Steel and cast-iron products, due to their low price and beneficial properties, are the most widely used among metals; their consumption has become an indicator of the economic development of countries. The characteristics of iron raw materials, in relation to current metallurgical requirements, are presented in the present this article. The globalization of the trade and development of steelmaking technologies have caused significant changes in the quality of raw materials in the last half-century forcing improvements in processing technologies. In many countries, standard concentrates (at least 60% Fe) are almost twice as rich as those processed in the mid-20th century. Methods of quality assessment have been improved and quality standards tightened. The quality requirements for the most important raw materials ‒ iron ores and concentrates, steel scrap, major alloy metals, coking coal, and coke, as well as gas and other energy media ‒ are reviewed in the present paper. Particular attention is paid to the quality testing methodology. The quality of many raw materials is evaluated multi-parametrically: both chemical and physical characteristics are important. Lower-quality parameters in raw materials equate to significantly lower prices obtained by suppliers in the market. The markets for these raw materials are diversified and governed by separate sets of newly introduced rules. Price benchmarks (e.g. for standard Australian metallurgical coal) or indices (for iron concentrates) apply. Some raw materials are quoted within the framework of the commodity market system (certain alloying components and steel scrap). The abandonment of the long-established system of multi-annual contracts has led to wide fluctuations in prices, which have reached a scale similar to that of other metals.
The aim of this paper is to present an assessment of the slip influence on the deflection of the steel plate-concrete composite beams, which are a new type of a design concept. The proposed method is based on the procedure included in the PN-EN 1992-1-1, which has been modified with taking into consideration interface slip. The theoretical analysis was verified by experimental studies.
Cold-formed structure connections utilizing gusset plates are usually semi-rigid. This paper investigates the behaviours of rectangular gusset plates in cold-formed connections of elements whose columns and beams are made with lipped back-to-back C-sections. Methods of calculating strength and stiffness are necessary for such semi-rigid joints. The main task of this paper is to determine a method capable of calculating these characteristics. The proposed analytical method could then be easily adapted to the component method that is described in part 1993-1-8 of the Eurocode. This method allows us to calculate both the strength and stiffness of rectangular gusset plates, assuming that the joint deforms only in plane. This method of design moment resistance calculation was presented taking into account that an entire cross-section shall reach its yield stress. A technique of stiffness calculation was presented investigating the sum of deformations acquired at the bending moment and from shear forces which are transmitted from each beam bolt group. Calculation results according to the suggested method show good agreement of laboratory experimental results of specimens with numerical simulations. Two specimens of beam-to-column connections were tested in the laboratory. Lateral supports were used on the specimens to prevent lateral displacements in order to better investigate the behaviour of the rectangular gusset plate in plane. Experiments were simulated by modelling rectangular gusset plates using standard finite element software ANSYS Workbench 14.0. Three-dimensional solid elements were used for modelling and both geometric and material nonlinear analysis was performed.
The temperature of liquid steel for continuous casting determines the casting speed and cooling conditions. The failure to meet the required casting process parameters may result in obtaining slabs of inconsistent quality. Numerical methods allow for real processes to be modelled. There are professional computer programs on the market, so the results of the simulations allow us to understand the processes that occur during casting and solidification of a slab. The study attempts to evaluate the impact of the superheat temperature on the slab structure based on the industrial operating parameters of the continuous casting machine.
Electrochemical Cr coatings doped with diamond nanoparticles were deposited on sintered steels with different carbon contents (0.2-0.8 wt.-%). The mechanical properties of surfaces as hardness and wear resistance increase as compared to the steel substrate. Microcutting and microgridding mechanisms were observed after tribological tests, but also adhesive wear in some areas was observed. X-ray examination indicated that the layer was textured, with the exception of the sample with the highest concentration of diamond nanoparticles in the electrolyte (42 g/l). The intensity ratio ICr110/ICr200 was calculated and compared with the indices for a standard sample. The greatest differences in the intensity ratio occurred for the samples with low carbon content (0.2%C). On the other hand, more the material is textured the greater the difference.
