Theory and Practice of Metallurgy

New metal-saving technologies of pipe rolling

V.F. Balakin — 2025-09-30

Rolling of thin-walled pipes with D/S =12.5-40 on a pilgrim mill is accompanied by significant metal consumption in the process cut, the so-called pilgrim head, which significantly increases the metal consumption factor compared this other mills (continuous, automatic, etc.). The analysis of known methods for reducing the mass of the pilgrim head allowed us this propose a new combined metal-saving technologies of pilgrim rolling, which significantly reduce metal consumption. For the first time, a new metal-saving technology of partial rolling of the pilger head on thin-walled pipes with D/S=12.5-40 was proposed and substantiated, which allows the pipe this be removed from the mandrel using a gate valve. This will allow reducing the mass of the pilger head by up to 50%.

Features of cold periodic rolling in the production of long conical tubular products

V.T. Vyshinsky — 2025-09-30

Significant metal savings are achieved when using tubular products of variable cross-section in metal structures. Special technical effects are achieved in pipelines with variable medium flow rates. The HPT process with a change in the length of the deformation zone as a result of varying the stroke length of the working stand provides solutions to the following problems. The following features are considered: – shaping of tubular products of variable cross-section; – tool calibration; – determination of the laws of changing the stroke length of the working stand. The issue of improving the mechanisms and components of these machines is considered.

Modern technologies for the production of fuel element cladding tubes (FEEL) from zirconium alloys and the state of production in Ukraine

V.S. Vakhrusheva — 2025-09-30

At present, nuclear energy retains its position as one of the main world energy sources. In Ukraine, further development of nuclear energy is planned, therefore, one of the important directions is the creation of its own nuclear fuel cycle (NFC). An integral part of the NFC is the production of fuel element cladding tubes from zirconium alloy Zr1Nb. The purpose of the work is the development of technology, the manufacture of pilot batches of tubes from zirconium alloy Zr1Nb in Ukraine and the study of their quality. Methodology. Production of tubes in production conditions. Research of the quality of tubes using optical microscopy, macrostructural analysis, mechanical tests at room and elevated temperatures, assessment of hydride orientation , corrosion tests, studies of long-term strength, creep. Results. For the first time in Ukraine, on the basis of the State Enterprise "Scientific and Design and Technological Institute of Pipe Industry named after Ya.Yu. Osada", work was carried out on the development of technology and the manufacture of pilot batches of tubes-shells of fuel elements (TVEL) from zirconium alloy Zr1Nb with a size of Ø9.13× in. 7.72 mm. The quality of the tubes was assessed in accordance with the requirements of ASTM standards. Comprehensive studies of the structure and properties showed compliance with the requirements of ASTM standards. Scientific novelty. For the first time in Ukraine, a technology has been developed and tubes-shells of heat-generating elements made of zirconium alloy Zr1Nb with a size of Ø9.13×in.7.72mm have been manufactured in industrial conditions. It has been shown that the quality of the tubes meets the requirements of the standards for tubes. Practical significance. Based on the research performed, it is possible to organize industrial production in the conditions of Ukrainian tube plants.

Improvement of the method for calculating rolling tables for continuous mandrel-free hot pipe rolling mills

E.I. Shifrin — 2025-09-30

The way in which the setup parameters and fork calibrations of calibration and reduction mills for hot mandrelless pipe rolling are calculated depends to a certain extent on their accuracy in terms of wall thickness and diameter. Significant factors that have a significant impact on the process of pipe forming during longitudinal rolling in the gauges of a continuous mandrelless mill include the methods of processing roll gauges (individual processing of each roll separately or processing of gauges as a whole). A new methodology has been developed for calculating pipe rolling tables in these mills, which takes into account the technology of cutting roll gauges. It is proved that the use of an improved methodology for calculating rolling tables on calibration and reduction mills of various design allows the production of hot rolled pipes with a significant increase in the accuracy of geometric dimensions and a reduction in metal consumption.

