Quality and operational properties of rails determine duration of their operational service. The main parameters that determine quality of steel are chemical heterogeneity and presence of non-metallic inclusions in metal. Efficiency of homogenization of metal melt and its refining from non-metallic inclusions in tundish is largely determined by organization of hydrodynamic processes, internal geometry of ladle, and presence of additional refractory elements. Using physical and mathematical modeling, study of the influence of additional refractory elements of various configurations of intermediate ladle on processes of melt flow was carried out. Physical modeling of hydrodynamic processes in the tundish taking into account requirements of similarity theory was made on specially created laboratory-experimental complex. Numerical experiments were carried out using computational fluid dynamics methods (finite volumes) on three-dimensional turbulent mathematical model with a singlephase representation of metal melt flow in tundish. To evaluate efficiency of melt homogenization according to results of physical and mathematical modeling, new technique has been developed based on analysis of distribution of time of liquid placement in continuous flow reactor. According to the results of experiments, configuration of the internal volume of tundish of four-strand CCM is proposed. A construction is considered that provides effective homogenization of molten rail steel and its refining from non-metallic inclusions. The design of full-profile compartments was developed and tested under industrial conditions, which ensure rational organization of melt flows, its homogenization and efficient refining of rail steel from non-metallic inclusions in the tundish. Industrial research was carried out under the conditions of four-strand CCM No. 1 of EAF shop at JSC “EVRAZ ZSMK”.

The article describes the study of welding processes with the subsequent control of cooling of full-profile rail joints, produced by passing alternating electric current pulses after welding. The influence of welding modes on the quality of welded joint was investigated. Welding was carried out on a resistance butt welding machine MCP-6301 in conditions of the rail welding company LLC “RSP-M” (RSP-29). For research, the samples of P65 type full-profile rails of DT350 category 600 mm long were cut out. The isothermal holding conditions after welding were controlled using a personal computer with a change in the program of the SIMATIC S7-300 industrial controller and the software SIMATIC STEP 7, which allows modes of controlled cooling to be set. The control program was written in the LAD graphic language. To search for optimal modes of controlled cooling, a complete factor experiment N = 2^k was carried out. Non-heat-treated joints were tested for three-point static bending according to the state standard STO RZD 1.08.002 – 2009 “Railway rails, welded by electric contact method”. Static bending tests were carried out on the press of PMS-320 type. Values of the force arising during bending Pbend and the bend deflection fpr at which the control sample is destroyed, were determined, as well as maximum values of these indicators if the sample was not destroyed during the tests. During the experiments, regression models were obtained for output parameters of the bending force and bend deflection. Macrostructure of the samples and distribution of the metal hardness on rolling surface of the rails welded joint were studied. A new method of resistance butt welding was developed, which makes it possible to obtain a welded connection of P65 type rails of DT350 category with properties that exceed the technical requirements of the mentioned state standard.

Аt present, there is a steady tendency to increase volume of i dustrial and civil construction in Russia and abroad. This in turn makes it necessary to enhance production of structural sections and in particular – reinforcing bar. One of the promising ways to increase production of reinforcing bar at existing rolling mills is development of rollingseparation technology. This technology provides growth in productivity of existing small-grade mills and reduces energy costs without large capital expenditures. However, despite its apparent simplicity, introduction of rolling-separation technology at existing enterprises causes difficulties associated with insufficient coverage of this experience in literature. The article presents experience of introduction of the rolling-separation technology on operating continuous small-grade mill. The research was carried out on equipment available in the workshop and used to monitor load of the main engines. Features of energy costs distribution on stands were studied at classical rolling and with the use of technology of rolling-separation of reinforcing bar No. 10, No. 14 made of 35GS and 3PS steel. Experimental graphs of the main engines of the rolling mill load show redistribution of energy consumption in stands for roughing, intermediate and finishing groups when using rolling-separation technology. Data on application of the main engine power and distribution of the specific load on the stands in classical rolling method and using rolling-separation technology are presented in graphic form. Analysis of the received data allowed us to reveal features of energy consumption at development of rolling-separation technology during operation. It is shown that use of this technology leads to additional load on stands of finishing groups. Energy savings during introduction of rolling-separation technology were quantified, and it was found that with a decrease of the rebar number, efficiency increases. Reduction of energy consumption during development of this technology in current production is associated with a decrease in machine time.

