Summing up the results of scientific research activity for 2017, we can confidently say that NUST MISIS, based on the scientific po­tential and experience of its teaching and research staff, has achieved even more substantial gains in the field of fundamental and applied research. Through the development of laboratories, invitation of inter­nationally recognized researchers to the university, and participation in ambitious international scientific projects, the university continues ev­ery year to conduct even more research and development in disciplines that are both conventional and new for NUST MISIS. This article presents the main results of the research and technology and innovation efforts of the National University of Science and Technology MISIS (NUST MISIS) for 2017. The issues of inclusion in international ratings, university financing, results of the researchers’ publishing activi­ties, as well as the results of scientific and innovation efforts, have been covered here in detail.  

The authors have investigated microstructure and crystal struc­ture of the steel samples of 9Kh2MF and 8Kh3SMFA steel with la­ser surfacing. The samples were taken from working shafts of reverse rolling mill in conditions of OJSC «Uralmashzavod». Brewing surface cracks in rolls with the use of laser is considered as an effective method of parts restoring in small-scale production. The research was carried out to control the quality of steel products with laser surfacing. Quality control of working rolls of rolling mills with laser surfacing is aimed at identifying the defects of metallurgical origin (nonmetallic inclu­sions, discontinuities, regions with heterogeneity of chemical compo­sition) in zones of surfacing and thermal influence and is performed by ultrasonic method. Metallographic study of the microstructure and crystal structure of steel samples with laser surfacing was necessary to develop an ultrasonic testing technique. The main way to detect de­fects of metallurgical origin in steels is scanning electron microscopy with functions of micro-X-ray spectral analysis (EDS-analysis) and diffraction of backscattered electrons (EBSD-analysis). The metallo­graphic study was carried out using a scanning electron microscope Carl Zeiss AURIGA CrossBeam equipped with analytical systems for studying the elemental surface composition by X-ray spectral analysis (EDS) and the crystal structure of the surface by diffraction of back­scattered electrons (EBSD). As a result of metallographic examination, steel-laser welded samples taken from the working rollers of the re­verse rolling mill were found to have defects of metallurgical origin along the surfacing boundary. The size of microinhomogeneities for 9Kh2MF steel is 10 – 50 μm; the elemental composition includes Mn, Si and O. The size of microinhomogeneities for 8Kh3SMFA steel is 1 – 3 μm, and the elemental composition includes Mn, Cr and Mo. It was established that metal on melting is less textured and has more homogeneous acoustic characteristics than base metal, it must be taken into account at ultrasonic quality control of steel products with laser surfacing. At ultrasonic inspection of laser-surfaced working rolls, we recommend setting the signal fixation level with reflectivity equivalent to the flat-bottom hole diameter of 1.5 mm.  

The analysis results of trends and modern techniques of research in the field of steel continuous casting are highlighted which are aimed at finding and eliminating of factors that have a negative impact on the surface quality of continuous cast billets. It is shown that the existing concept of creating quick change systems of submerged nozzles, which are used on the slab CCM, leads to the formation at the each stream of machine during serial casting of 20 heates of substandard portion of the billet with 30 – 40 m of length, formed as a result of unstable hydrodynamic conditions in the mold. The research results are given for the physical model of changes of trajectory and speed of the metal flows into the CCM mold, which are related with submerged nozzles replacement in the process of serial casting of steel. Recommendations to reduce duration of the negative impact of this factor on the con­ditions of cast billet formation are offered. Using control-measuring system with strain gauge transducer, it was found that the fluid flows velocity difference at the opposite narrow walls of the mold model, causing a violation of the thermal conditions of crust formation of con­tinuous casting billet, in the case of once-through submerged nozzles can reach 2.0 – 2.3 and for non-pressure hollow-bottom nozzles with two lateral holes separated by divider – 1.2 – 4.0. Information about the trajectory symmetry breaking of circulation circuits of melt flows in the mold, caused by conducting of operation of outworn submerged nozzle replacing, also was obtained using high speed video materials. During the research the visualization of water flows trajectories, which simulated the molten steel in the mold model, was provided by intro­duction of air through a channel of model of stopper-monoblock of the tundish, so that the input of argon during casting was simulated. The obtained information allowed to develop a new principle of construc­tion of system of submerged nozzles quick change which consists the combined and parallel implementation of individual stages of refracto­ries replacement by its structural elements (manipulator, teeming and pushing devices). It allowed to reduce the time required to replace a outworn submerged nozzle and to increase the yield during the produc­tion of slab billets on CCM.  