The concept of a universal cross-rolling mill

V.F. Balakin — 2025-09-30

The concept of a universal oblique rolling mill (UBM) of a pilgrim unit is proposed to solve its technological capabilities by obtaining shells and thick-walled pipes when rolling on short and long mandrels. A new design of a running-in device for the front ends of shells during the piercing process on the UBM is proposed, which is placed on a separate frame connected to the cage and guide block. The proposed UBM concept can be used to modernize the elongator mill of the pilgrim unit 5-12 of PJSC "Interpipe NTZ".

Improvement of hot pilgrim pipe rolling

V.F. Balakin — 2025-09-30

The main methods of improving the feeding mode taking into account the D/S ratio of rolled pipes are considered. It is proposed to carry out rolling of pipes in the with variable feed rate according to a given program, as well as new solutions for butt shell rolling. Two new directions for the preparation of the front ends of the sleeve liners on a four-row hydraulic press and on a planetary type reeling machine are considered. New methods of preparing the rear ends of the sleeves by thinning the wall at the rear end of the sleeve in the process of piercing the workpiece on the rotary piercer mill by moving the mandrel, as well as by crimping the rear end of the sleeve on the mandrel on a two-punch hydraulic press. The combined use of the considered methods of improving the inoculation mode is proposed, which will increase productivity and reduce metal consumption in the cut.

Improvement of methods and software for technological design of cold roller rolling sections

I.A. Soloviova — 2025-09-30

The purpose of the work is to develop mathematical models of deformation parameters for rolling on CPTR mills with their implementation in the software for technological design of CPTR sections. The data for obtaining models are practical and experimental routes for the production of stainless-steel pipes of various assortments on HPTR mills. The data was structured and correlation-regression analysis was used for modeling. Based on the obtained deformation parameter models, software was developed that solves the issue of designing routes for the production of cold-formed pipes on CPTR mills. The results of the work make it possible to reduce the time for designing routes and production technologies, obtain new route options for selection and optimization of production in order to reduce route passes, metal consumption coefficient, and analyze the load on equipment.

The influence of energetic and chemical-catalytic intensification of iron reduction on the oxidizability of the metallized product

O.M. Grishin — 2025-09-30

The purpose of the work is to analyze the influence of the electromagnetic field and catalytic additives on the parameters of the oxidation process of reduced sponge iron. Methodology. The experiments were carried out in an alternating magnetic field using the thermogravimetric method. The oxidation process was studied with the determination of the temperature of the onset of oxidation and the degree of oxidation. Results. The results of laboratory experiments indicate the influence of the electromagnetic field on the oxidation process of solid-phase iron reduction products. The introduction of catalytic additives into the reducing charge has a positive effect on the oxidation of the product. The low-frequency field increased the temperature of the onset of oxidation and reduced the degree of oxidation. Scientific novelty. The influence of the electromagnetic field (EMF) on the temperature of the onset of oxidation, the degree and rate of oxidation of the metallized product was experimentally confirmed. The mechanism of the passivating effect of EMF and catalytic additives on reduced iron was proposed. Practical significance. The obtained research results allow to reduce losses during oxidation of metallized iron powder.

Obtaining sponge iron in a rotary shaft furnace using Inmetco technology with combined sintering and metallisation processes

A.A. Vanyukov — 2025-09-30

Of the numerous processes without coke metallurgy, sponge iron production has now reached its greatest industrial development. The reason for this development was the possibility to organise the production of high-quality metal according to the following scheme: technology for processing finely dispersed waste from blast furnace and steelmaking production into ore-coal composite pellets, their calcination and metallisation on a PVP ring chamber calciner; use of this technology in the INMETCO, FastMet, and DRYIron processes. This article substantiates the conditions for obtaining sponge iron in a PVP furnace (rotary hearth furnace). The aim of this work is to experimentally study the process of obtaining sponge iron by combining sintering and metallisation of ore-coal composite pellets in a rotary hearth furnace. Research methods: chemical analysis of the obtained pellets, determination of total and metallic iron, residual carbon, slag-forming components. Material and heat balance of the metallisation process, calculation of specific energy consumption and determination of heat losses by furnace zones.