Dependence of plastic deformation resistance of chromiumalloyed rail steels on the thermomechanical parameters of deformation (degree, speed, and temperature of deformation) and chemical composition of the steels under consideration was obtained by hot mechanical tests for torsion and compression. According to the obtained data, an increase in rate and a decrease in deformation temperature cause an increase in resistance to plastic deformation. Effect of relative deformation on resistance to plastic deformation is nonlinear with an expressed maximum at deformation degree of the order of 0.25. Analysis of influence of chemical composition of 76KhF, 76KhSF and 90KhAF rail steels and their resistance to plastic deformation was carried out using methods of multiple regression analysis. It has shown that increasing of content of carbon, manganese, vanadium, nitrogen, sulfur and phosphorus in the actual range of changes in their concentration leads to an increase in their plastic deformation resistance. Mechanism of this effect was revealed. Approximation of the obtained data allowed us to determine interval of changes in deformation resistance when chemical composition varies within the actual range of changes in elements content. Value of specified interval was up to 19 % of the absolute value of deformation resistance. When varying content of chemical elements in the interval specified in state standard for production of railway rails, value of deformation resistance interval was up to 30 %. Checking adequacy of the obtained dependences was performed by oscillographing the stands drives engines of rail mill of JSC “EVRAZ ZSMK” when rolling billets of different chemical composition. This checking made it possible to confirm the revealed patterns.

Obtaining castings of given quality is the main task of foundry production. One of the stages of casting technology is solidification of melt in the mold. When studying the process of castings solidification, it is necessary to fully take into account all the features of heat transfer between casting and mold. Influence of various thermophysical parameters of alloy and mold material on casting formation is considered. In the analysis, original mathematical models were used to calculate the coefficient and time of complete solidification of castings in sand-clay and metal forms. These models take into account geometric parameters of casting, main thermophysical parameters of casting metal and mold material, heat transfer conditions at crystallization front, on casting-mold boundary and on the mold surface. Analysis of dependence of time and rate of castings solidification on thermophysical parameters (heat capacity, density, heat conductivity of casting material and mold, specific heat of metal crystallization) was carried out. Storage capacity and process of heat storage are quite fully characterized by the value of heat storage coefficient. This coefficient practically determines the rate of heat loss by the casting which plays a decisive role in its properties forming. Therefore, this parameter is selected for a comprehensive analysis of thermal processes occurring in casting and mold. The influence of thickness and thermal conductivity of chill paint layer on solidification of castings in metal molds is considered. The basic calculation formulas and initial data are presented. Calculations were carried out for castings of the following types: endless plate, endless cylinder, ball. The results of simulation of solidification process parameters are presented in graphic form. Using various alloys as an example, it has been shown by calculation that when changing composition and properties of mold material, it is possible to change time and speed of alloys solidification in a wide range. In this case, processes of forming the structure and properties of castings are controlled.

