JPRS ID: 10588 USSR REPORT MATERIALS SCIENCE AND METALLURGY

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- JPRS L/ 10588
~ 15 June 1982
.r.
- USSR Report
- MATERiALS SCIENCE AND METALLURGY
- "FOUO 3/82)
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JPRS L/10588
15 June 1982
USSR REPORT
MATERIALS SCIENCE AND METALLUR6Y
(FOUO 3/82)
CONTENTS
FERROUS METALLURGY
Problems of Iron and Steel Industry Development.................. 1
FOUNDRY
Advances in Electroslag Metal Technology 8
MISCELLANEOUS
Fluoride Process for Producing Tungsten 15
Scientific Fundameztals of Materials Science 19
Interaction of Molten Mptal With Carbon Materials 22
_ a _ [III - LISS3'< - 21G S&T FOUO]
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FERROUS METALLURGY
PROBLENdS OF IRON AIdD STEEL INDUSTRY DEVELOPMENT
~ Moscow VOPROSY EKONOMIKI in Russian No 3, Mar 82 pp 54-59
[Article by S. Kadetov: "Economir_ Problems of Development of Ferrous Metallurgy"
[Text] The CPSU CentralComittee and USSR Cour~cil of Ministers decree entitled
_ "On Intensifying Efforts to Achieve Ecnnomy and Efficient Utilization of Raw
- Materials, Fuel-Energy and Other. Material Resources" stares: "Tc expend raw
materials and supplies carefu?ly, to reduce waste, and to eliminate losses
~ means to aehieve savings in the labor of millions of people and capital invest-
ment, to increase output, and to protect the snvironment. The decree focuses
the ferrous metallurgical industry on accomplishing two principal tasks in-
- tensification of inetallurgical production and efficient utilization of re-
sources.
The USSR contains approy-imately half of the world's iron ore reserves. Of the
- total quantity of proved reserves, approximately 15 percent are rich ores, con-
taining on the average more than 55 percent iron and not requiring concentra--
- tion, 67 percent are ores which arz concEntrated by simple processes, and 18
percent are ores requiring complicated concentration methods.
Iri the. USSR the largest iron ore reserves are concentrated in the Ukr4ine, in
the Central part of the RSFSR, in Kazanhstan, Siberia, and in the Urals, ac-
counting for 85 percent of all iron-ore resources. For the most part rich and
easily-concentrated ores a~e beirg develnped tn this countrys Rich ores comprise
17 percent of total production. Ores requiring complicated methods of concen-
tration are being utilized in blast-furnace productian to an insignificant
- degree at the present ti_me. Approximately 90 perceat of the merchantable ore
consumed by metallurgicaZ plants is mined locally; the remaining 10 percent is
- hauled long distances. Prineipal g:owth in iron ore.reserves for the immediate
future is projected in the western areas of t'ie country. In connection with
- this, increase in ferrous metals production 13 te be achieved by expanding the
Staro-Oskol'skiy Electrometallurgical Combine in the area of the Kursk
- Magnetic Anomaly (KMA), as well as construction of second aiLd third units of
2xisting plants in the northeast of the Eurcpean part of the country and in the
~ ukraine.
Studies indicate that the economic effectiveness of production of inerchantable
iron ore is significant2y greater in the western areas of the USSR than in the
eastern.l E.ffectiveness is particulary low in the Urals and Western Siberia.
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The main reason for this is the abaence of large surveyed ore bodius which c3n
be sLrfa~::.-`{^~^ = The largest deposits in Eastern Siberia in terms uf reserves
= are the Tagarskoye and the Nizhue-Angarsk.oye. The economic effectiveness of
- commercial iron ore productior, here, howeveY, is calculated to be lower than
: in the western areas of the USSR. The fact is that, in the first place, a
large portion of the ore requires beneficiation; secondly, rail Yines must be
- constructed; thirdly, because of the harsh climatic conditions, pit transport
- vehicles, loading and other equipment must be provided in Arctic models;
urban-type communities must also be built.