Assessment of the flexural buckling resistance of bisymmetrical I-section beam-columns using FEM is widely discussed in the paper with regard to their imperfect model. The concept of equivalent geometric imperfections is applied in compliance with the so-called Eurocode’s general method. Various imperfection profiles are considered. The global effect of imperfections on the real compression members behaviour is illustrated by the comparison of imperfect beam-columns resistance and the resistance of their perfect counterparts. Numerous FEM simulations with regard to the stability behaviour of laterally and torsionally restrained steel structural elements of hot-rolled wide flange HEB section subjected to both compression and bending about the major or minor principal axes were performed. Geometrically and materially nonlinear analyses, GMNA for perfect structural elements and GMNIA for imperfect ones, preceded by LBA for the initial curvature evaluation of imperfect member configuration prior to loading were carried out. Numerical modelling and simulations were conducted with use of ABAQUS/Standard program. FEM results are compared with those obtained using the Eurocode’s interaction criteria of Method 1 and 2. Concluding remarks with regard to a necessity of equivalent imperfection profiles inclusion in modelling of the in-plane resistance of compression members are presented.
Heating of steel or structural aluminum alloys at a speed of 2 to 50 K/min – characterizing the fire conditions – leads to a reduction in mechanical properties of the analyzed alloys. The limit of proportionality fp, real fy and proof f₀₂ yield limit, breaking strength fu and longitudinal limit of elasticity E decrease as the temperature increases. Quantitative evaluation of the thermal conversion in strengths of structural alloys is published in Eurocodes 3 and 9, in the form of dimensionless graphs depicting reduction coefficients and selected (tabulated) discrete values of mechanical properties. The author’s proposal for an analytical formulation of code curves describing thermal reduction of elasticity modulus and strengths of structural alloys recommended for an application in building structures is presented in this paper.
An attempt to summarize the primary iron raw materials and steel market’s hundred years history as well as influence of economic indicators on the iron ore deposit qualification for extraction has been undertaken in the paper. Steel products are crucial to the world economy, and their production has a major impact on the environment. The main factor is the huge scale of the production and growth rate, unprecedented among minerals. Iron ore and concentrates production has increased more than thirty times over the past century, and the geological resource base at the current level of consumption has provided almost 250 years of sufficiency. There have been tremendous changes in the world geography of the ore and steel industry. The iron ore mining industry is the driver of other economic activities (land transport, freight, metallurgy) and involves huge capital and human resources. The consumption of iron raw materials is also considered as an important indicator of the countries development and current or even future economic situation. Population growth remains one of the key stimulating factors. The prices of ore and iron concentrates depend on the quality of the raw material, delivery conditions, market balance and the weight of the ordered cargo. They are usually the subject of negotiations. In the past, they were long-term contracts, while short-term (yearly, quarterly) and current spot transactions are now significant. The prices of ores and concentrates in relation to steel prices are showing a strong correlation. The average iron content of the reserves has been reduced in the largest producers in the 21st century, however it does not translate into the quality of mining output. Exploitation of the richer parts of the mineral deposit is usually carried out. The high content of iron in the output is a response to the technological requirements of the metallurgy where the blast furnace charge should contain at least 56% Fe and 5–8% FeO. The current surplus of geological-mining supply (large resource base) justifies that a mineral deposit choice, destined for excavation, is economic profit maximization as well as social and environmental considerations.
The ways of the improvement of the method for the determination of steel losses in the electrical devices of basic types are substantiated. The method is refined by taking into account the magnetic system properties at high saturation. The presence of the interrelation between the special features of the domain structure movement and the shape of the hysteresis loop is proved for laminated cores. It enabled the explanation of the causes for the abnormally high values of the losses in the steel and the atypical shapes of the hysteresis loops at its high saturation. The empiric dependence for the determination of steel losses is obtained. It provides for the high convergence of the calculated and experimental data at the actual degree of saturation and can be used in the direct-current operation of the analyzed devices.
The present work has the objective of studying the effect of shot peening with glass microspheres on SAE 1020 steel in its resistance to fatigue. Fatigue tests were carried out by rotary bending with load control and loading on balance in specimens with and without shot peening. A rotation speed of approximately 750 rpm (12.5 Hz) was employed in the fatigue tests. Vickers microhardness tests were performed in order to verify the surface hardening produced by shot peening with glass microspheres. Analysis of the steel surface and fatigue fractures was performed using scanning electron microscopy (SEM). Fatigue tests were performed in order to obtain S-N curves (Wöhler curves). It was observed that shot peening with glass microspheres improved the fatigue strength of the steel at high cycle.
