The article provides studies on reduction processes in model thermodynamic systems and processes of nickel reduction from nickel concentrate and cobalt and nickel from cobalt-nickel concentrate. Concentrates are obtained during hydrometallurgical enrichment of polymetallic manganese-containing ores of the Kemerovo region – Kuzbass. By thermodynamic modeling using TERRA software complex, it was determined that nickel can be completely reduced from oxide in the NiO – C system at a carbon consumption of 0.08 kg/kg NiO, and at a carbon consumption of 0.15 kg/kg NiO ‒ in the NiO – Fe₂O₃ – C system. It was found that cobalt reduction in the CoO – C system begins at a temperature of about 513 K at any carbon consumption. With a further increase in temperature, the reduction process depends only on consumption of the reducing agent. From the obtained thermodynamic modeling data, it follows that cobalt reduction from the cobalt-nickel concentrate begins at a temperature of about 513 K and subsequently depends slightly on temperature. The extraction of cobalt increases with the amount of reducing agent at temperatures up to 553 K, then remains constant up to 1473 K temperature. Nickel reduction takes place at a temperature above 473 K. The degree of nickel reduction slightly depends on the temperature and amount of reducing agent at consumption of the latter over 0.02 kg/kg of concentrate. Laboratory studies showed that during the melting period, nickel can be reduced from its oxide almost completely with solid carbon, since nickel has less sensitivity to oxygen than iron. Theoretical and experimental studies of steel direct alloying showed that it is advisable to use a solid phase process in reduction of nickel and cobalt. Nickel concentrate and cobalt-nickel concentrate during steel smelting in an electric furnace is advisable to be introduced into charge in the form of mixtures pelletized with a carbonaceous reducing agent.

The work is devoted to identification and analysis of patterns of change in the elemental and phase composition, defective substructure, mecha­nical (microhardness) and tribological (wear resistance and friction coefficient) properties of stainless high-chromium steel subjected to complex processing, combining vacuum irradiation of the samples surface layer with an intense pulsed electron beam of submillisecond exposure duration and subsequent nitriding under electron-ionic heating conditions. High-chromium steel AISI 310S, which in the initial state is a polycrystalline aggregate based on γ-iron, was used as the research material. Pulsed electron beam treatment of steel was carried out on a “SOLO” installation equipped with an electron source with a plasma cathode based on a low-pressure pulsed arc discharge with grid stabilization of the cathode plasma boundary and an open anode plasma boundary. Steel nitriding was carried out on a “TRIO” installation with a chamber size of 600×600×600 mm, equipped with a switching unit to implement the electron-ionic processing mode. Nitriding was carried out at 723, 793, and 873 K temperatures for 1, 3 and 5 h. It was found that electron-ionic nitriding of the samples pre-irradiated with an electron beam (10 J/cm², 200 μs, 3 pulses at 723 and 793 K for 3 h) is accompanied by the formation of a ceramic layer containing only iron and chromium nitrides. The highest values of steel wear resistance after electron-ionic nitriding, exceeding the wear resistance of the initial steel by more than 700 times, are observed at nitriding parameters of 793 K, 3 h.

In this work, a coating of a high-entropy alloy CoCrFeNiMn of non-atomic composition is formed on a substrate made of alloy 5083 by the method of wire-arc additive manufacturing (WAAM). The authors investigated the change in microhardness in the contact zone of the coating – substrate system. Using the methods of modern physical materials science, the structural and phase state, defect structure and elemental composition of the coating – substrate system were analyzed. The discovered physical mechanisms contribute to an increase in hardness in the contact zone.

The paper investigates the microstructure and phase composition of nickel- and aluminum-based intermetallic alloys obtained using two-wire electron-beam additive manufacturing (EBAM). Relevance of the research is related to the widespread use of intermetallic alloys based on nickel and aluminum (mainly Ni₃Al) in various high-temperature applications and the need to use modern production methods when creating machine parts and mechanisms from these alloys. Using EBAM, the billets from intermetallic alloys with different ratios of the content of main components were obtained. Change in concentrations of the basic elements was carried out varying the ratio of feed rates of nickel and aluminum wires during additive manufacturing in the range from 1:1 to 3:1, respectively. The results of microscopic studies of the obtained alloys showed that, regardless of nickel content, the obtained alloys are characterized by a large–crystalline structure with grain sizes in the range of 100 – 300 μm for alloys with a component ratio of 1:1 and 150 – 400 μm for alloys with a component ratio of 2:1 and 3:1. At the same time, the alloy with an equal content of base components is characterized by more uniform grain and microstructure compared to those with high content of Ni. By changing the concentration ratio of the components, phase composition of the resulting billet can be purposefully controlled. In the case of an “equiatomic” content of the base components in the alloy, a NiAl-based compound with a small phase content based on the intermetallides Ni₃Al₅ and Ni₃Al is formed. At high concent­rations of nickel, the intermetallic Ni₃Al phase is formed, and at a component ratio of 3:1, structure of the resulting billet consists mainly of Ni₃Al phase and the γ solid substitutional solution based on nickel. The paper demonstrates the possibility of direct production of intermetallic alloys with a given phase composition during electron-beam additive manufacturing.

