The paper considers the condition features of the H-beam capture grooved with rolls and break-down stand 1300 of a universal-beam mill of Nizhny Tagil Metallurgical Plant. The authors have carried out the study of the stress-strain state of metal arising in the deformation zone during rolling of the beam in the calibers of rolls of a breakdown stand. The results of the calculation of the rolling process are presented in the form of plots of the distribution of contact normal and tangential stresses in the deformation zones as the rolls grip the H-beam. The value of normal tensile stresses arising in the wall of the H-beam does not exceed 52 MPa. In the deformation zones the shelf and the zone of interface the shelves with the wall are normal contact compressive stresses, indicating a favorable position of the beam quality of the scheme of stress state with a predominance of high compressive stress. The paper also presents the developed calculation method of dynamic loads in drive line of a breakdown stand 1300 considering the gaps in the spindle connection.

The article describes the fulfilled modeling of the formation process
of oscillation tracks on the surface of continuous casting billets on a cool model when splitting the liquid phases through the hard crust. It has been shown that the forming hard crust near the walls of a crystallizer consists predominately of fine equiaxial crystals; that can be explained by the increased intensity of heat removal in this area. The growth processes of hard crust in the area of meniscus have been analyzed in the period of prime crystallization of billets. It has been shown that among the processes, connected with the formation of oscillation tracks on the surface of continuous casting billets, special attention deserves the phenomenon, occurring in the area of meniscus. The partial hardening of meniscus, which has a convex surface, provides the formation of hard crusts in the form of crista, which is introduced into a molten-pool at splitting, caused by the increase of the level in the crystallizer in the result of its movement upwards.

Decrease of NOx oxide emission at the iron ore sintering is able to reduce the negative anthropogenic impact on the environment and the population health. In the article the authors present the forming mechanism of NOx oxides at the iron ore agglomeration on the basis of experimental data. According to the results of experimental researches on a real sintering machine it has been established that not more than half of nitrogen comes in the form of NOx oxides, contained in a solid fuel. NOx content in process gases of sintering machines is directly proportional to the content of carbon monoxide. This dependence can be used with forecasting NOx oxide emission with sintering machines at mathematical modeling and technological calculations.

The paper presents the results of iron solid-phase reduction study obtained by means of TERRA software package. Investigations were carried out in two stages: the experiment on the model elementary system and the study of iron reduction from iron ore by the coals of various grades. As a result of thermodynamic modeling in the first stage of oxidation-reduction conditions study in Fe – C – O system there were some boundaries of reducing, transition and oxidizing zones and the corresponding values of the ratio of oxygen to the amount of carbon in that system. Studying of coal reduction properties by calculating of equilibrium compositions in a temperature range of 373–1873 K with TERRA software package usage showed that the composition of a gas phase in the given temperature range is almost the same for all types of coals and differs according to the amount of released volatiles. The sharp increase of gas volume begins at 673 K and ends at 1073 K. The results of thermodynamic modeling in the second phase of the experiment enabled to determine the optimal CC coals consumption (low-caking), D (long-flame), 2B (lignite) required for a complete iron reduction from iron ore of the specified composition.

The paper presents the results of the comparative researches of structural-phase states and internal stress fields of plasma-powder surfaces of the system of Ni – Cr – B – Si – Fe/WC with the use of a modifier in the form of nanodisperse particles of Al2O3 and without it. Using the methods of transmission diffraction electron microscopy on thin foils, scanning electron microscopy, X-ray structure and electron probe X-ray analysis, the authors have conducted the researches of powder alloy PS-12NVK-01, welded on a substrate of steel 20. The phase composition has been defined, as well as defect structure and internal stresses. The material structure has been studied before and after the introduction of nanopowder Al2O3 into the melt. It has been established that the introduction of the modifier leads to the decrease of the material grain size, to the formation of tungsten carbide W2C and boride Fe3Ni3B in a carbide subsystem, as well as to the decrease of the internal stress values and dislocation scalar density .

The paper presents the analysis of the residual stresses caused by the processes of technological welding cycle of steels and alloys. It has been found that the maximum residual stresses arise during cooling of the weldment. The research has established a satisfactory convergence of the calculation results of the mathematical and experimental design values of strain during welding on a special stand that allows identifying the direction of internal stresses action, as well as assessing the geometry details on the calculation model of temperature fields in butt welding of steel and titanium billets. In the article the authors show the possibility of using the coercimeter to assess the stress state of the material, its defects, the ability to predict the structural state and properties of welded joints. The studies have enabled the authors to give an opinion on the timing and dynamics of the flow of welding deformation as a result of internal residual stresses and structural changes caused by the welding process.