During the research, rolled scale and gas cleaning slimes from oxygen-converter workshop No. 1 of JSC “EVRAZ ZSMK” were used as iron-oxide-containing materials. Semi-coke from brown coals of the Berezovskoye deposit of the Kansko-Achinsk basin (temperature of semi-coking is 750 °C), coke fines of PJSC “Coke” and dust from coke dry-quenching plant of JSC “EVRAZ ZSMK” were used as carbon reducing agents. Total iron, FeO and Fe2 O 3 oxides amount to 73.3, 75.5 and 20.9 % in scale, 41.2, 4.7 and 53.7 % in sludge, respectively. Sludge also contains 4.3 % of total carbon and 20.6 % of CaO. Brown-coal semi-coke, coke fines and coke dust contains carbon and volatiles 94.05 and 9.5 %, 97.50 and 2.1 %, 97.47 and 1.6 % on dry ashless weight, respectively. For metallization of furnace charges with composition: scale, slime–semi-coke, coke fines, dust with addition of 10 % water-soluble binding–molasses, strong unroasted briquettes were pressed. Metallization modes of analyzed charge compositions were thermodynamically predicted and technologically determined. Metallization degree and metal iron content at usage of brown-coal semi-coke were found to be 97.5 and 90.2 % for scale, 97.5 and 71.3 % for sludge; of coke fines: 70.7 and 61.9 % for scale, 68.9 and 48.4 % for sludge; of coke dust: 72.1 and 62.6 % for scale, 69.2 and 48.2 % for sludge. The possibility of achievement the metallization degree of 97.0 – 98.0 % was established for briquetted charge from scale – brown-coal semi-coke with 92.0 – 93.0 % of total iron, 89.8 – 90.6 % of metallic iron, 2.8 – 3.2 % of FeO, 0.06 – 0.08 % of S, 0.016 – 0.018 % of P, 1.7 – 1.9 % of C, 1.0 – 1.2 % of CaO and 0.25 – 0.35 % of MgO at 1173 K and duration of 40 min.

Manganese ores of the vast majority of domestic deposits are of low quality: with low content of manganese (18 – 24 %) and high specific content of phosphorus (ratio P/Mn > 0.006). They have an increased content of iron and silicon and they are difficult to enrich. The main part of balance reserves of manganese ores – 98.5 million tons (64.2 %) is concentrated in large Usinskoye field in the Kemerovo region. In addition to Usinskoye, there are also deposits in this region Kaigadatskoye (32.7 million tons), Durnovskoye (300 thousand tons), Selezenskoye fields and the Chumay plot. For a comprehensive approach to solving the proposed problem it is needed to assess technical and economic feasibility of all stages (exploration, extraction and enrichment of manganese ores, their subsequent processing and consumption) of involvement of manganese ores from these deposits in production. Using developed technology of calcium-chloride enrichment, high-quality manganese concentrates are obtained from carbonate, including high-phosphorous ores of the Usinskoye field, poor oxide and ferromanganese ores of the Selezenskoye and the Durnovskoye fields. Extraction of manganese from manganese-containing raw materials into concentrate was at least 90 %. The resulting concentrate contains 58 – 64 % of manganese, less than 0.01 % of phosphorus, 0.02 – 0.05 % of iron oxide, 0.5 – 1.0 % of silica and sulfur. Thermodynamic calculations and experimental studies on the enrichment of polymetallic manganese-containing ores from the Chumay plot allowed us to determine the main technological parameters for extracting valuable components. The use of optimal technological parameters of enrichment allows extraction of up to 95 – 97 % of manganese and 98 – 99 % of nickel from raw materials.

Modification of the surface of VK10KS solid alloy with titanium alongside with boron by the method of pulse-plasma exposure (electro-explosive alloying) is considered. In this case, a superhard (27,500 MPa nanohardness) layer is formed with a thickness of 2.0 – 2.5 μm and a low (μ = 0.10) friction coefficient compared to the friction coefficient of a hard alloy in the sintered state (μ = 0.41). This layer consists of finely dispersed high-hard phases TiB₂, (Ti, W)C, W₂C (according to scanning, transmission electron microscopy and X-ray phase analysis). Below is a hardened (with a nanohardness of 17,000 MPa) surface layer (heat affected zone) 10 – 15 μm thick, identified by W₂C and WC carbides and alloyed with a cobalt binder. This layer smoothly passes into the base. By profilometric studies it was established that after electroexplosive alloying with titanium and boron, the roughness increases (Ra = 2.00 μm) compared to the initial one (Ra = 1.32 μm), but remains within the specifications (Ra = 2.50 μm). The authors have revealed changes that occur in the surface carbide and near-surface cobalt phases during electroexplosive alloying. In the carbide phase, accumulations of dislocations were indicated. In the cobalt binder, deformation bands (slip bands), single dislocations, and also finely dispersed tungsten carbide precipitates were found. This change can be explained by stabilization of the cubic modification of cobalt, the crystal lattice of which has a large number of slip planes during deformation and a greater ability to harden compared to the hexagonal modification of cobalt. Additional alloying with a cobalt binder will positively affect the operational stability of tungsten carbide alloys as a whole due to their stabilization.