The paper, which is a summary and supplement of previous works and research, presents the results of numerical and physical modeling of the GX2CrNiMoCuN25-6-3 duplex cast steel thin-walled castings production. To obtain thin-walled castings with wall in the thinnest place even below 1 mm was used the centrifugal casting technology and gravity casting. The analyzed technology (centrifugal casting) enables making elements with high surface quality with reduced consumption of batch materials and, as a result, reducing the costs of making a unitary casting. The idea behind the production of cast steel with the use of centrifugal technology was to find a remedy for the problems associated with unsatisfactory castability of the tested alloy. The technological evaluation of the cast construction was carried out using the Nova Flow & Solid CV 4.3r8 software. Numerical simulations of crystallization and cooling were carried out for a casting without a gating system and sinkhead located in a mold in accordance with the pouring position. It was assumed that the analyzed cast will be made in the sand form with dimensions 250×250×120 mm.
The study presents the summary of the knowledge of energy-active segments of steel buildings adapted to obtain electrical energy (EE) and thermal energy (TE) from solar radiation, and to transport and store TE. The study shows a general concept of the design of energy-active segments, which are separated from conventional segments in the way that allows the equipment installation and replacement. Exemplary solutions for the design of energy-active segments, optimised with respect to the principle of minimum thermal strain and maximum structural capacity and reliability were given . The following options of the building covers were considered: 1) regular structure, 2) reduced structure, 3) basket structure, 4) structure with a tie, high-pitched to allow snow sliding down the roof to enhance TE and EE obtainment. The essential task described in the study is the optimal adaptation of energy-active segments in large-volume buildings for extraction, transportation and storage of energy from solar radiation.
Analysis of the use of the Russian materials (liquid glass and softening additives) has been made in accordance with the modern requirements for use in the technological processes of casting as binding materials in the production of large-sized steel railway casting. The reasons for poor knockout of liquid glass mixtures have been investigated. A complex action softening additive has been recommended for a better knocking-out ability. This solution provides a softening effect at the points of maximum formation of the liquid glass matrix strength in the processes of polymorphic transformation of the material under the influence of elevated temperatures as the result of filling the mold cavity by the melt. It has been shown that the use of additives of complex action leads to the decrease in the specific work of the knockout by four – seven times depending on the composition of the mixture and the design features of the casting. Experimental-industrial tests of the proposed method for softening the liquid glass mixtures have been made and the "Front Buffer Stop" casting has been made (for the rolling stock of locomotives and railway wagons). The tests confirmed the effectiveness and expediency of implementation of new liquid glass mixtures with softening additives in conditions of foundry enterprises.
In this work, the 316L austenitic steel based milled and sintered composites with 0.33 wt% and 1 wt% SiC ultra-fine particles addition have been prepared. The high efficient attrition milling provided an efficient size reduction of the 316L steel grains and homogeneous distribution of the SiC nanoparticles before sintering process. Spark plasma sintering (SPS) was used for compaction of milled powder mixtures. The effect of SiC addition on the milling efficiency and the structure of the composites have been studied. It was found that the amount of ceramic addition did not influence the efficiency of milling process, powder mixtures with flake like grains have been obtained. On the other hand, the intensive milling assured an optimal coverage of 316L stainless steel grains with submicron sized ceramic particles in both cases. The sintered composites showed high densities with the presence of small amount of closed porosities. Structural, mechanical and tribological examinations of 316L/SiC composites have been performed and presented.
AISI 316L/TiB2/2p composites were manufactured by HP-HT using different pressures (5 and 7 GPa) and temperatures (900-1300°C), with constant reinforcing particle content 2 vol%. The mechanical properties of the composites were evaluated on the basis of hardness (HV0.3) and compression tests (20°C, 10−5 s−1). The results showed that the role of sintering pressure increased with increasing process temperature. At temperatures of 900°C and pressures of 5 and 7 GPa the difference in measured values of compressive strength was 1-2%, while at 1300°C they reached 20%. At constant pressure of 5 GPa, a change in hardness and compressive strength of 40% were obtained with a temperature change of 900 to 1300°C. Changes in mechanical properties in the composite occurred without substantial changes in density, microstructure, reinforcement phase distribution, and phase composition in the matrix.