Consistent patterns in the combustion of ferrosilicium in nitrogen are rather similar to those of metal silicon. As the concentration of silicon in initial ferrosilicium is increased, the intensity of its interac­tion with nitrogen increases as well, resulting in a significant growth of the combustion rate. The concentration of nitrogen in the combus­tion products here increases as well. In the entire investigated range of initial parameters (nitrogen pressure, powder fineness, burden mix), the main phase in the combustion products is β-Si3N4. No considerable amounts of α-Si3N4 have been observed. In practical applications, the use of FS75 and FS90 ferrosilicium is optimal for producing fire-re­sistant materials, while FS65 and FS75 (being the purest alloy grades) are optimal for obtaining alloying steel compositions. Introducing iron into the (Ti – B) (Tad = 3190 K) system significantly narrows down the concentration limits of combustion. ((Fe – B) + Ti) mixture with 16.9 % B alloy burns in a narrow range of Ti:B concentrations close to 0.86. When a ferroboron-titanium mixture burns, an increase in the initial temperature significantly expands the synthesis concentration limits. In all the cases, an increase in the initial temperature leads to a significant increase in the combustion rate. Heating up to T0 ≥ 300 °C allows for involving mixtures with more coarse titanium powders (rav. Ti ≥ 0.4 mm) into the SHS process. The synthesis is implemented in a wide range of B:Ti ratios. By burning such mixtures one can ob­tain alloys with 6 – 14 % B and 30 – 60 % Ti. Specialized industrial equipment has been built: a series of SHS reactors with the operation  volume of 0.06, 0.15 and 0.3 m3 for the serial production of manufac­turing items based on hard-melting inorganic compositions (nitrides, borides, silicides, etc.) for metallurgical applications. Industrial SHS production of composite materials based on oxygenless compositions has been set up.  

To determine the reasons that decrease life of the grate bars of pellet cars from steel 40Kh24N12SL during the operation, a compara­tive analysis of the results of macro-investigations of the grate bars af­ter operation with the results of modeling the operating conditions for the grate was performed. The modeling of the operating conditions was carried out using the finite element method, which allowed achieving high reliability of the obtained results. For the reliability of the model­ing results, the maximum possible number of boundary modeling con­ditions was obtained, obtained from both macro-examples conducted earlier and from the scientific literature. The application of the finite element method made it possible to determine that a high temperature gradient with local overheating zones is formed along the section of the component. It is shown that the nature of overheating is predictable and is related to the conditions of the coolant supply to the working area during operation of the part. It is established that zones with large values of internal stresses and deformations are locally formed during operation. The regularity of appearance of these zones is shown, which highly dependents on the presence of inhomogeneities in the structure of the part, and is also supposedly related to geometric complexity of the casting. It is also established that in the presence of shrinkage shells, all values of stresses and deformations increase sharply, espe­cially in local maximums. In this case, the distribution of local zones with high stresses and deformations in the presence of shrinkage shells remains practically unchanged. An analysis of the location of zones with high stresses and strains made it possible to explain the existing principle of the destruction of the grate by cracking during operation. It is proved that one of the main causes of buckling, cracking and fracture of the grates of the pellet cars made of steel 40Kh24N12SL is the pres­ence of shrinkage shells in the metal structure. As a result of modeling the operating conditions, mechanism of the occurrence of buckling, cracking and fracture of the grates of steel 40Kh24N12SL during op­eration is described, which completely coincides with the results of macro-investigations and observations obtained during operation.  

A short analysis of existing methods for reducing the feeders’ volume is carried out. Their advantages and disadvantages are singled out. The area of application of optimization methods of the feeders’ form is substantiated with the purpose of increasing the casting yield. The actual location of shrinkage defects in variously designed feeders is considered. The patterns of location and shape of shrinkage cavity are shown depending on the shape of the feeder upper section. This allowed to distinguish four groups of feeders and noted the differences in the effectiveness of their work. To clarify the mechanism of shrinkage defects formation in feeders with a different form of the upper section and to estimate the effectiveness of their work, it is proposed to use methods of mathematical modeling. The appropriateness of using mathematical modeling methods is emphasized, by means of the pos­sibility of idealizing external influencing factors on thermal processes in the form that is difficult to achieve in real conditions of foundry pro­duction. The SOLIDCast application is used as the modeling means. The initial and boundary conditions for mathematical modeling were identical for all types of feeders. The results of the shrinkage cavities prediction are presented as isosurfaces diagrams, the sizes were used for estimation of the feeders work efficiency. The method of estima­tion of variously designed feeders’ effectiveness is proposed on the basis of mathematical modeling results. Characteristics of shrinkage defects location in feeders’ volume are proposed to use for estima­tion of feeder’s effectiveness. Its calculation for the feeders of equal size but having differently designed top part is shown. The introduced efficiency index has a good adjustment with geometric module (ratio between volume and surface of feeder). Increasing feeder’s geometric module increases its thermal efficiency. It is shown that the use of a notch allows to increase feeder’s efficiency. The explanation of mecha­nism of notch thermal behavior and its influence on shrinkage defects location is offered on the basis of analysis of isothermal lines in feed­ers’ cross section. Recommendations towards maximization of casting yield are substantiated due to the change in feeder top part design. The opportunity of increasing of casting yield up to 4% and reducing casting defects by optimization feeder’s upper section shape is shown.  