Molecular dynamics method was used to study the effect of impurities of light elements of carbon, nitrogen and oxygen on crystallization process near the triple interface of grain boundaries in nickel. Tilt boundaries with misorientation axis <111> were considered as the grain boundaries. Interactions of nickel atoms with each other were described by many-particle Clery-Rosato potential constructed within the framework of the tight binding model. To describe interactions of atoms of light elements impurities with nickel atoms and atoms of impurities with each other, Morse pair potentials were used. Calculation cell had a shape of cylinder, axis of which coincided with the line of triple interface and the axis of grain misorientation. Periodic boundary conditions were imposed along the cylinder axis, and the atoms on side surface of cylinder were motionless. To simulate crystallization, calculation cell was melted by heating to a temperature well above the melting temperature of nickel. After the simulated polycrystal become liquid, the thermostat was turned on and held at a constant temperature below the melting temperature. Rigid boundary conditions on the lateral surface of cylindrical calculation cell in this case simulated crystallization fronts from three crystallization centers. The area near the triple interface had crystallized the last. In this area, defects and free volume were concentrated. Presence of impurities led to a significant slowdown in the rate of crystallization. With introduction of 10 % of impurity atoms, the rate of motion of crystallization front decreased several times. The effect of impurities on crystallization rate was enhanced in C – N – O direction, which is due to difference in crystal lattice deformation caused by impurity atoms. The greater this deformation was, the stronger was impurity atoms inhibit crystallization front. Formation of aggregates at fairly high concentrations was typical for impurity carbon atoms. Crystallization front had impeded on these aggregates. The oxygen and nitrogen atoms did not form aggregates. However, due to distortions of crystal lattice caused by them, they also strongly slowed down the crystallization front.

The paper presents the method and instrumental system for modeling and optimizing technological modes of direct metal reduction processes in a jet-emulsion aggregate (JER). Stages of the method are considered. The first one is the problem statement: formation of target conditions, choice of the process type, the task and system of optimization criteria. The second stage includes selection of the object of study: setting parameters of input and output flows, process parameters, stages and subprocesses. The third one includes thermodynamic modeling to assess the final equilibrium state in which optimization problem is solved to determine the best conditions for implementation of the processes of metal reduction from oxides in model systems. The fourth stage is development of metallurgical technology (finding the optimum modes and ways for achieving these modes by specified output stream parameters). And the final one is process optimization in technical and economic indicators. As part of the fourth stage, the complex of mathematical models has been developed that reflects relationship of flows and processes in a metallurgical unit. The structure of instrumental system is presented, in which mathematical models and an algorithm for determining optimal technological modes are implemented. A set of optimization criteria has been developed and a scheme for solving two types of optimization problems are presented: finding optimal conditions for reduction processes in thermodynamic systems and determining optimal modes of direct metal reduction. Application of the method to develop optimal technological modes of direct metal production in a JER-type aggregate is shown: metal production from cast iron and mill scale; direct reduction of metal from dusty ores and iron-containing man-made materials; obtaining manganese alloys from carbonate and oxide ores; processing titanium-magnetite concentrates with an almost complete separation of iron-containing and titaniumcontaining component; and direct reduction of iron with associated production of high-calorie synthesis gas.