- As calculations show, all iron ore deposits in the Urals and Siberia which
- are presently in operation or scheduled to go into operation have worse economic
- indices than ore bodies in the western areas of the country. A,Zcording to the
- method of determining economic effectiveness of capital construction, it is
advisable to bui?d metallurgical enterprises only in the European part af the
country, and the USSR Ministry of Ferrous Metallurgy has no interest in pushing
industry eastward. In our oginion the existing method is little suited for the
eastern parts of the country. Analyzing the reasons for increase in the cost
- of capital construction in the eastern regiona and a decline in return on in-
- vestment, Academician T. Khachaturov noted that a decline in the capital-output
ratio does not constitute grounds for a decision not to build new enterprises
_ in the eastern part of the country.2
The iron ore bodies of the Kursk Magnetic Anomaly are unique among the
- country';s iron ore deposits. Proved reserves of high-grade ore total approx-
imately 27 billion tons, and 40-50 billion tons including projected reserves.3
The iron ore bodies of the KMA constitute the raw materials base for the
Staro-Oskol'skiy Metallurgical Plant which is under canstruction. The mining
- enterprises of the KMA can meet the iron requirements of the Novo-Lipetskiy
- and Novo-Tul'skiy metallurgical plants and plants of Western Siberia. Con-
sidering the enormous reserves of high-grade ores in the KMA, Northern
_ Kazakhstan and the Ukraine, the USSR Ministry of Ferrous Metallurgy is planning
~ to obtain 80 percent of inerdlantable ore production increase in these areas. Jf
interest in this connection is the "Long-Range Capital Investment Erogram for
= Develbpment of Ferrous Metallurgy Based on the Iro-n Ores of the KMA and Coking
Coal of the Kuzbass." This program attempts to provide an economic substantia-
tion of the feasibility of supplying with iron-flre resources the metallurgical
plants of Western Siberia and with coking coal the plants of the central region
- on analogy with the Ural-KuZnetsk metallurgical base. The KMA-Kuzbass
- program, however, should be viewed as a reserve Arogram. If large and
economical ison ore deposits are disc:overed in Western Siberia in the near
_ future, there will be no need to implement this program.
- The percentage share of surface-mined iran ore is increasing at present. From
1970 to 1980, for example, the share of surface-mined production increased
from 79 to 82 percent, while the share of underground-mined production declined
= from 20.8 to 16.1 percent. Subsequently the ratio of these two modes of
= production will stabilize. Surface mining of iron ore is much more economical.
_ Specific capital investment per ton of production increase in merchantable ore
with underground mining is 11 times greater than with surface mining. Con-
- tinuing underground mining operations, however, is dictated both by a shortage
2
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- of iron ore deposits capable of supplying existing metallurgical plants and by
the conditions of occurrence of natural high-grade iron ores. In the future a
number of surface mines will exhauet reserves at the upper levels and will in
part shift to mixed mo des of production. Subsequently there will evidently be
- a decline in the percentage share of surface-mined production. This is based
- on the assumption that practically all known large deposits where mixed-mode
production will be employed will have been bro ught into operation. One should
bear in mind thereby that open-pit mining is accompanfed by removal from use of
- large acreages of fertile land. For example, exploitation of the KMA iron ore
. bodies led to the removu.L of approximately 15,000 hectares, including 9000 hec-
_ tares of arable land. A comparison of the acreage occupied by the underground
and surface mines of the KMA shows that only 1200 hectares are required for
- the underground Yakovlevskiy and Gostishchevskiy mines for the entire period of
= exploitation, while agproximately 20,000 hectares are required for the
- Stoylenskiy, Lebedinskiy, and Mikhaylovskiy surface mines.