Steels of X70 strength class are particularly widely used in the field of heavy engineering. One of the most important issues when choosing steel for structures is its behavior under cyclic loads. It is difficult to find a description of the behavior of all zones of the welded joint under fatigue. The purpose of this study was to determine the fatigue characteristics of welded joints made of the Russian analogue of S690QL steel with fixation of acoustic and magnetic parameters for their use in the diagnosis. The objects of the study were the samples from domestic steel of X70 strength class. The chemical composition was determined using optical emission spectrometry. The grinds for microstructural analysis were prepared according to the standard technique with etching in the metal. The fatigue test was carried out on a specialized test bench. The authors used the acoustic system AIS NRK-3 for acoustic measurements and the acoustic parameter D – as an informative parameter. A MA-412MM coercitimeter was applied to evalua­te the magnetic characteristics. The following were evaluated: residual magnetization B_r, coercive force H_c, H_c/B_r ratio. The smallest number of cycles corresponds to the deposited metal zone. The decrease in amplitude showed a significant variation in the behavior of the material depending on the junction zone. However, the curves for heat affected zone (HAZ) and the deposited metal are practically the same. HAZ differs to a lesser extent from the base metal than the deposited metal zone. The graph of the acoustic parameter in its form is the reverse of the magnetic characteristics graph. Thus, there is a minimum for the acoustic parameter, depending on the operating time, and a maximum for the magnetic characteristics. For both graphs, the extremum is the point corresponding to the operating time of 0.6.

The article is devoted to the study of martensitic transformation in porous sintered steels. When analyzing the process of development of marten­sitic transformation in porous sintered steel, the influence of two factors was assessed: depletion of carbon in the near-surface layers of pores and a change in the energy balance due to relaxation of transformation stresses on free surfaces of the pores. The martensitic transformation was studied in porous steel with a carbon content of 1.56 wt. % obtained after pressing and sintering of a mixture of PZhRV iron powders and GK-3 graphite in hydrogen atmosphere at 1200 °C. Gas carburizing at 1100 °C and homogenization helped to achieve the specified carbon content. The samples were quenched in a sodium chloride solution at a temperature of 27 °C. Pre-cooling was used from temperatures A_st to 800 °C at a rate of 62 °C/s. X-ray microanaly­sis of carbon distribution was carried out using the installation CAMECA Microsonde M.S. 46 with a probe diameter of two microns. The martensite plates predominantly formed on the pores’ surfaces and their cross section had shape close to rhomboidal. The data obtained on the morphology of α′-phase crystals growing from pores and the study by X-ray spectral microanalysis of carbon distribution along the largest martensite plates convince us of the absence of any significant changes in carbon content and, as a consequence, their influence on development of martensitic transformation in the area of pores is not the leader. For sintered porous steels, an irremovable factor in the increase in temperature is the presence of porosity, in contrast to a removable factor – inhomogeneity of the chemical composition, which is caused by incompleteness of the alloy homogenization processes, both during sintering and during the austenitization process that precedes quenching.

In Russia, with its extensive railway system, for more than 5 years, special-purpose rails of increased wear resistance and contact endu­rance of the DH400RK category were produced from steel with a carbon content >0.8 %. On the head rolling surface of differentially hardened long rails made of hypereutectoid steel after long-term operation, transmission electron microscopy methods revealed the morphological components of the structure: lamellar pearlite, fragmented pearlite, destroyed lamellar pearlite, globular pearlite, completely destroyed pearlite, subgrain structure. The contribution of hardening due to: lattice friction, solid solution hardening, pearlite hardening, incoherent cementite particles, grain boundaries and subboundaries, dislocation substructure and internal stress fields were quantified. A hierarchy of these mechanisms was made and it was noted that for the fillet surface of the rail head, the main hardening mechanism is hardening by incoherent particles, as well as mechanisms caused by internal long-range (local) stresses, internal shear stresses (“forests” of dislocations) and substructural hardening. For the rolling surface along the central axis of the rail head, the main role in hardening belongs to long-range stress fields (especially its elastic component), hardening by incoherent particles and substructural hardening. Taking into account the volume fractions of the morphological components and their yield strength, the additive yield strength on the head rolling surface in the center and on the fillet was determined: 7950 and 2218 MPa, respectively. The paper presents a physical interpretation of the difference in values of the additive yield strength on the rolling surface of the rail head in the center and on the fillet.

