RESOURCE SAVING IN FERROUS METALLURGY
The article describes the composition and properties of technogeneous metallurgical waste to obtain colored cement. A basis of binder is bleached clarified slag. Activators and pigments are manmade products. They are: gas cleaning dust of lime production – alkaline activator, replacing lime; waste of by-product coke production – sulfate activator instead of scarce gypsum rock; spent sand mixture (foundry product) – activator of cement grinding; hardware production waste - red pigment. Optimal composition of slag cement is selected, the factors affecting its properties are studied. The process flow diagram of colored cement production of grade 250 with the activity of 27.4 MPa has been developed. To assess the quality of raw materials an universal indicator has been proposed – the ratio of basicity.
METALLURGICAL TECHNOLOGIES
The paper presents the results of two experimental campaigns of silicon-manganese smelting brand MnS17 using coke nut and semicoke as a reducing agent, produced from brown coal of Kansk-Achinsk basin on the technology, which is based on the slicing coal gasification process. The experienced campaign of silicon-manganese smelting was performed using a manganese ore containing 42.7 and 38.44 % of manganese in value in charge 1:3. The manganese content in the melted alloys were 65.9 – 68.11 %, silicon – 17.47 – 18.3 %. It was established that using restorative mixture of 80 % of coke and 20 % of semi-coke the technical and technological parameters of the process deteriorated; with the introduction into restorative mixture of brown coal in the amount of 35 % at a flow rate of semi-coke of 27 % and coke of 38 % the electrical performance of the furnace stabilized, gas permeability of the furnace throat recovered. The best performance was achieved with the introduction into restorative mixture of semi-coke of 32,5 %, a further increase of its quantity affects the performance of the furnace.
The article outlines the methodology and results of solving the task of measuring the temperature field and the thermoelastic stress in the horizontal rolls in the process of rolling of a broad-flanged beam in the universal beam mill stand. The authorsets and solves the problem of measuring the temperature field of the composite rolls. The author discloses the algorithm of measuring the thermoelastic stress in the horizontal rolls with the known temperature field. The article contains distribution diagrams of the tangential thermoelastic stress in the cross section of a horizontal roll in the process of rolling beams in the universal mill stand. The author shows the effect of the heat emission factor on the level of the tangential stress in cooling the rolls with water. The theoretical research determines the value of the tensile tangential stress which lowers the endurance of the horizontal rolls of the universal mill stand. The article determines the resultant stress field in the horizontal composite rolls caused by the rolling pressure and the cyclic thermal effect with the residual stress taken into account. The author provides recommendations how to increase the endurance of the composite rolls of the universal beam mill.
Nonmetallic inclusions in the cast and rolled samples of austenitic stainless steel C0.03-Cr18-Ni10 and C0.08-Cr18-Ni10-Ti1 were studied by scanning electron microscopy. In steel alloyed with titanium, titanium nitrides and oxides of different dispersion were found around globular nonmetallic inclusions with separation of second phase. The inclusions in titanium-free steel have predominantly globular shape and represent oxide inclusions of complex composition. In C0.03-Cr18-Ni10 steel there is no big clusters of nonmetallic inclusions; that leads to high quality of cold-rolled sheet surface. On a surface of a cold-rolled sheet of C0.08-Cr18-Ni10-Ti1 steel there are defects as delaminations from the surface of the sheet, containing titanium nitride and slag-forming mixture.
The article examines the results of the kinetics studies of decarburization of alum-periclase-carbon refractories, which are widespread at the metallurgical enterprises to perform the working layer of casting ladle linings. The article describes the dependence of decarburization depth on the time – temperature factors, as well as on the composition of the atmosphere. From the point of view of durability of alum-periclase-carbon resinbinded refractories not only the porosity is important but also the presence of flaked graphite and carbon particles in the surface layers, because they reduce the surface wettability of the refractory by metal and slag, as well as reduce the uniformity of the thermal and mechanical properties of refractories by the section. The difference of the compositions of de-carbonized and the base layer of refractories can result in a formation of cracks and spallings caused by thermal stresses during heating and cooling of the lining. The influence of temperature and atmospheric composition on porosity of alumpericlasecarbon ladle refractories is studied. The studies show that hightemperature exposure leads to an increase of the porosity of the material. Heat treatment of refractories in oxygen-free atmosphere eliminates the decarburization, however, water absorption and porosity of the refractory changes slightly.