Ferrous metallurgy in the USSR is developing in conformity with the directions
specified at the 25th and 26th CPSU congresses increasing the unit output of
- metallurgical equipment and intens:ifying the process of concentration of
metallurgical production, a result of which is an increase in steelmaking at metal-
lurgical plants of tp to 10 -25 million tons per year. This ferrous metallurgical
= industry growth focuses the irnn ore industry toward increasing the perce-ifi age
- share of large surface-mining operations. In tne future the peYCentage share
- of open-pit mines with an annual crude ore output of 20-30 million tons or more
- will increase to 60 percent of the t.otal volume of surface-mined ore production.
In spite of this, however, concentration of-production in the iron ore industry
- still lags behind the demands made by blast-furnace production. At the present
time all metallurgical plants are consuming iron ore from a group of ore bodies,
which involves worsening of the technical-economic indices of pig iron produc-
tion. In addition, there arises the problem of blending the raw materials at
storage sites, which causes additional costs. Existing equipment.is unable to
provide proper blending. As a result iron content in the sintered ore fluctuates
�1-2.0 percent. At ore blending facilities abro3d this ratio runs as ioilows:
= 0.2 percent in Japan, and 0.25 percent in the United Sta4.es. Providing Soviet
- sinter plants with modern blending equipment will make it possible to boost the
- produc*_ivity of blast furnaces and improve the economic indices of blast-fur-
- nace production.
Expenditures involved in mining and preparing or.e for smelting are takin; up an
_ increasiiigly larger share of production cost. Increase in the cost of the
- processes of preparing ores for smelting has been caused by objective factors.
= tn 1958, for example, 1.3 tons of crude ore were required to produce a ton of
= merchantable ore, while in 1965 the figure was 1.6 tons, 1.85 tons in 1971, and
- 1.92 tons in 1980. The increased amount of crude ore required to produce a ton
- of inerchantab?e cre is due to the limited reserves ef high-grade iron ores and
the uneven geographic distribution af these reserves in this country; the large-
scale utilization of low-grade ores requiring beneficiation, and impoverishment
- of a porzion of high-grade ores as a result of working ore bodies with high-
= output mass caving systems, etc. All this inevitably Ieads to an increase in
the percentage share of beneficiated iron ore in the total production volume and
to expanded construction of beneficiation plants at practically all surface and
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underground mines coming into production. S3.milar results are brought about by
: a decline in the percentage content of iron in the mined ores. For example,
the percentage content of iron in the crude ore declined from 37.3 to 35.1 per-
. cent from 1970 ta 1980.
= Improvement in the qua]ity of iron ore and increase in the iron content in the
merchantable ore takes place in the process of beneficiation. A trend toward
- increase in iron content in concentrate is becomi.ng increasingly more marked,
~ since the savings achieved in blast-furnace production by smelting high-grade
ore exceeds by severalfold the expenses involved in high-concentration ore
_ beneficiation and concentrate pelletizing. In addition, beneficiation of iron
~ ores on the one hand reduces the cost of producing pig iron, whlle on the
other hand it fosters technolog,ical advances in the iron and steel industry.
- Iron cantent in concentrate is h3gher in the USSR than in the United States.
Plans for new Kursk Magnetic Anomaly mining and beneficiation combines call
for obtaining concentrates with a 67-68 percent iron content. The perfornaance
indices of these entergrises are equal to those of foreign enterprises in
- quality of concentrates and fineness of the final grind. Large capital in-
- vestment is required, however, to achieve cuch results. Expenditures on con-
struction of new, renovation ar.d expansion of existing crushing-sizing and
beneficiation plants make up a substantial percentage share of the total
amount of capital spending in the iron ore inclustry.
Growth in fixed assets at crushing-sizing and beneficiation plants is running
ahead of increase in volume of concentrate, xesulting in a worsening of the out-
_ put-capital ratio at ore preparation enterprises and reduced return on capital.
