SUBSTITUTES FOR NONFERROUS METALS IN USSR

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00809A000700150166-0
• Release Decision: RIPPUB
• Original Classification: R
• Document Page Count: 6
• Document Creation Date: December 22, 2016
• Document Release Date: September 13, 2011
• Sequence Number: 166
• Publication Date: November 24, 1953
• Content Type: REPORT

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CLASSIFIG:,iION RESTRhTEII-- Ss/~./~ ~,
sr~1rR
N0. 7F PAGES 6
SUPPLEMENT TO
REPORT N0.
THIS IS UNEVALUATED INFORMATION
2a Ekonomivu Materielov, No 4, pp 3p_3q
SUBSTITUTES FOR NODTFERROUS hf!';PALS IN USSR
~he following excerpts from an article, "Developing the Pro-
duction of Substitutes for Ponferrous idetals," by Docent I. lO.inov.
Candidate of Technical Sciences, in the monthly periodical Za
Ekonomi Materialov (For the Conservation of Materials), Nom,
April 1953?
During the postwar years, the Soviet Union has achieved considerable prog-
ress in manufacturing nonmetallic chemically stable materials on an organic base.
These materials serve in many cases as fea^,ible substitutes for nonferrous metals
and in other cases as protection against corrosion for ferrous metals.
An especially urgent problem is the replacement of lead, tohich, being
practically the only acid-resisting metal, is widely applied in the nlachine-
building, metallurgical, paper-making, pc:troleun, and other branches of the na-
tional economy. In particular, lead consumption is high in the chemical industry
and related productions.
The appearance in tiro last 2-3 years of new materials, such as polyiso-
butylene, asbovinyl, and graphite, and the wider application of a comparatively
old material, viniplast, all used as lead substitutes, have promoted considerable
conservation of lead.
One of the most valuable lead substitutes is polyisobutylene, which is s
rubber like material. Products made on the ba~ve of polyisobutylenc.s are used as
?nticorrosive protection an3 for facing metal, cel::crete, and wooden equ_yae::t.
Folyisobutylene is also used as interlaying material in lining apparatus
to th silicate tiles to create an impervious layer. Application of polyisobutylenc
also has the purpose of eliminating deformations which usually occur in linings
es n >.?~sult of the difference in the expansion coefficients of metal and silicate
PUBLISHED Monthly periodical DATE D(ST. ~~ Nov
plastic materials, lead substitutes
HOW
CENTRAL INTFLLIGEN~'CE AGENCY
REPORT
INFORMATION FROM
FOREIGN DOCUMENTS OR RADIO BROADCASTS CD NO.
COUNTRY ussR
SUBJECT Scientific -Metals, metal substitutes
WHERE
PUBLISHED Moseow
DATE
PUBLISHED Apr 1953
LANGUAGE Russian
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The basic principles of obtaining polylso}?rtylenes sere developed in the
Soviet Union by S. V. Lebedev
d
an
his students in the 1930s. Using the idens
and experience of Russian scientists, other countries have organized industrial
production of polyisobutylenes, known under the trade names of "oppanol" in
Germany and "'vietanex" in the US.
Polyisobutylenea differ from each other by their molecular weight. Their
Buml.lY,e properties appear only at molecular weights of 50,000 and higher.
Pol3'isobutylenes with low molecular weight are viscous oillike liquids.
Principally, high-molecular polyisobutylenes of the P-100 and P-200 types,
i.e., with molecular weights of 100,000 and 200,000, are produced in the USSR on
an industrial scale. The polymerization of isobutylene for obtaining a high-
molecular product is carried out at a temperature of about minus 100 C in the
presence of a catalyst. Commercial polyisobutylene in sheet form, usually con-
taining various admixtures, such as graphite, lampblack, asbestos, and talc, is
made on machines used in the rubber industry. Polyisobutylene for lining is pro-
duced under the name PSG200 as 0.$_ x 5-m sheets of 2- to 3-mm thickness.
The mayor advantages of polyisobutylenes, as compared with rubbers, are
the lack of a need for vulcanization and high resistance to aging xith retention
of elasticity in the temperature range from minus 55 to 600. The physicamechanical
properties of polyisobutylene of PSG2p0 grade arc as follows: tensile strength,
~+5-65 kg/sq cm; relative elongaticn, 475-550$; specific gravity, 1.32; Shore
hardness, 67; plasticity, 0.09; and recovery value, 0.17 mm.