In order to improve the efficiency of power generation system and reduce CO2 emissions power plants work at high temperature and pressure. Under such conditions modified steel 9Cr, which fulfils the requirements concerning creep resistance, is used. However, Cr2O3 formed on the steel does not protect the construction material in the atmosphere which contains CO2 and SO2. The aim of the experiment was to study the behaviour of P91 steel in CO2 atmosphere with the addition of 1% and 5 vol.% of SO2 at different temperatures (700, 800 and 900°C). It was concluded that the corrosion rate of P91 steel is increasing with a rise in temperature. Scales formed in CO2 atmosphere at 900°C contain a mixture of iron oxides in the outer layer and chromium-iron spinel in the inner layer. The FeS and Ni were found in the inner zone of scales formed in SO2 atmosphere.
The mining of hard coal deposits at increasingly greater depth leads to an increase in hazards related to the loss of stability of steel arch supports as a result of excessive static and dynamic loads. Camber beam reinforcement via rockbolting is often utilised in order to improve the stability of the yielding steel arch support. This article presents the results of comparative bench tests of the ŁP10/V36-type steel arch support, tested with and without reinforcement by means of self-drilling bolts with drunken R25 threads, using short joists formed from V32 and V25 sections. It also presents the results of comparative tests of the ŁPP10/4/V29/I-type steel arch support, tested with and without reinforcement by means of rock bolts with trapezoidal Tr22/13 threads, using short joists formed from V25 sections. The obtained test results, in the form of load courses and work values of the steel arch and mixed (arches and rock bolts) support systems, demonstrate that the utilisation of mixed support may significantly improve the stability of workings, particularly immediately after they are driven. A mixed support system quickly achieves its maximum load capacity together with a significant increase in its work value. It may thus prevent the stratification of the rocks surrounding the working, and therefore better utilise the self-supporting capacity of the rock mass. As evidenced by the test results, the mixed support work may be as much as 3.5 times as great compared to the steel arch support at the beginning of the height reduction process initiated by loading – i.e. until its reduction by a presupposed value of 100 mm.
The main purpose of the paper is to present a method which allows taking into account the anisotropic properties of dynamo steel sheets. An additional aim is to briefly present anisotropic properties of these sheets which are caused by occurrences of some textures. In order to take into account textures occurring in dynamo sheets, a certain sheet sample is divided into elementary segments. Two matrix equations, describing changes of the magnetic field, are transformed to one non-linear algebraic equation in which the field strength components are unknown. In this transformation the flux densities assigned to individual elementary segments are replaced by functions of flux densities of easy magnetization axes of all textures occurring in the given dynamo sheet. The procedure presented in the paper allows determining one non-linear matrix equation of the magnetic field distribution; in this equation all textures occurring in a dynamo sheet are included. Information about textures occurring in typical dynamo sheets may be used in various approaches regarding the inclusion of anisotropic properties of these sheets, but above all, the presented method can be helpful in calculations of the magnetic field distribution in anisotropic dynamo sheets.
This research paper shows the influence of a repeated SPD (Severe Plastic Deformation) plastic forming with the DRECE technique (Dual Rolls Equal Channel Extrusion) on hardening of low carbon IF steel. The influence of number of passes through the device on change of mechanical properties, such as tensile strength TS and yield stress YS, of tested steel was tested. The developed method is based on equal channel extrusion with dual rolls and uses a repeated plastic forming to refinement of structure and improve mechanical properties of metal bands [1-2]. For the tested steel the increase of strength properties after the DRECE process was confirmed after the first pass in relation to the initial material. The biggest strain hardening is observed after the fourth pass.
In paper is presented technology of bimetallic layered castings based on founding method of layer coating directly in cast process so-called method of mould cavity preparation. Prepared castings consist two fundamental parts i.e. bearing part and working part (layer). The bearing part of bimetallic layered casting is typical foundry material i.e. unalloyed cast steel, whereas working part is plate of austenitic alloy steel sort X2CrNi 18-9. The ratio of thickness between bearing and working part is 8:1. The aim of paper was assessed the quality of the joint between bearing and working part in dependence of pouring temperature and carbon concentration in cast steel. The quality of the joint in bimetallic layered castings was evaluated on the basis of ultrasonic non-destructive testing, structure and microhardness researches.