Metal products obtained by cold heading from rolled metal are used in all branches of mechanical engineering. Its quality is estimated by the required chemical composition and plasticity, the absence of a dispersion of mechanical characteristics along the entire length, the absence of internal and surface defects. The competitive advantage of metalware is the result of optimization during all technological pro­cesses: from rolled metal smelting to heading of finished metalware. At the same time, to reduce costs and to achieve the required quality of metalware, an important condition is to ensure safety and to reduce the energy intensity and labor input of its manufacturing process. An important controlling role in this technological chain is the preparation of the material for its cold volume forging. High-strength fasteners, obtained in conditions of cold heading, are most often obtained from chromium steels. Recently, alternative boron-containing steels have been actively introduced. However, because of the possible formation of boron oxides and nitrides, which lead to a decrease in hardenability, they exhibit instability of thermal hardening during thermohardening of metal products. In addition, the rolled metal of chromium steels, as a rule, is cheaper by 12 – 16 %. And as the fact that foreign deliveries of such steels are associated with additional costs, the fasteners produced from boron-containing steel are obtained with even higher increase in value, which again shows the favor of chromium steels. The standard mechanical characteristics were obtained as well as the destruction cri­teria of 40Kh rolled steel, subjected to patenting in a nylon bath with different temperatures and subsequent drawing with different degrees of deformation during cobbing. The optimum mode of preparation of structure parameters and mechanical characteristics of rolled products before the operation of metalware cold volume forging was identified: patenting (temperature of salt bath of 400 °С) and drawing (deforma­tion degree in the range of 5 – 10 %). It was established that treatment under this mode ensures the obtaining of the required quality of rolled products and is more preferable than the one that operates in produc­tion.

The actual location of shrinkage defects in variously designed feeders is considered. The method of estimation of variously designed feeders’ effectiveness is proposed on the basis of mathematical modeling results. Characteristics of shrinkage defects location in feeder volume are proposed to use for estimation of feeders effectiveness. The calculation of the feeders’ effectiveness of equal size but having differently designed top part is shown. The introduced efficiency index has a good adjustment with relation between volume and surface of feeder (V/S). Increasing feeder V/S increases its thermal efficiency. It is shown that the use of a notch allows to increase feeder efficiency. The explanation of mechanism of notch thermal behavior and its influence on shrinkage defects location is offered on the basis of analysis of isothermal lines in feeder cross section. Recommendations towards maximization of casting yield due to the change in feeder top part design are substantiated.

For existing and already constructed coal TPP plants, known methods of utilization of fly ash and slag wastes (FASW) may be in de­mand when all emerging environmental and economic risks are taken into account. But for the new power generating source when choosing coal combustion technology, it is necessary to increase the significance of the environmental component of the project more essentially. It is known that the most promising technologies for coal combustion, which increase environmental safety exactly by burning, are technolo­gies based on a circulating fluidized bed. These technologies can sig­nificantly reduce sulfur and nitrogen oxide emissions behind the boiler, but the solution to the problem of flay ash and slag waste remains at the same level. It is proposed to solve the problem of FASW utilization during the implementation of new energy projects or when replacing the decommissioning capacities of coal generation by replacing the method of coal combustion in a stream or fluidized bed with meth­ods of burning solid fuel in a bubbling slag melt. The descriptions and schemes of these methods are given. The comparison of the main qual­itative technical and ecological parameters of pulverized coal combus­tion and technologies of coal combustion in slag melt is presented. The development of coal generation is expected in two main areas: coal combustion with increasing steam parameters and gas generation with a combined cycle of electricity generation: steam and gas, based on the gasification of solid fuels. These directions will allow achieving electric efficiency of steam-power plants from 30 – 36 %, up to 44 – 45 % on supercritical steam parameters, and using a combined steam-gas cycle up to 50 – 55 %. A technological scheme of gasification of coal in a slag melt is proposed, which increases the electrical efficiency of the installation. The ecological and economic efficiency of the gasifica­tion method for solid fuel and the simplicity of the production of slag products by casting are shown. The quality of cast slagstone products is much higher than similar cement-sand products with the addition of fly ash, and the ease of transition from one casting mold to another allows quickly responding to market demands.  