MATERIAL SCIENCE AND NANOTECHNOLOGIES
The differential quenching of the rails by compressed air is the most perspective strengthening method. The layer by layer analysis of differentially quenched rails is carried out using transmission electron microscopy methods and the quantitative parameters of structure, phase composition and dislocation substructure are established and comparison of these parameters for different quenching regimes is made. It is established that the differentiated hardening of rails by compressed air in different regimes is accompanied by the formation of morphologically different structure, being formed according to the diffusion mechanism of γ → α transformation and consisting of plate perlite grains, free ferrite grains and grains of ferritecarbide mixture. The being formed structure has the expressed gradient character: surface layer state of rail steel depends not only on the quenching regime but on the investigation direction and the depths of analyzed layer from the surface. The dislocation substructure in the form of chaos, nets, cells and fragments is revealed.
INFORMATION TECHNOLOGIES AND AUTOMATIC CONTROL IN FERROUS METALLURGY
This article proposes a new approach to building control systems, consisting in the joint synthesis of the controlled object and the control subsystem. The authors made the formulation of such a synthesis based on a set of object models and control algorithms with the formation of allowable combinations “model of object control algorithm”. The effective solving of the problem by simulation of natural and mathematical modeling was proposed. The article shows the examples of synthesis of control systems of steel melting in basic oxygen furnace (steel melting control system in basic oxygen converter). The authors identified the need to expand models for steel melting by including factors affecting the parameters of the converter during oxygen blowing. The technical and economic performances of various control systems were received. It is shown that the system “The combined model of the object with the op-erational settings of the сonverter caracteristics the combined control algorithm” has the best technical and economic indicators.
SHORT REPORTS
The paper presents estimated data on the relative strength of the solid fuel for various ratios of coke and anthracite coal in the fuel bed charge when carrying out tests on the facility for determination the solid fuel strength by the developed technique. The optimal experimentally reasonable value content of anthracite and coke in the fuel bed charge (60 % and 40 %, consequently, while relative strength of 0.85) is recommended.
TOPICAL COLLECTION OF ARTICLES «NANOSTRUCTURED MATERIAL SCIENCE»
The article presents the results of the analysis of phase equilibrium of the ordered phases in binary systems on the basis of Pd palladium Pd – Me (where Me – Co, Rh, Ir, Cu, Ag, Au, Ni, Pt) to find correlations of crystallochemical and crystallogeometrical factors. It is established that packing index in disordered solid solutions in binary systems based on palladium is close to the value of 0.74 against the background of a isignifiant deviation of the atomic volumes from the law Zena. It is revealed that the increase in a hydrogen diffusion in binary alloys of Cu – Pd system correlates with considerable decrease in a packing index in the ordered phase B2 in the field of 40 % Pd (at). It is established that different structural and phase states are formed in binary Pd – Me systems at certain combinations of temperature and dimensional factors. The diagram in the coordinates temperature factor – size factor is constructed. This diagram is divided into three ranges which allow to categorize structurallyphase states depending on the ratio of the temperature and size parameters in binary systems based on Pd. Range I includes system forming solid solutions only; Range II contains systems in which ordered phases are formed from solid solutions; Range – III is a compounds range where a solid solutions layering occurs.
The review of regularities and possible mechanisms of grain refinement in TiNi-based alloys under the equal-channel angular pressing (ECAP) on the basis of the experimental results and liter-ary data is presented. The dependence of grain size on the accumulated true deformation in the framework of the continuous dynamic recrystallization model is considered. The results of experimental researches of ECAP effect on functional properties of TiNibased alloys are presented. The microstructure evolution of Ti50Ni47.3Fe2.7alloy with increasing number of ECAP passes affects nonmonotonically on mechanical properties, the regularities of accumulation and the recovery of inelastic deformation and the development of plastic deformation under isothermal loading unloading cycles and the shape recovery during heating predeformed samples. It is shown that the maximum of hardening achieved after the formation of ultrafine grain structure in samples of this alloy during the first pass of ECAP correlates with the maximum (5 %) of superelasticity at 295 K.
The structure of a surface layer of highstrength 30CrMnSiNi2 steel modified by means of ion beam treatment was investigated by optical, scanning electron and transmission electron microscopy as well as X-ray diffraction analysis. Formation of softened surface layer with depth up to 100 μm was revealed due to the specimens heating in the course of treatment. Cyclic and static tension tests have been carried out for steel specimens in assupplied state and after surface irradiation by Zr+ ion beam. It is revealed that modified surface layer during cyclic loading inhibits initiation and development of a fatigue crack, resulting in a more uniform strain distribution along the working part of the specimen. Differences of the specimen deformation behavior and changes of their mechanical properties are analyzed. Displacement vectors and strain distribution fields were constructed according to micrographs obtained during tests, which illustrate regularities of fatigue crack growth in specimens without treatment and after irradiation..
ANNIVERSARIES
To the 75th anniversary of Nikolai Mikhailovich Kulagin
ISSN 2410-2091 (Online)