis of the production of certain metallurgical enterprises of Urals and Siberia on waste formation and their secondary application is carried out.

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The ways of quality improvement of briquetted ferrosilicon are considered. It is shown that quality of briquettes of ferrosilicon siftings is connected with the properties of the applied sodium silicate binder material.

There are not enough of production facilities on crushing of newly-formed slag due to increase of production volume on steel smelting. The tendencies of slag-processing at JSC «BMZ» are considered.

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Experience of operating of the section continuous casting machines of JSC “BMZ” shows that technologies dealing with industrial exploitation of these machines must solve problems on improvement of installations constructions, smelting technologies and out-of-furnace steel processing, selection of refractory materials, improvement of the billet crystallization process, metal protection from secondary oxidation, improvement of the billet quality, etc.

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The method of “instant” calculation of heat and material balances of melting, which can be used for various steel grades and for electric arc furnaces of different capacities, is developed. The possibility of the calculations of steel smelting both with application of melting intensification and by the traditional method is realized.

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The structure formation in electric steel 42Cr4Mo2 under continuous cooling is investigated, the results are summarized in the form of the thermo-kinetic diagram. It is shown that rolled metal annealing during 3.5-4.0 hours at 650-680°C provides the necessary properties of steel and enables to maintain energy consumption.

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The regularities of formation of the nonstick covering properties on the basis of high-refractory aluminosilicate filler at modifying of coating with nanostructured materials (AlOOH) were studied.

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New mechanisms of the metals and alloys crystallization processes on the basis of the thermodynamic analysis of the homogeneous and heterogeneous nucleation processes are given.

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On the basis of the thermodynamic analysis of the hydrogen bubbles formation it is shown that they can have a direct effect on forming of the structure of metals and alloys during solidification of castings.

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The possibility of fortification of the cast iron smelted in cupola due to alloying it with copper of copper-bearing wastes is studied.

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Thermodynamic probability of the processes of the formation of compounds of aluminum (which release in the environment by hydrolysis ammonia, acetylene, propane and hydrogen sulfide) is determined. In the article the economic loss from irrecoverable waste of aluminum and fines for emissions of air pollutants is estimated.

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The mathematical model for simulation of process of the shrinkage porosity formation in castings, taking into account the flows convection in crystallizing metal, is offered. The numerical simulation of the temperatures fields and metal density in the process of its crystallization is carried out.

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The computer simulation of the characteristics of manufacturing technology of the iron casting «body» for different correlations of feeder, slag traps and riser, recommended for the molds obtained by vacuum-film forming is carried out. The volume evolution of filling of the casting is calculated and dependences of speed instability and its projections on period of filling in assigned points of the mold are established.

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It is offered to use the J-integral, which considers the plastic deformation at the crack tip, for layered materials based on high-strength steel Z8HN3MFA and erosion-resistant cobalt alloys EP131 or molybdenum alloy MT, which collapse under the laws of elastoplastic mechanics.

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It is shown that the plastic deformation of cast irons with impurities of fragile phases of cement and graphite is an example of the general case of deformation of heterogeneous materials, in which fragile phase is located inside of the plastic base. It is confirmed that the most important factor is application of the deformation schemes close to uniform compression, what enables to deform plastically the fragile phases in the cast iron structure.

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The paper discusses special features of heat treatment of axial (end) cutting tool bimetallic billets made using the resource-saving technology with the aid of simultaneous hot plastic deforming through a forming die. The microstructure and hardness of 40X and P6M5 steels have been investigated after subjecting them to various conditions of heat treatment.

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Researches of diffuse-alloyed self-fluxing powders, based on austenitic steels, suggest that the resulting material will have high dyuromatricheskimi characteristics that allow its use for wear-resistant coatings.

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On a condition of equality of speeds of cooling conformity between distance from a face surface of the tempered face sample and the module of gears for different areas of section of a tooth is established. It is shown, that on the basis of the received dependence with use of diagrammes hardenability of carburized layers and a core of concrete mark of a steel the proved choice of the material providing set quality indicators of chemical heat treatment of gears is carried out.

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The question of the metallographic researches of unconnected objects using dark-field illumination is considered.

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The technological scheme of the new tool steel 5HVMFS smelting by means of electroslag casting method with the use of different combinations of steel scrap of R6M5 and CH5 steels and dressing the chemical composition directly in the bowl and also filling into metal bowl is developed.

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The results of carried out investigations enabled to recommend for factory testing the production of chipping knives of steels, subjected to high-temperature thermomechanical processing, particularly 65S2VA и H12MF.

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On concrete examples it is shown that application of technologies and materials for cold hardening enables to reduce financial and time costs during repair work.

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