The quantitative parameters of structure phase states and dislocation substructure in volumetric quenched rails of high quality class were established by methods of transmission electron diffraction microscopy. In accordance with the morphological indication the following structure constituents of rail steel were selected: plate perlite, grains of ferrite-carbide mixture and grains of structure-free ferrite. The grains of perlite are main type of steel structure, their relative content is 0.68; relative content of ferrite-carbide grains is 0.28; the grains of structure free ferrite is rest. The analysis of curvature extinction contours was carried out and it was shown that interfaces of cementite plates of perlite grains; interfaces of perlite and ferrite grains; interfaces of globular particles of carbides – ferrite matrix are the sources of stress concentrators. It was established that interfaces of globular particles of carbides – ferrite matrix are the places with the highest value of stress concentrates. They were regarded as the places of possible crack formation.

The methods of modern materials science to quantitative changes in structural and phase states and dislocation substructure of steels of different structural classes (08Cr18Ni10Ti, 20Cr13, 20Cr23Ni18, E76F), under graver-electron-beam processing, the energy density 10 – 40 J/cm2 have been established. The gradient type has revealed the nature of changes in structural and phase states in steels after electronbeam processing, destroyed during high-cycle fatigue. The authors have identified and analyzed the main factors and mechanisms that determine the fatigue life of steels after electron-beam processing up to 3.5 times. The article presents the results of the change in the structural-phase states and faulty substructure of the steel due to grinding grain and subgrain structure (for 20Cr13 and 20Cr23Ni18 steels), suppression of the processes leading to the formation of zones, potential for microcracks formation (for 20Cr13 steel), the formation of needle-profile interface leading to a more homogeneous plastic flow in the substrate (for E76F steel).

The authors have used high degree of deformation (rolling on the great degree of deformation and the shift under high (5 GPa) pressure) to receive nanocrystalline structural state of the materials based on aluminum and titanium. The received materials in the nanocrystalline state have been used to create thin-layer composites with the introduction of nanocrystalline silicon among homogeneous layers. The measure of microhardness has shown that the microhardness of the composites after pressing under high pressure is in 2.5 times (Al – Si) and in 6 times (Ti – Si) more than the microhardness of the materials in the initial state. The study of the composite structure has showed (according to the received fracture pictures) that the composites are plastic. The increase of composites microhardness is observed at the preservation of an optimal level of the practical properties. The obtained nanocrystalline composites can be recommended as thin-layer very hard coatings on narrow or tensed areas of billets, as well as for the corrosion protection of local sites of the items.

The paper presents the information about the use of modern information systems in control processes. It considers the problemsof information, algorithmic, technical, software and mathematical software to create such systems. The authors have analyzed the issues of improving the reliability of information control systems to be used as expert systems when operating in the forecast. The expert system (simulator) for the technological process in metallurgy, scientific-methodical and program-algorithmic maintenance of the system based on technologies imitation modeling has been discussed. The system was designed for the training of personnel of potentially dangerous technological object, as well as for teaching the students of technical specialties of metallurgical profile. This system allows to explore an object of study in various modes of operation and to receive practical experience for optimal and trouble-free management.

The article discusses the formulation of the problem of creating
a simulation model of the gravity separator in the column jet-emulsion reactor. The main attention is paid to the forces acting on the particle and generation of particle size on the normal distribution within a predetermined range. The flow rate of gas through the reactor at a height of the turbulent motion and random velocities acting on the particle height of the reactor are considered as well as the velocity and mass of the two particles in elastic and inelastic collisions. The patterns of interaction of particles of iron ore, slag, metal, carbon emissions CO and CO2 and the calculation of the density of gas and the reactor mixture adjustment were made. The authors have determined the defining costs and mass arrivals of iron ore particles of slag and metal.

The paper describes the study of influence of finite element form that is used for partitioning of rectangular strip in simulation of rolling process with the use of smooth rolls. The accuracy of determining of velocity in longitudinal direction has been analyzed at each point of the deformation zone. Simulation of the rolling process has been performed using the penalty functions method and ESVDeform software package that was developed at the Chair of Metal Forming of DSTU. The results of the analysis allow recommending the 3D finite elements of rectangular form for practical use. It grants high accuracy of velocities prediction. The tetrahedral elements have been recommended to use in the cases when the accuracy of velocities prediction is not very important, but a large uneven strain distribution is presented in deformation zone.