Polyisobutylene is soluble in aromatic solvents, mineral oils, paraffin,
chloroform, and some other organic solvents. It is stable in mineral acids,
alkalies, and other active media. IZitric acid has no effect on it at room tem-
perature. In particular, polyisobutylene is stable in hydrochloric acid of high
concentration, in sulfuric acid up to 70~, in acetic acid of various concentra-
tions, in solutions of salts, in gaseous media, and in a number of organic com-
pounds.
It is essential to notice that polyisobutylene, like viniplast, is weldable
at 150-200o C. The strength of a welded ,joint amounts to,70-80~ base-material
strength. In contrast to viniplast, polyisobutylene may be welded without s
welding rod.
Homogeneous ,joints of polyisobutylene sheets are also obtainable in the
cold state by subjecting an overlapping Joint to the proper pressure. However,
this method is ineffective because of lox productivity and difficulties of form-
ing vertical irregular ,joints.
So-called "cold flow," i.e., deformation of material under load, is s de-
ficiency of polyisobutylene. In cases where mechanical loading takes place, the
protection of polyisobutylene with silicate tiles is recotnrnended. Thus, the
application of polyisobutylene as an independent supporting structural member
is excludei:. A similar protective facing is required when polyisobutylene is
exposed to a temperature above 60?. Polyisobutylene is attached to metal, wood,
or concrete by means of various glues. The adhesi^e strength amounts to 25
kg/sq cm for metal, 16 kg/sq em for concrete, and 15 Y.g/sq cm for wood.
Polyisobutylene is nova in use as lining material for containers, apparatus,
pipes, and various equipment at a number of establishments, and is showing good
results. A column 12 n high and 3 m in diameter, installed at a steam-electric
power plant, is one oi' the largest structures for which polyisobutylene has been
used as a substitute for lead.
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metals. It is a plastic mass obtained~bJymixin iwr a numoer or nonferrous
asbestos with a binding substance, knownyin industry~underdtheinamesoftlae-
ethenol. The binder, being a production waste material, is a solution of high-
polymer acetylene derivatives of 40-50~ concentration. As long ago as 1938,
Engineer I. P. Shabodalov suggested asbovinyl as a substitute for nonferrous
metals, but wide application of this materiel has occurred only during the last
2-3 Years.
Asbovinyl is usually, applied to the surface to be protected by the ordinary
pargeting method and shows; upon setting, considerable adhesion with a coated
surface. In its physicomechanical. properties, the asbovinyl product is close
to a generally known plastic material -- faolite -- but has a number of ad-
vantages over faolite or viniplast. The asbovinyl mass may be used as a lining
for metal, concrete, ceramic and other materials, while the faolite mass has a
low. adhesive property.
The asbovinyl product may also be used in the fabrication of pipes, cocks,
rectifying tower plates, and other similar articles. Asbovinyl possesses acid-
resistant as well as alkali-resistant properties, depending on the type of as-
bestos used, and is sosuitable material for lorr temperatures in the range between
minus 40 and minus 50 The asbovinyl product may be cured at room temperature
or higher. Its manufacture requires no expensive or scarce raw materials and,
in addition, preparation and application of lining material requires no special
equipment.
The following are the physicorechanicc,l properties of asbovinyl: specific
gravity, 1.5-1.6; water absorption, 0.5-1.0~i? tensile strength, 150-200 kr,;/sq cm;
compressive strength, 150-300 kg/sq cm; bending strength, 250-300 kg per sq cm;
hardness, 18-25 kg per soq mm; heat conductivity, 0.11 cal/m/hr o C; resistance
to frost, up to minus 50 C; adhesiveness, 20-25 kg/sq cm; coefficient of linear
expansion is low.
The composition of asbovinyl depends on its purpose. The ratio between
binder and asbestos is of the order 1:1.3-1.5.
The asbovinyl paste is applied on a surface to be covered in the form of a
three-layer coating 10-12 mm thick. Each coat should not exceed 3-l+ mm in thick-
ness. Curing is done by heating in a special chamber to 120?. Coatings on large
pieces, which cannot be placed into n drying chamber, are cured in the open at a
temperature of 15-20? for 30 days. To decrease the reriad of drying, a lining
may be heated with hot air obtained by any method. t, hen equi~ent with jackets
or coils is lined, heating may be performed through the jackets with the aid of
hot water and steam.