Employment of high-concentration beneficiation and utilization of the most
- modern equipment inevitably raise the cost of beneficiation and specific out-
lays per ton flf concentrate. According to the figures of N. Lelyukhina,4 with
- a 1 percent increase in iron cnntent in magnetic concentrate within the range
~ of 60-65 p ercent, the cost of the concentrate increases by 10-20 kopecks, and
- specific capital outlays (figuring mining of quartzites) by 50-65 kopecks. The
savings obtained in producing pig iron, however, exceed by 3-4-fold outlays
_ connected with increasing iron content.
Increase in the economic effeciiveness of beneficiation of iron ores is deter-
mi:aed in large measure by the comprehensiveness of their utilization. Solving
the problem of comprehensive utilization of complex ores will make it possible
to reduce the cost of produGing the main product and to obtain a number of
associated constituents. The difficulty here lies in the fact that the iron and
steel industry will be compelled to turn out products of other branches:
sludges for fertilizing soil, rare elements, building materials, etc. The lack
of interest on the part of mining enterprises to produce useful by-product
constituents is due to the fact that this requires additional capital invest-
ment and more complicated enterprise structure and management. In addition,
- many scientific and engineering pr.oblems pertaining to separating attendant
constituents during extraction of the principal element have not yet been
solved.
s
= 4
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The final process in preparing iron ore for blast-furnace smelting is pelletiz-
ing. In 1980 the percentage share of pelletized ore in blast-furnace charges
= exceeded 90 percente Analysis of future developmPnt of the USSR iron-ore base
indicates that the percentage share of pelletized iron ore will increase, as
will expenditures on this process.
Pelletizing of iron ore is accomplished by sintering and nodul.izing. Sintering
tss both positive and negative features. Following are drawbacks of sintering:
high expenditure of fuely difficulty of producing a strong sinter capable of
standing up under lengthy hauls; poor efficiency of pelletizing finely grour.Ld
- concentrates. The cost of sinter is also steadily increasing. The USSR is the
world leader in sinter production volume. At the same time Soviet plants are
surpassed by plants abroad in equipment output capacity and product quality.
The increase i:t cost of sinter is due not only to the fact that obsolete equip-
ment is being used but also-is due to objective factors: in recent years the
percentage share of concentrates smaller than 0.1 mm in size in the sinter
- charge has cnntinuesi to rise, which diminishes the productivity of sintering
= equipment and incraases sinter cost.
- Worsening of the technical-ecanomic indices of sinter.ing with employment of
fine concentrates and increase in their production volumes have dictated the
necessity of developing the -most pronising method of pelletizing fine con-
centrates nodulizing. The end product of nocivlizing is iron ore nodular
- pellets. At the present time we produce for the most part fluxed and unfluxed,
- metallized and unroasted pellets. Fluxed and unfluxed pellets are employed in
coke blast-furnace metallurgy, but in producing pig iron employment of unfluxed
= pel.lets is possible only in a combination with basic sinter. Metallized pellets,
� depending on the degree of inetallization, are used for making pig iron and
steel. Metallized pellets are one type of pre-reduced iron ore. With a high
- degree of inetallization, various types of reduced ore are employed in steel-
making. Thus sintering and pelletizing of iron ore are initially supplementing
one another, while subsequently nodulizing will evidently replace blast-furnace
- production.
The nodulizing method is more promising than sintering. The sintering process
_ is developing in the direction of increasing the size of the sintering machines
together with attendant equipment, by parallel improvement in the quality of
the sinter (increasing strength, etc). Its cost is increasing, howeveY, while
the cost of producing pe3.lets is decreasing. In spite of the fact that there
- is taking place, as it were, a countermovement of increase in the cost of
- sinter and decrease in the cost of pellets, the cost of iron ore pellets is
frequently greater than the cost of sintex. In our opinion this attests to the
= fact that there is occurring a n.ot quite correct distribution of scientific,
financial and material resources in the area of scientific and technical
development projects between sintering and nodulizing. Accelerated development
of the more advanced method of pelletizing fine concentrates nodulizing
will prove to be more economical, which wi11 have a favorable effect on the
03 cost of ferrous metals.