The further development of the Russian coal electric power industry, especially in the regions of Siberia and the Far East, in line with the Energy Strategy, predetermines the need to address the problem of utilization of ash and slag wastes in newly implemented projects. The use of the main existing and proposed technologies for the utilization of ash and slag in the form of production of building materials, extraction of metals and other useful substances is limited to economic, organizational, transport factors or the emergence of new environmental risks. It is proposed to solve the problem of utilization ash and slag wastes by replacing the method of coal combustion in the flow with the gasification method for solid fuel in a bubbled slag melt.

Calculations of analytical expressions of Fe – Si – Al – Mn quaternary metal system and phase compositions of complex alu­mosilicomanganese alloy are presented in the article. Analytical expressions were obtained by the derivation of transformation equations that show any secondary system through the primary components of the base system. The location of the melt given composition was determined from positive values of coefficients of the equations of certain polytope calculated by Heath equation. Chemical composition of the complex alumosilicomanganese al­loy obtained under semi-industrial conditions corresponds to the tetrahedron FeAl3 – Al – Si – Mn11Si19 with the volume equal to V = 0,216811. It was established that compositions of alumosili­comanganese obtained from coals of the Karaganda coal basin, in contrast to the AMS alloy from Ekibastuz coals, tend to be in the re­gion of tetrahedra with a relatively large volume. The alloy compo­sitions modeled by such large-volume tetrahedrons are more stable and technologically predictable. Practical application of the results of the thermodynamic-diagram analysis (TDA) to the compositions of different grades of alumosilicomanganese reduces to finding of elementary tetrahedra within which their compositions are limited, and the normative distribution of primary phases between second­ary compounds for them is equal to 100 % of the considered tetra­hedron. Based on the normative distribution of the primary phases between the compounds (secondary phases) located on vertices of the Fe – Si – Al – Mn tetrahedron, a metallurgical evaluation of the melts can be made. This will subsequently allow to determine the phase composition of metal products at smelting of various grades of alumosilicomanganese and to limit the residual content of silicon and aluminum in them while using the latter in the recovery of man­ganese from manganese ore, as well as silicon and aluminum from high-ash coal. The derived analytical expressions for estimating the type and number of secondary phases of Fe – Si – Al – Mn system formed in it are universal and can be used both at smelting of vari­ous grades of alumosilicomanganese and in assessing the composi­tions of ferrosilicoaluminum and ferrosilicomanganese.  

The continuous method of deformational nanostructuring is pre­sented. It consists of simultaneous applying of the tensile deformation by drawing, bending deformation while going via the rolls system and twisting deformation to the continuously moving wire. Combination of different kinds of deformation makes it possible to change in a wide range its mechanical properties matching high strength and ductility. The advantage of this scheme of deformational processing consists in arranging together tools which are used in metal ware manufacturing industrial processes as well as its simplicity and compatibility with rates at coarse and middle drawing processes. The scheme of the labo­ratory unit for the method implementation is considered. Wire from medium carbon steel of grade 50 was chosen as the object for inves­tigation because it is considered to be the needed kind of metal ware product. Chemical composition and mechanical properties of this wire are described. Experiments on investigation of the possibility for ultra­fine-grained structure formation effectiveness in carbon steel wire were conducted using the developed laboratory unit. Deformation modes and drawing route are given. Microstructure of the wire from medium carbon steel of grade 50 was studied after different kinds of deforma­tional processing in longitudinal and transversal cross-sections. Dur­ing experimental researches the effect of deformational processing on carbon steel wire microstructure was specified as well as its anisotropy in the cross section. The mechanical properties of the wire of grade 50 steel were studied after different kinds of deformational processing. The verification of these properties was carried out in accordance with the demands in current national wire standards. It was proved that car­bon steel wire mechanical properties matches well with norms set in GOST17305-91. Investigation results of microstructure and mechani­cal properties of the wire from medium carbon steel of grade 50 after different kinds of deformational processing show the perceptiveness of the chosen direction for combination of different kinds of deformation for ultrafine-grained structure formation in carbon steel wire.  

Thermodynamic analysis of the effect of vanadium on the solu­bility of oxygen in Fe – Co – Cr melts has been carried out. Vanadium in Fe – Co – Cr melts at low contents increases oxygen concentration, which is determined by the chromium content. With a higher content of vanadium after changing the mechanism of the interaction process of chromium and vanadium with oxygen, when vanadium already de­termines the solubility of oxygen in the melt, the oxygen concentration initially decreases, and then, after passing through the minimum point, increases.