Deployment of new service assets in operational IT environment is associated with the risk of disruption of the assets of its “basic” condition. Such disruptions cause failures of functioning services. To reduce the risk of disruption, the deploying service assets are divided by releases – sub-sets of service assets that will be embedded in the IT environment in one period. The traditional approach to formation and deployment of releases uses information on services structural properties to predict the number of failures due to the deployment of each service asset, each release and each application for deployment. As a result, the task of managing deployment of service assets is reduced to a sequential solution of three tasks: determining number of releases; determining composition of releases; building a release deployment schedule. The approach is based on the assumption that incorrect deployment of releases is manifested through the failure of services immediately after deployment. In practice, as a rule, this assumption is usually not fulfilled, because the use of various services by users who detect service failures is cyclical (daily, weekly, monthly, quarterly, annual). Many service failures can be detected by users in periods of time that are quite remote from the deployment time of the corresponding IT assets. The article contains the case where the managing process of IT provider configurations of the metallurgical company is well developed, i.e. its configuration database contains information on frequency of various services use at different periods of time. Information on dynamics of services application by users is used to predict time sequence of operating services failures due to deployment of each application. As a result, the task of forming and scheduling deployment of releases is formalized in the form of a discrete nonlinear programming task, the solution procedure of which allows simultaneous determination of number of releases, their composition and schedule for their deployment.

Study of Russian researchers’ works, as well as official methods devoted to various issues of evaluating performance of enterprises, allowed us to conclude that these methods are generally not focused on environmental factors specific to the industry. Availability of strategic management tools to clearly identify enterprise’s position in the same industry segment is in high demand in the context of changes rate increase and ability to adjust the strategy. The study is based on methodological premise that in enterprises with corporate strategies have remained stable in conditions of crisis processes in economy. Using a toolkit based on benchmarking, gap analysis and process approach, and sets of key indicators of efficiency of the basic functional strategies implementation (financial, marketing, technological strategies and human resource management strategy), we have made an integral assessment of the results of corporate strategies implementation in Russian ferrous metallurgy enterprises in conditions of 2014 crisis. We have defined the “best in class” enterprises and “potential bankrupts” in 2014 which has allowed us to calculate average values and median value for ferrous metallurgy enterprises, to identify position of each enterprise and to assess the gap of integral efficiency indicators of basic functional strategies and corporate strategy implementation.

The article presents a retrospective of scientific and educational activities of the Chair “Applied Information Technologies and Programming”. At the time of organization (in 1980), the Chair’s staff has set a task: to create specialists of a new plan (problem programmers) who simultaneously possess methods of research and mathematical description of specific objects (including metallurgical ones) and computer programming. By special order of the RSFSR Ministry of Higher Education, a new specialization was created in experimental order: “Computer support and computers in metallurgy”, which after 20 years of pedagogical experiment developed into the specialty “Information systems and technologies (by industry)”. The Chair was the first to produce such specialists not only in the region, but also in the country, and this experience was then adopted by other universities. The staff of the newly created Chair was one of the first in the country to create mathematical models of metallurgical processes, and then simulators and training systems based on them. An activity-based approach to learning based on a mathematical model of specific subject area was adopted as a pedagogical concept. Many years of experience in applying this approach has shown its high effectiveness. For the first time in metallurgy, a concept and a set of models of fundamentally new metallurgical process and unit with elements of self-organization was developed, characterized by an order of magnitude lower specific volume and one and a half times less energy consumption. Together with the designers and specialists of ZapSibMetKombinat (West Siberian Metallurgical Plant), a large-scale pilot installation of JER unit process was created, which confirmed the correctness of the proposed concept, worked out the main design points, and showed the practical feasibility of a number of new technologies developed. In a new process creating, software and tool systems were worked out: an algorithm for calculating the interrelated parameters of the process and the unit, the “Engineeringmetallurgy” system, a system for modeling complex heat transfer processes, and a system for simulating the particle level using the Monte Carlo method.