The place of invention as a component of the intellectual and professional potential of scientists in improving industrial technologies

A.P. Mishalkin — 2025-09-30

The current stage of development of science and technology is characterized by a growing need to find new solutions that ensure increased efficiency of industrial production, its environmental friendliness, energy saving, rational use of mineral resources and competitiveness. In this context, invention is of particular importance as a manifestation of the intellectual and professional potential of scientists, capable of transforming fundamental knowledge into applied innovations that directly affect the improvement of modern industrial technologies. Invention is not an isolated process - it is formed in the system of interaction of scientific and educational, production and technological and socio-economic environments. Its development is conditioned by a number of conditions - from the presence of a favorable regulatory and institutional framework to stimulating the process at all stages of its life cycle. Invention, as a form of creative activity, can be born where these components interact in the environment, if it becomes a factor stimulating its emergence, promoting development and further implementation - in the educational and scientific space, the production and technological environment, and the innovative and attractive economic field. The expediency of defining the professional component of the potential of the individual as a mediator between knowledge and practice Vanyukov A.A., Kamkina L.V., Myanovskaya Y.V., Kovalyov M.D., Tsibulya E.V., Chumak D.D., the use of useful properties of which contributes to the transformation of intelligence and creativity into specific results of the professional and creative activity of the individual, is substantiated. As a way of self-expression, a person's ability to invent in his activity does not appear by itself, it can be purposefully developed using the following means: educational, practical, psychological and socio-professional. It is shown that the professional component occupies an equal place alongside the mental and emotional components, because it is it that ensures the practical application of the other two in the field of labor activity and self-realization in scientific activity. The study used analytical and survey methods to study the conditions for the development of invention in the direction of improving metallurgical processes, with an emphasis on their physical and chemical nature and orientation. It is shown that leveling the role of the features of the transformation of the properties of the physicochemical potential of the object/process of research reduces both the scientific value and does not contribute to determining the spectrum of real functional possibilities of their transformation. The purpose of the study is to substantiate the factors of influence, external and internal in origin, and the conditions that contribute to the development of invention as a creative form of activity of a scientist with the definition of key components of the potential of the individual, which, in turn, is a condition for the development of innovative, competitive solutions. The latter are able to more rationally solve the problems of energy efficiency, conservation of mineral resources, energy and a significant reduction in the loss of useful properties of the environmental potential. For the first time, it is theoretically substantiated that the professional component is the third and key component of the potential of the individual, along with the mental and emotional. There are works, the results of which, determined by their authors, closely outline the role of professional or professional potential in the structure of personal development. Their approaches, used in determining the composition and role of factors of influence, indirectly confirm the importance of the professional component precisely as a component that ensures professional, creative self-realization of the individual and in inventive activity. But researchers have not found a direct mention of the model-triad "mental - emotional - professional-professional" components of the intelligence of the individual. Invention, occupying a central-integrative place among the factors of influence, combines them into a single system, creates the effect of synergistic acceleration of the development of science and technology, translating the intellectual - professional potential of society into specific innovative results in practice.

