MetallurgistPub Date : 2025-08-07DOI: 10.1007/s11015-025-01978-5
Olga K. Mansurova, Huy H. Nguen
{"title":"Parametric analysis for supervisory control of cathode copper production","authors":"Olga K. Mansurova, Huy H. Nguen","doi":"10.1007/s11015-025-01978-5","DOIUrl":"10.1007/s11015-025-01978-5","url":null,"abstract":"<div><p>This paper presents a parametric analysis methodology for supervisory control of the electrolytic copper refining process. The approach employs an antisymmetric dynamic regulator to compensate for deviations in key process parameters, including electrolyte composition, current density, and circulation rate. The developed mathematical model captures the input–output relationships of the system, enabling precise prediction and adjustment of operating conditions. Modeling was conducted to assess the influence of sulfuric acid concentration, copper content, and electrolyte circulation rate on productivity and current efficiency. The results demonstrate that the proposed method effectively mitigates disturbances, stabilizes current efficiency, and maintains productivity within target ranges. Additionally, the identification of optimal operating ranges contributes to improved energy efficiency and reduced material consumption. The model’s integration into a SCADA-based control system enables real-time monitoring and high responsiveness, enhancing both operational reliability and adaptability.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"599 - 606"},"PeriodicalIF":0.8,"publicationDate":"2025-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196152","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-07DOI: 10.1007/s11015-025-01979-4
Denis N. Chikishev, Eduard M. Golubchik, Alexander S. Tselishchev, Alexey V. Yaroslavtsev
{"title":"Effect of roller table level on vertical bending of the leading edge in asymmetric thick-plate rolling: A finite element analysis","authors":"Denis N. Chikishev, Eduard M. Golubchik, Alexander S. Tselishchev, Alexey V. Yaroslavtsev","doi":"10.1007/s11015-025-01979-4","DOIUrl":"10.1007/s11015-025-01979-4","url":null,"abstract":"<div><p>The influence of the roller table level on the vertical bending of the leading edge during asymmetric thick-plate rolling has been investigated using finite-element modeling. The study demonstrates that a mismatch in the rotational speeds of the work rolls can produce inconsistent deformation patterns, causing the strip to bend toward either the slower or the faster roll. A finite-element model developed in the <i>Deform</i> software was employed to simulate the bending behavior of K60-grade pipe steel strips under various asymmetry conditions. The results show that for strip thicknesses of 25–50 mm, a mismatch between the roller table level and the rolling line leads to upward bending of the leading edge. This effect is amplified when the lower roll rotates faster than the upper roll and the reduction is below a critical threshold. To mitigate vertical bending, intentional counterbending can be induced by adjusting roll speed asymmetry. In doing so, it is necessary to account for the critical reduction or the deformation zone shape factor, defined as the ratio of the deformation zone length to the average strip thickness.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"607 - 613"},"PeriodicalIF":0.8,"publicationDate":"2025-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196153","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01950-3
D. A. Ringinen, I. T. Spitsberg
{"title":"A survey of the experience in the physical modeling of the processes of production of high permeability steel and its implementation at the NLMK","authors":"D. A. Ringinen, I. T. Spitsberg","doi":"10.1007/s11015-025-01950-3","DOIUrl":"10.1007/s11015-025-01950-3","url":null,"abstract":"<div><p>We present a version of implementation of the physical modeling of the processes running in the course of production of transformer steels in all stages of the process after hot rolling. We consider various types of installations applied for this purpose throughout the world and analyze the advantages and disadvantages of their application. The requirements for the set of equipment are specified and a criterial assessment of the implementation options is carried out. The results obtained in the work make it possible to realize the possibility of acceleration and improvement of the quality of development of new grades of transformer steels.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 3","pages":"358 - 368"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144909673","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01966-9
V. B. Ankudinov, Yu. A. Marukhin, V. P. Ogorodnikov, V. A. Ryzhkov
{"title":"Technology for producing monodisperse spherical granules","authors":"V. B. Ankudinov, Yu. A. Marukhin, V. P. Ogorodnikov, V. A. Ryzhkov","doi":"10.1007/s11015-025-01966-9","DOIUrl":"10.1007/s11015-025-01966-9","url":null,"abstract":"<div><p>Experimental studies of the forced capillary disintegration of a system of jets of molten lead were carried out. It has been shown that increasing the number of dispersed jets makes it possible to increase the productivity of the process by an order of magnitude. At the same time, the high quality of monodisperse spherical granules is preserved. The main patterns of the influence of oxidation of the surface of a liquid metal jet on the process of its disintegration have been studied. Obtained results can be used later to expand the functionality of monodisperse granulation technology.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"497 - 502"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196258","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01971-y