Surfacing, like welding, is associated with heating metals in a wide range of temperatures and subsequent cooling of heated zones at different rates. This leads to complex structural and phase changes that are crucial for operational properties of the “protected material – coating” joint. The structure and properties of the alloyage zone of these two materials depend on the degree of penetration, nature of the intermediate layers that arise, and carbon diffusion in the boundary areas. When surfacing on low-carbon steel, depending on the composition of the deposited metal, the structures with a predominant amount of martensite or austenite can be obtained in the alloyage zone, depending on carbon content. The structure and mechanical properties of the bimetallic joint between carbon steel and stainless steel were studied depending on the modes of electric arc surfacing (submerged arc surfacing in one pass, in argon for one and two passes). It was established that the structural and phase composition of the deposited metal is austenite, finely dispersed carbides and a needle component. The structure of the layer deposited in argon in one pass is more homogeneous and does not contain defects. The microhardness increases smoothly along the depth of the deposited layer. As a result of surfacing in argon in two passes, the joint has a homogeneous microstructure, but a large number of microdefects are formed in the layer, which can further lead to the formation of a crack near the alloyage boundary. In submerged surfacing, the heating rate and specific heat input are insufficient, therefore, the surfacing bath is poorly mixed, which leads to a suboptimal structure and the formation of thermal stresses at the alloyage boundary and to the formation of a coating that is heterogeneous in structure and microhardness.

The molecular dynamics method was used to study the structure formation during austenite nanoparticles crystallization in the presence of carbon impurities. The paper describes the dependence of the melt cooling rate, particle size, concentration of carbon atoms in the particle on the resulting structure features during crystallization and temperature of the crystallization onset. Formation of the nanocrystalline structure of nanoparticles can be controlled by varying the cooling rate and introducing a carbon impurity: at a cooling rate above 10¹³ K/s in the model used, crystallization did not have time to occur; at a rate below 5·10¹² K/s, the austenite particle crystallized to form a nanocrystalline structure. At the same time, with a decrease in the cooling rate, a decrease in the density of defects in the final structure was observed. At a rate of 5·10¹¹ K/s or less, crystallization of carbon-free particles took place with the formation of low-energy grain boundaries (with a high density of conjugate nodes: special boundaries, twins). The crystallization temperature during cooling at a rate below 10¹² K/s is inversely proportional to the particle diameter: as the particle size decreases, the proportion of free surface increases, which leads to a decrease in the probability of crystalline nuclei formation. In addition, the crystallization temperature increases with a decrease in the cooling rate. The introduction of a carbon impurity led to a decrease in the crystallization temperature of nanoparticles: in the presence of 10 at. %. As a percentage of carbon, it decreased by about 200 K for particles of different sizes. Carbon atoms often formed clusters consisting of several carbon atoms. Such clusters distorted the resulting crystal lattice of metal around them, preventing crystallization. In the presence of a carbon impurity, the final structure of the crystallized particles contained a higher density of grain boundaries and other defects. Carbon atoms, especially clusters of them, were fixed mainly at grain boundaries and triple joints.

The development and research of new materials for machine parts of the mining and metallurgical complex by the method of surfacing with flux cored wire has a lot of attention nowadays. Flux cored wires are widely used for surfacing of steels with high wear resistance, in which reduced tungsten in the form of ferroalloys, ligatures and metal powder of various degrees of purity are used as fillers. However, due to the scarcity and high cost of tungsten, its rational use is an urgent task. For practical application, the technology of surfacing with tungsten-containing flux cored wire is of interest; using it the maximum extraction of tungsten into the deposited layer is achieved due to reduction processes in the arc. In order to increase the beneficial use of tungsten, the technologies of indirect alloying with tungsten during surfacing under the flux of flux cored wires, in which tungsten oxide is used as a filler on the one hand, and reducing agent – on the other, deserve consideration. It can be expected that during arc discharge, tungsten and (or) chemical compounds of tungsten with reducing agents can be formed during the surfacing process. This paper presents the results of a comparative analysis of the thermodynamic processes of tungsten oxide reduction by carbon, silicon, aluminum and titanium during arc discharge occurring during surfacing with flux cored wires under a layer of flux. The thermodynamic analysis of 41 reactions in standard states showed that the presence of reducing agents (carbon, silicon, aluminum, titanium) in the flux cored wire used for surfacing will contribute to the formation of silicides and tungsten carbides, and, possibly, tungsten itself. It was determined that the best state for the participation of tungsten oxide in reactions in the arc is WO₃(g) gaseous state.