An increase in pig iron and steel production volumes causes an inerease in the
_ volume of ore and rock moved by in-mine transport. In connection with the
- fact that the percentage share of outlays on hauling ore and rock will
5
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- increase, efficiency of means of transport determines in large measure in-
crease in efficiency of producing merchantabZe ore. Mnre than 1.5 billion
- tons of ore and rock are hauled in the USSR iron ore industry: 49.3 percent by
rail, 39.4 percent by truck, 10 percent by conyeyer, snd 1.3 percezt by other
modes of transport.
- In the United States and Canada the bulk of hau.ting (80 percent) is done by
, truck. Comparing the basic specifications and performance figures of Soviet-
built dump trucks with those built in the i;nited States, we can note that ,
specific horsepower, speed, and load factor are approximately the same, but U.S.
, dump trucks have less downtime. In the USSR ttie percentage of the surface-
mine truck fleet in serviceable condition is relatively low. A higher per-
centage is achieved in the United States and Canada through maintenance ar.u
maintaining a complete stock of factory-built spare parts. An increase in load
_ capacity and engine horsepower is the principal trend in the development of
today's surface-mine motor transport in this country.
An increase in the load capacity of Soviet-built surface-mine dump trucks is
in conformity with the world development trend in this mode of transport. As
regards pawerplants, one way to improve the efficiency of surface-mine dump
truck engines is to replace diesel engines with gas turbines. A 1200 horse-
power gas turbine engine has been developed in the USSR. The great advantage
of a gas turbine engine lies in the fact that it can use liquefied natural gas
' as fuel; this will make it possible to achieve greater economy and to reduce
- air pollution around surface mines.
The present iron ore base in the USSR comprises 27.5 percent of total balance-
sheet iron ore reserves and makes it gassible to pravide a crude iron ore
production volume in excess of 700 million tons, which corresponds to an
annual production of 259 million tons of iron. However, in connection with
_ a worsening of the quality of the iron ore base (a decli.ne in the percentage
of iron content in the ore), increasingly deeper mining le�vels, an3 an in-
crease in ore hauling distance to the customer, the economic indices of
- ferrous metallurgy are w orsening.
- In iron ore beneficiation one should expect changes in technology as d result
of total utilization of iron ores. Scientists and engineers are already
working on processes for recovering secondary constituents contained in com-
- plex ores. The iron and steel industry will be putting out a broader product
~ mix.
- Changes are expected in development of inethods of preparing ore for smelting.
A substantial quantity of concentrate will be nodulized. One can already
- note a trend toward a steady increase in production of pellets. Production of
pig iron will gradually be replaced by a new technique direct reduction of
iron from ore.
This country's iron ore industry is focusing on more economical utilization
- of already produced ferrous metals. Up to the present time, however, metal
losses are still quite large along the entire process chain, from mining the
= ore to manufacture of the eiid product. In the lOth five-year plan, for
- example, irretrievable tnetal losses in beneficiation processes totaled
~
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- approximately 130 million tons, which is equivalent to 400 million tons of
crude iron ore.5 Considerable ferrous metals lossea occur in machine building
from machinery and equipment wear, from shortcomiags in orgai.ization of col-
lection of scrap metal, poor quality of steels, metal corrosion, etc.
FOOTNOTES
1. See N. D. Lelyukhina, "F.konomicheskaya effektivnost' razmeshcheniya chernov
- metallurgii" [Ecoaomic Effectiveness of Distribution of the Iron and Stee..
Industry], Izdatel'stvo Nauka, 1973, pp 116, 11$.
2. See T. S. Khachaturov, "Intensifikatsiya i effektivnost' v usloviyakh
, razvitoga sotsializma" [Intensification and Efficiency in Cond'tians ot
Developed Socialism], Izdatel'stvo Nauka, 1978, page 233.
_ 3. See "Dolgosrochnyye programmy kapital'nykh vlozheniy" [Long-Term Capital
- Investment Programs], Izdatel'stvo Ekonomika, 1974, page 76.