M. V. Lyange, B. O. Zotov, L. V. Fedorenko, V. Yu. Egorov, S. V. Chernyshikhin
{"title":"Selective laser melting of aluminum-based composites: challenges and prospects","authors":"M. V. Lyange, B. O. Zotov, L. V. Fedorenko, V. Yu. Egorov, S. V. Chernyshikhin","doi":"10.1007/s11015-025-01971-y","DOIUrl":"10.1007/s11015-025-01971-y","url":null,"abstract":"<div><p>Synthesis of composite materials by the method of selective laser melting based on a metal matrix with improved properties is actual and extensively developed direction of scientific research. The development of aluminum-matrix composites and their adaptation to the technology of selective laser melting requires taking into account numerous critical factors, such as the composition of the composite, the method used for the preparation of the source powder material, conditions of synthesis, etc. In the present work, we analyze the role played by the main factors in the development and synthesis of aluminum-matrix composites, the processes running in the melt pool during synthesis, and the key problems and tasks encountered in this field. On the basis of the deep analysis of data available from the literature, we determine the main trends in the subsequent development of the procedure of synthesis of aluminum-matrix composites by the method of selective laser melting, among which we can mention the development of aluminum-matrix composites accompanied by the formation of new phases as a result of the <i>in situ</i> reactions in the melt pool, computer simulation of the process of synthesis of aluminum-matrix composites, and the implementation of the <i>in situ</i> control over the process of melting by using various methods with a possibility of affecting the conditions of synthesis by using the accumulated data. We also formulate the tasks and fields of scientific investigations that require solutions and further efforts of the scientific community aimed at improving the properties of the aluminum-matrix composites.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"541 - 551"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196184","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01973-w
G. Yu. Romanovskiy, G. A. Filippov, O. N. Chevskaya, A. R. Mishetyan, V. G. Filippov
{"title":"Effect of deformation processing on mechanical properties and fracture resistance of low carbon martensitic steel","authors":"G. Yu. Romanovskiy, G. A. Filippov, O. N. Chevskaya, A. R. Mishetyan, V. G. Filippov","doi":"10.1007/s11015-025-01973-w","DOIUrl":"10.1007/s11015-025-01973-w","url":null,"abstract":"<div><p>The structure and properties of sheet steel produced from low carbon martensitic steel using various controlled rolling regimes was investigated. Standard mechanical properties, ductility parameters, and steel toughness were determined. The effects of the temperature range and the final deformation temperature during the finishing stage of rolling on the structure and consequently on the strength properties, cold resistance, and fracture resistance of the rolled steel were investigated. The study reveals the relationship between the processing regime and the level of steel properties. The results indicate that reducing the final deformation temperature improves low-temperature impact toughness and increases the proportion of crack propagation work in the total fracture energy.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"563 - 571"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196154","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01968-7
E. Yu. Gerashchenkova, M. A. Markov, D. A. Gerashchenkov, R. Yu. Bystrov, A. D. Bykova, A. D. Kashtanov
{"title":"Investigation of aspects of compensation for thermal expansion of 3D gradient materials Al–Al2O3 using “cold” spraying technology","authors":"E. Yu. Gerashchenkova, M. A. Markov, D. A. Gerashchenkov, R. Yu. Bystrov, A. D. Bykova, A. D. Kashtanov","doi":"10.1007/s11015-025-01968-7","DOIUrl":"10.1007/s11015-025-01968-7","url":null,"abstract":"<div><p>The article analyzes the results of studying a promising method for obtaining functionally graded 3D materials based on the use of the “cold” gas-dynamic mono-powder spraying technology in a separate dispenser system. In particular, for Al–Al<sub>2</sub>O<sub>3</sub> composite, the effect of the ceramic component content on the coefficient of linear thermal expansion was determined. The study results can be used when designing and creating materials operating in thermally-stressed assemblies to reduce stresses by adjusting thermal gaps. The obtained data highlight the advantages of the “cold” spraying method as a progressive way to create 3D metal and metal-ceramic materials with a functionally graded structure. Future development of these findings requires further scientific and technical justification.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"510 - 520"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196255","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01953-0
A. V. Amezhnov