Since 1950, asbovinyl materials have been widely .used not only for lining
various equipment in the cellulose-paper industry, but alto as substitutes for
nonferrous metals -- chiefly lead -- in chemical, petroleum, and other bran,:hes
of industry.
The fields of application of asbovinyl are 3efined by its dtu?ab;.lity in
nonoxidizing mineral acids, in solutions of salts, in certain organic acids sad
solvents, in gases, and in creak solutions of alkalis, including, for e:~~nple,
hydrochloric acid up to 30$ concentration, sulfuric acid up to 75i,, bleachi:,:;
powder, chlorobenzene, solution of caustic soda up to 30~, glacial ncctic acid,
etc. it should be remembered that asbovinyl deteriorates in nitric acid, h;p3rogen
peroride, and other oxidizing media. Asbovinyl may be used at temperatures tr
to 110-120 .
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A comparatively long experience in operating equipment lined with asbovinyl,
particularly in the sulfite-cellulose and paper industry, has,hown that in
numerous cases this material is a very effective and sound substitute for lead
and other critical materials.
Among the substitutes for nonferrous meals, impregnated graphite deserve>
to be mentioned. Its application as ar. indepbudent structural material or in
Soviet Unionlbecauseiofsthernovelty osthis material andeinsufficie~ntlfemiliarity
of designers and technologists with its Pro^crties.
Lnpregnated graphite is one of the r??
practice. Together with extremely high irz~?.~tne:;~mtowardmthermajorityaofi$o~roeive
substances and the possibility of its use nt hi;;h temperatures, depending on the
nature of the impregnating agent, gr:_rhitc }:e.s a number of other essential prop-
erties. The high thermal conduction of r-_?apl~ito is one of its most valuable
qualities, permitting its use in the fabrication of heat exchange equipment.
Impregnated graphite is practically not eroded at high temperatures even by
strong mineral acids, including phospho~?ic acid, by allsali hydroxides, hydro-
fluoric.acid, etc. It is subject to erosion only by strong oxidizers.
The application of impregnated graphite is restricted by its porosity,
since various synthetic resins recently used for the elimination oi' porosity
by impregnation do not withstand temperatures higher than 150-200?. The impreg-
nation of graphite with solutions of mineral salts would permit its application
at higher temperatures, but experiments in this respect have not yet given
positive results.
Craphite.is now impregnated mainly with phenol-formaldehyde resin and, to
a leaser extent, with organosilicon compounds. The impregnation of graphite
articles is usually. nerfomed in an autoclave connected with a compressor and
vacuum pump,
By alternating pressure and rarefaction in an autoclave, it is possibly to
decrease 3raphite porosity from an initial 30-kOp to 10-15~. The mechanical
strength of impregnated graphite is considerably higher than that of ;;rephite
without impregnation. Graphite products, impregnated xith phenol-forraldehyde
resin, are subjected to heat treatment by a process gene: ally adopted for the
polymerization and curing of these resins.
The following table gives techaical chsrscteristics i'or graphite;; of two
plants before and after impregnation with phenol-formaldehyde resin:
Deforc
Ffter
3efore
?~r
V
Specific gravity, g/cu cm
?,zS
?
o"
?
Volume weight, kg/cu dm
i
? ~
-'''-7
~?~?'3
Porosity, ~
?57
1.85
1.38
).,F
Tensile strength k
30...
__
35,~1~
_:
s;~q ~~
Com
ressi
t
7C
lA0
.;7
, ?~
p
ve s
rength, ?;r,;,,q c;;
feat conductivity at rorn~al
tempe.ratw?e, cal/m;'hrf? C
Phickness ~f impre
nated l
260
__
1,.9jo
__
2~-1
9h
~4,
g
ayer
.__-assible temperature of
ap_~lication, ? C
__
__
8
180
_
--
="
1`~0
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assembled b - -----`~"~ """ "' 1?`='reenaLeo graphite, are being
y gluing with phenol-formaldehy3~ adhesives and with various glues.
The adhesiveness of these gluing materials with impregnated graphite amounts
to 25-30 kg/aq cm.
Threaded joints are also applicable for graphite parts. Impregnated graphite
may be machined on metal-cutting machine tools. At present, soma plants use im-
pregnated graphite in the form of lining tiles or parts of chemical equipment.
Viniplast is the oldest of the structural nusterials used in the Soviet Union
during the postwar period as substitutes for nonferrous metals. Its application
in the chemical industry was initiated in 1945 - 1946.