In paper is presented technology of bimetallic layered castings based on founding method of layer coating directly in cast proces so-called method of mould cavity preparation. Prepared castings consist two fundamental parts i.e. bearing part and working part (layer). The bearing part of bimetallic layered casting is typical foundry material i.e. ferritic-pearlitic unalloyed cast steel, whereas working part (layer) is plate of austenitic alloy steel sort X2CrNi 18-9. The ratio of thickness between bearing and working part is 8:1. The aim of paper was assessed the quality of the joint between bearing and working part in dependence of pouring temperature and carbon concentration in cast steel. The quality of the joint in bimetallic layered castings was evaluated on the basis of ultrasonic non-destructive testing, structure and microhardness researches.
Results of investigations of wear resistant of two species of cast steel were introduced in the article (low-alloyed and chromium cast steel) on the background of the standard material which was low alloy wear resistant steel about the trade name CREUSABRO ®8000. The investigations were executed with two methods: abrasive wears in the stream of loose particles (the stream of quartz sand) and abrasive wears particles fixed (abrasive paper with the silicon carbide). Comparing the results of investigations in the experiments was based about the counted wear index which characterizes the wears of the studied material in the relation to the standard material.
Weld metal deposit (WMD) was carried out for standard MMA welding process. This welding method is still promising mainly due to the high amount of AF (acicular ferrite) and low amount of MAC (self-tempered martensite, retained austenite, carbide) phases in WMD. That structure corresponds with good impact toughness of welds at low temperature. Separate effect of these elements on the mechanical properties of welds is well known, but the combined effect of these alloy additions has not been analyzed so far. It was decided to check the total influence of nickel with a content between 1% to 3% and molybdenum with content from 0.1% up to 0.5%.
Heavy steel castings deoxidized with aluminium are sometimes brittle intercrystalline failed during their service along primary grain boundaries what is initiated by aluminium nitrides and so called conchoidal fractures are formed. The tendency to forming the conchoidal fractures depends in particular on cooling rate (the casting modulus), aluminium and nitrogen contents in steel. During deoxidation, when manufacturing heavy castings, the elements with high affinity to nitrogen, zirconium or titanium, are added to steel that would decrease nitrogen activity by the bond on stable nitrides. The formation of stable nitrides should reduce the tendency of steel to the formation of conchoidal fractures. Deoxidation was thermodynamically analyzed at presence of the mentioned elements. For particular conditions a probable course of deoxidation was estimated at test castings. The deoxidation course was checked by microanalysis of deoxidation products (inclusions). For service and experimental castings the anticipated composition of inclusions was compared. It has been proved that in heavy castings with high aluminium contents in steel under studied conditions neither the addition of zirconium nor of titanium nor of rare earth metals will prevent the formation of conchoidal fractures.
In this paper, an analysis of various factors affecting machined surface texture is presented. The investigation was focused on ball end mill inclination against the work piece (defined by surface inclination angle a. Surface roughness was investigated in a 3D array, and measurements were conducted parallel to the feed motion direction. The analysis of machined surface irregularities as a function of frequency (wavelength A), on the basis of the Power Density Spectrum - PDS was also carried out. This kind of analysis is aimed at valuation of primary factors influencing surface roughness generation as well as its randomness. Subsequently, a surface roughness model including cutter displacements was developed. It was found that plain cutting with ball end mill (surface inclination angle a= 0°) is unfavorable from the point of view of surface roughness, because in cutter’s axis the cutting speed vc ~ 0 m/min. This means that a cutting process does not occur, whereas on the machined surface some characteristics marks can be found. These marks do not appear in case of a* 0°, because the cutting speed vc * 0 on the fill I length of the active cutting edge and as a result, the machined surface texture is more homogenous. Surface roughness parameters determined on the basis of the model including cutter displacements are closer to experimental data for cases with inclination angles a* 0°, in comparison with those determined for plain cutting (a= 0°). It is probably caused by higher contribution in surface irregularities generation of plastic and elastic deformations cumulated near the cutter’s free end than kinematic and geometric parameters, as well as cutter displacements.