The paper presents the results of theoretical research of stress-strain state of a billet – mandrel system when producing steel hollow billets in a unit of combined continuous casting and deformation, in which the working surface of the calibrated anvils are made with a variable radius. The necessity of making the working surface of the calibrated anvils with a variable radius is substantiated and initial data for the calculations is given. The calculation results are considered along the lines of the volumetric model passing through the characteristic points of deformation centers. The authors determined the forces when the anvils compress the wall of a hollow billet and the force of pulling the hollow billet from the mold. The laws of metal axial displacements and stresses in the deformation centers during compressing the wall of a hollow billet was established at the combined process of continuous casting and deformation in the unit. Nature of the stressed state of the metal wall of a hollow billet is considered from the perspective of improving its quality. The technique studied allows to determine the stress-strain state of a mandrel when producing a hollow steel billet using such a unit. The authors provided the recommendations for reliable gripping and compression with calibrated anvils of a hollow steel billet coming from a water-cooled copper mold of the unit of combined continuous casting and deformation.

The paper presents the results of numerical calculations of the solution to the problem of modeling the process of possible cracking in a spherical shell mold when pouring liquid steel into it and cooling the solidifying casting. The numerical scheme of the axisymmetric problem and the algorithm for its solution were given in Part 1. The crack resistance is estimated by magnitude of the normal stresses in the ceramic shell during its co-cooling with a solidifying casting. The results detailed analysis considered: fields of displacement, stresses, and temperatures both on spherical surface and in growing crust of solidified metal. The solution took into account the change in the shear modulus of the mold material from temperature, and an assessment of this refinement was given. The problem was solved in two ways. The first – with a constant shift modulus of the shell mold; the second – with its temperature-dependent shift modulus. There is a significant difference between these variants in terms of magnitude of the normal stresses arising in the shell mold. The authors analyzed resistance of the shell mold spherical geometry to external influences from its support filler and filling funnel. The problem of determining the contact and free surfaces at the boundary of the shell mold and support filler was solved. The results are presented graphically in the form of diagrams of stresses and temperatures over the studied area in its different sections and time intervals for cooling of the growing metal crust. The role of compressive normal stresses σ₂₂, σ₃₃ on the surface of contact of the shell mold with liquid metal at the initial moment of cooling on probability of cracking in a spherical mold is shown. The level of strain-stress state in a spherical shell mold when cooling a steel casting in it is significantly determined by dependence of shift modulus of the shell mold on temperature.

As part of the study, a method was proposed for assessing the metal purity for non-metallic inclusions using optical emission spectrometry. To assess the content of non-metallic inclusions in the slabs, two columns of metal were selected from two slabs of low-alloy metal deoxidized with aluminum. Each column was divided into seven samples in the direction from the small radius of the continuously cast ingot to the large one. We studied these samples to assess metal contamination with non-metallic inclusions using quantitative optical metallography according to ASTM E1245-03, fractional gas analysis (FGA) and optical emission spectral analysis PDA. Analysis of the samples according to ASTM E1245-03 standard showed that in all samples the percentage of oxides and sulfides is on average 10 and 90 %, respectively. According to the results of FGA, it was concluded that such non-metallic oxide inclusions as aluminates predominate in the metal samples of both ingots. A comparison was made between the results of the determination of oxygen in non-metallic inclusions obtained by FGA method and the number of sparks in inclusions at the analysis by PDA method; analysis of the dependencies showed that there are two clearly defined point distributions. To carry out PDA analysis, a program was deve­loped that allows determining the number of inclusions of various types and calculate their volume fraction.

An approach to managing the main modes of smelting steel in heavy-duty electric arc furnaces (EAF) using digital twin technology was defined and formulated. It was noted, that the existing power regulators do not have the function of balancing the effective power of phases and, accordingly, electric arcs because they are focused on working with a certain average value of the signal. It is proposed to use the analysis of dynamic characteristics based on instantaneous values of input parameters instead of operating ones, as it’s usually implemented in most devices. This allows us to obtain more accurate data on the arc state and reduce the amount of time and computing power required to obtain a result and form recommendations. Based on the data obtained as a result of long - term observations of the heavy-duty EAF-135 operation, the relationship of the constant component of the arc voltage (CCAV) with the metal oxidation is shown. An example of its use as a criterion for controlling the melting oxidative stage is given. This reduces the consumption of electrochemical sensors for each melting in the case of serial metal production. Based on the recorded data, it is possible to timely determine the unevenness of the arc power release between the furnace electrodes and issue recommendations on gas burners operation regulating to equalize the rate of scrap melting at electrodes with less power release. The authors propose the idea of using digital twins based on models of the active power distribution across the melting bath zones and dependence of metal oxidation on oxygen blowing for monitoring and controlling the electric mode and the oxygen blast mode at the oxidative stage of the melting process. Simplified schemes of these twins are given.