Although the properties of viniplast and the conditions for its application
have been described in technical literature in sufficient detail, new data on
its behavior under various operational conditions have appeared recently. In
addition, certain modifications and improvements have been introduced into the
technology of viniplast application as an independent or lining material.
It is generally knoxn that the wide application of viniplast is attributed
to its valuable properties, including high chemical stability, weldabillty,
thermoplasticity, and :nachinability. The negative properties of viniplast in-
clude inadequate thermal stability, brittleness at temperatures lower than
:sinus 20?, high coefficient of linear expansion, warping at sharp changes in
temperature, etc.
Viniplast is prnetically resistant to the action of almost all mineral and
organic acids, solutions of alkalies and salts, and the majority of solvents and
gases. However, it deteriorates in oxidizers, aromatic and chlorinated hydro-
carbons, and certain other media.
Viniplast is easily machinable under conditions where the cutting speed
does not exceed 700 m/min and when effecti?re elimination of heat is provided.
Upon unifora heating Prom 80 to 180? C, vini-nlnst becomes croft end nlastlc.
This permits the fabrication of viniplast products by pressing, stamping, and
molding,
The welding of viniplast is based on its proparty to become soft with no
modification of chemical stability when hated for a short period. 41ire from 2
to 8 ,;~ in diameter, made out of viniplast, is used for z:eldinb rods. Types of
joints in welding viniplast are similar to those obtainable in welding metals.
Viniplast articles may be joined also by .*,ecns of special glues.
Viniplast is used for the fabrication of various eeuipment ant fittings,
such as containers of various sizes and intricate shapes, centriilrgal rn+:as,
valves, pipe elbows, and tees, condensers, injectors, ventilation ;r:.pes, etc.
Pipelines nr^.de out of viniplast n;cy be used ?.uidcr pressure un to 5 xtr^.. ~.r;grc;r;
viniplast pipelines have been in operation foa a nwnbar of ycar~, aua'in~ ;;^od
results.
In addition, viniplast iwy be used as alining mate_?ie1 for 'the ...n
of equipment against active and corrosive substances. Vini_~lsst _1_rc ^,j_l,';
mm thick is used for lining, being glued to the metal su?facc to be n;? ' L ^';..:_ ?
SJhere a Thicker lining -- up to 3 nnn -- _~ used, vininlast is ._tt^c?~.,1 t:; ~? ' ~1
walls with bolts. "'-
Large rectangular containers are made out of viniplast plates, :~~ 1=a=?~
5-10 mm thick, which are welded together. All joints must be covered cC`?Y: glued-~r_
viniplast foil or treated with paste Wade on n base of phenol-f ere;nl'eii;le .csin,
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STAT
Engineer A. V. Goryaninova has recently conducted tests studying the strength
properties of viniplast which has been under constant tension and also under the
combined effect of three factors -- temperature, loads, and active medium. The
results have shown that the mechanical strength of viniplast decreases under such
conditions and the field of its application as a structural material becomes more
limited.
A load of over 200 kg~sq cm causes creep of viniplast with increasing de-
formation rate, leading to fracture. A load of 50 kg/sq cm induces deformations
in xelded joints equal to the deformations of base material under a load of
200 kg~sq car. The high creep of viniplast under constant load and the low
strength of xelds, are thus significant deficiencies of this material, especially
in operation under pressure. For elimination of these faults, viniplast con-
structions have to be either reinforced with metal bindings or enclosed in metal
housings. In these cases, the considerable difference in the coefficients of
expansion of viniplast and iron must be taken into consideration, and the vini-
plast co~?ponent of the apparatus has to be made smaller than the inner volume of
the metallic enclosure.
The rate of welding -- 0.2 m~min Yor a single-row joint -- is considered In-
adequate. Recently a new method has been developed for xelding viniplast without
welding rods by forcing together under high pressure the pieces to be xelded
after preheating their edges. The method, being very productive, employe a
specially designed machine tool with pressing rolls, preheating burner, and
driving gear.
Despite the deficiencies of viniplast, this materiel continues to be an
essential substitute for nonferrous metals. At some chemical plants, the length
of viniplast pipelines is measured by the tens of kilometers. Several hundreds
of viniplast linings have been installed instead of lead linings in the elec-
trolysis shops of the industry of nonferrous metallurgy, and there are numerous
other cases of viniplast application.
Examination of the properties of various substitute meterials reveals. tre-
mendous opportunities for saving nonferrous metals. These opportunities must
be xidely utilized.
STAT
~~s
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