{"title":"Influence of structural characteristics of low-alloy steels on their corrosion resistance in aqueous environments","authors":"A. V. Amezhnov","doi":"10.1007/s11015-025-01953-0","DOIUrl":"10.1007/s11015-025-01953-0","url":null,"abstract":"<div><p>Comprehensive studies of five varieties of hot-rolled microalloyed steels with different chemical compositions were conducted. The influence of structural characteristics of steel on its corrosion resistance was assessed. It was shown that the greatest contribution to the increase in corrosion resistance of steel is made by the chromium content; its increase to 0.5–0.6 wt. % raises the corrosion resistance of steel by 2 times. The high density of nanosized interphase precipitates of carbides and carbonitrides of microalloying elements, such as vanadium and niobium, leads to a decrease in corrosion resistance of steel, while the reduction of corrosion resistance of steel because of the presence of non-metallic inclusions of unfavorable composition is significantly lower.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 3","pages":"389 - 400"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144909674","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01975-8
G. M. Koishina, E. E. Zholdasbay, A. A. Argyn, I. N. Nursainov, N. K. Dosmukhamedov
{"title":"Impurity behavior in low-temperature sintering products of ironmaking dust in the presence of ammonium chloride","authors":"G. M. Koishina, E. E. Zholdasbay, A. A. Argyn, I. N. Nursainov, N. K. Dosmukhamedov","doi":"10.1007/s11015-025-01975-8","DOIUrl":"10.1007/s11015-025-01975-8","url":null,"abstract":"<div><p>In this study, the elemental composition of dust from the melting of scrap metal in an electric arc furnace was analyzed using an X‑ray fluorescence energy dispersive spectrometer (RLP-21) to determine the concentrations of impurities at their lower detection limits. A wide range of impurities was identified in the dust: Cu, Fe, Ti, Cr, Ni, Cd, Mn, Sn, Si, Ca, K, S, Cl. Using the Olympus BX51 microscope, new data on the forms of impurities in dust have been obtained. It was shown that impurities in the dust are present in the form of oxides. Based on the new results, a thermodynamic analysis of the reactions between dust components and ammonium chloride under low-temperature sintering conditions (573–1073 K) was performed. It was found that almost all impurities, except chromium, concentrate in the clinker as solid oxides during the sintering process. A high potential for the removal of titanium and tin as gaseous chlorides in the vapor phase was identified. Laboratory experiments were conducted on sintering dust with NH4Cl under optimal process conditions (temperature—773 K, NH<sub>4</sub>Cl consumption—1.5 times the stoichiometric amount required for lead chlorination, sintering time—60 min). Based on these experiments, the quantitative proportions of impurities in the resulting clinker were determined. It was found that during sintering tin and titanium are volatilized in significant amounts (more than 30% of their total content in the initial dust). The results obtained are fundamental for the development of selective lead extraction technology from dust. They will be used to develop an integrated chlorination process for the treatment of ironmaking dust with selective recovery of valuable metals into marketable products.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"578 - 585"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196165","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
MetallurgistPub Date : 2025-08-04DOI: 10.1007/s11015-025-01965-w
L. E. Gorlov, A. O. Mosleh, M. V. Glavatskikh, R. Yu. Barkov, A. V. Pozdniakov
{"title":"Effect of iron and silicon impurities on the phase composition and hardening of Al-0.3Zr-REM (REM = Er, Y, Yb, Gd) alloy ingots during annealing","authors":"L. E. Gorlov, A. O. Mosleh, M. V. Glavatskikh, R. Yu. Barkov, A. V. Pozdniakov","doi":"10.1007/s11015-025-01965-w","DOIUrl":"10.1007/s11015-025-01965-w","url":null,"abstract":"<div><p>The effect of iron and silicon impurities on the phase composition and hardening of Al‑0.3Zr-REM (REM = Er, Y, Yb or Gd) alloy ingots during annealing was studied. The Al<sub>3</sub>Fe phase was observed in the Al‑0.3Zr alloy with impurities content less than 0.01%. Alloying of the Al‑0.3Zr alloy with REMs leads to the formation of (Al, Fe)<sub>3</sub>REM phases. The Al<sub>3</sub>Fe and Al<sub>8</sub>Fe<sub>2</sub>Si phases were formed in the Al‑0.3Zr‑0.5Fe‑0.5Si alloy. The Al<sub>10</sub>Fe<sub>2</sub>Er and Al<sub>10</sub>Fe<sub>2</sub>Y phases, as well as the Al<sub>3</sub>Er<sub>2</sub>Si<sub>2</sub> and Al<sub>2</sub>Si<sub>2</sub>Y phases, were crystallized instead of the Al<sub>3</sub>Fe phase after Er or Y addition. The Al<sub>2</sub>Si<sub>2</sub>Yb or Al<sub>2</sub>Si<sub>2</sub>Gd phases with dissolved Fe were present in alloys with Yb or Gd. Iron and silicon impurities lead to a significant boost in hardness increase in all studied compositions during annealing at 400 and 440 °C. Hardening begins as early as 0.5 h into the annealing process and reaches its maximum after 8–11 h. The greatest hardening was achieved after annealing at 400 °C in alloys with erbium and ytterbium. High hardness after annealing of alloy ingots with impurities due to hardening by dispersoids and low silicon content in (Al) makes them promising candidates for creating current conductors characterized by high strength, thermal stability and electrical conductivity.</p></div>","PeriodicalId":702,"journal":{"name":"Metallurgist","volume":"69 4","pages":"488 - 496"},"PeriodicalIF":0.8,"publicationDate":"2025-08-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145196151","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}