Development of a method for laser strengthening of railway wheel tread

E.V. Parusov — 2025-09-30

The goal of this work was to develop a method for laser strengthening of the cove zone of railway wheels in order to obtain a bainitic structure and eliminate undercutting of the crests. Methodology. Laser irradiation of the samples was performed in continuous radiation mode using the LG-701 “Cardamon” device (radiation power: 600 W; laser beam movement speeds: 20, 15, 10, and 5 mm/s). The hardness and microhardness of the samples were measured. Wear tests of the wheel steel samples, after different laser irradiation modes, were conducted on the “SMC-2” testing machine using the rolling with slipping method. The research was carried out using a Neophot-31 optical microscope, as well as X-ray structural analysis. Findings. According to the analysis of literary sources, the feasibility of locally strengthening the cove zone of the tread through laser treatment has been demonstrated. Based on a study of railway wheels worn during operation, which exhibit different tread profiles, it has been shown that intense plastic shear flow under high contact stress conditions leads to accelerated wear in the cove zone. This wear can result in the undercutting of the wheel flanges. Originality. It has been shown that during laser processing in continuous radiation mode, it is possible to obtain a microcomposite bainitic structure in the laser-strengthened layer, which is favorable under operating conditions. At the same time, the characteristics of the strengthened layer – such as the fine steel structure, microhardness, and hardness – can be varied within certain limits depending on the initial state of the wheel steel and the parameters of the continuous laser exposure. A comparative analysis demonstrates that both the laser processing parameters and the degree of dispersion in the initial microstructure significantly influence the effect of laser strengthening on wheel steel. A promising processing mode, involving a laser beam power of 600 W and a speed of its movement of 5–15 mm/s, is proposed and is recommended for use, particularly in combination with traditional heat treatment. Practical value. The prospects of local laser processing of the wheel tread to obtain a microcomposite bainitic structure using continuous laser radiation are discussed. This approach not only increases the wear resistance of railway wheel treads but also reduces the risk of crest undercutting during operation. This treatment can be applied both to new railway wheels after traditional heat treatment and during the restoration of worn tread profiles by regrinding in railway depots.

Rational ways of forming, utilization and restoration of the production potential of a metallurgical enterprise

A.P. Mishalkin — 2025-09-30

Purpose and objectives. To provide a theoretical and analytical substantiation of the category "production potential of an enterprise"; to identify, based on the analysis of existing scientific approaches, its main specific components and the conditions for their rational implementation in metallurgical production; to determine external factors influencing the dynamics of the rational use of potential components and effective methods for forming the production potential of an enterprise.Methodology. A comprehensive systematic approach to scientifically substantiate the conditions for ensuring a positive balance between the components of an enterprise’s production potential and the rational use of its resource and raw material component at the main stages of the production process life cycle. Scientific novelty. The concept of "potential" is clarified as a category that defines the ability of an object or its components, under the influence of certain external factors, to transform a set of initial properties (formed naturally or artificially) into a set of consumer properties of products that meet the evolving needs of society. Practical significance. Taking into account the current state of the domestic mining and metallurgical complex and the societal demand for socio-economic development, a comprehensive framework is proposed. Its implementation will enable the most rational use of the beneficial properties of the existing potentials of metallurgical production.

Влияние электромагнитного поля на кинетику твердофазного восстановления оксидов железа газами

O.M. Grishin — 2025-09-30

The aim of the work is to study the physicochemical correlations of the intensifying effect of an electromagnetic field on the process of solid-phase reduction of oxides by gases. Methods. The experiments were carried out in an alternating magnetic field with an alternating current frequency in the inductor up to 40 kHz using the thermogravimetric technique. The process of indirect reduction was studied to determine the degree and rate of oxide reduction in the temperature range of 973-1373 K using various iron ore materials. Results. The results of laboratory experiments indicate the influence of a high-frequency intensifying electromagnetic field on the process of solid-phase reduction of iron ore materials. A physicochemical model of the mechanism of the intensifying effect of EMF on the reduction process is presented. The high-frequency field significantly accelerates the diffusion processes and increases the electronic and structural defectiveness of the crystal lattice, which positively influenced the development of the adsorption-chemical link. Scientific novelty. The effect of EMF on the kinetics of gas reduction of iron ore materials has been experimentally confirmed. Practical significance. The intensification of solid-phase reduction of iron ore raw materials leads to the intensification of the process and increase of the process productivity.