- 4. Lelyukhina, op. cit.
5. See L. Zusman, "The Metal (iron) Balance Sheet in the Nation's Economy,"
VOPROSY EKONOMIKI, No 10, 1979.
COPYRIGHT: Izdatel'srvo "Pravda", "Voprosy ekonomiki", 1982.
- 3024
CSO: 1842/127
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FOUNDRY
UDC: 669.187.26.004.12
ADVANCES IN ELECTROSLAG METAL TECHNOLOGY
Kiev ELEKTROSHLAKOVYY MFTALL in Russian 1981 (signed to press 31 Jul 81) pp 4-
8, 678-679
.
~
_ [Aunotativn, table of contents and foreword from book "Electroslag Metal", Ly
Boris Izrailevich Medovar et al�, edited by Academxcians B. Ye. Paton and
B. I. Medovar, Izdatel'stvo "Naukova dumka", 2000 copies, 680 pages]
, [Textj This monograph deals with questions pertaining to the quality of
electroslag metal, that is, metal materials and blanks of inetals obtained by
electroslag technology methods: electroslag remelting, electroslag casting,
electroslag working, and all methods of enlarging blanks.
This volume contains information on the chemical composition, structure,
mechanical, physical-mechanical and industrial properties of electroslag metal:
steels of practically all existing classes, heat-resisting alloys, cast irons,
and a nwnber of nonferrous, highly reactive and heavy metals and alloys.
~ This volume presents data on the technical-economic effectiveness of production
and employment of electroslag metal.
This book contains xeference materials which will be of use to specialist
metallurgists and naachine builders, designers, students enrolled at higher
technical schools, as well as many other specialists involved in the production,
_ consumption and processing of inetals.
Contents
Foreword
Page
5
Chapter I. What Are EShP [Electroslag Remelting] and EShL [Electroslag
Casting]? 9
1. History of Development of EShP Based on the Electroslag Welding
Process 9
2. Electroslag Metals List 1.3
3. Types of Electroslag Castings 19
4. Development Prospects of EShP and EShL 25
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C1apter
II. CEemical Composition, Structure and Mechanical Properties
of Electreslag Metal
30
= 1.
Chemical Camposition
30
40
_ 2.
Structure
49
3.
Mechantcal Properties
53
4.
End.urance
53
5.
Corrosion-Mechanical Strength
- Chapter III. Manufacturing Properties of Electroslag Metal ,
73
73
1.
Deformabill.ty
99
2.
Weldability
130
3.
Workability
131
4.
Hardenability
Chapter IV. Electroslag Ballbearing Steel
134
1.
Nonmetallic Inclusions and Service Properties of Steel
134
- 2
InfluenCe of EShP on Contamination With Nonmetallie Inclusions
.
and Service Properties af Steel
141
- 3.
Mass of an EShP Ingot and Quality of the Steel
151
153
" 4.
Steel for Instrument and Heat Resistant Bearings
158
5.
Steel for Cold-Rolling Rolls
Chapter V. Electroslag Steel for Merchant Shapes, Forgings, Drop
165
Forgings and Tut~s
165
1.
Tool Steels
177
_ 2,
Die Steels
187
3.
Carbon and Low-Alloy Structural Steels
'
194
4.
Medium-Alloy Struccural Steels
208
5.
Heat-Resisting Steels
211
" 6.
Drill Bit Steels
215
7.
Transforcaer Steels
216
8
Stainless and Heat-Resisting Steels
.
9.
Heat-Resisting Alloys
253
287
_ 10.
Tubes and Hollow Deformed Blanks
Chapter VI. Electroslag Sheet and Plate Steel
308
l.
Present State of Production of Sheet Steel
308
313
2
Features of Production of Electroslag Sheet Steel
.
3.
Low-Al1oy Plate Steels
322
362
4.
Medium-Alloy Plate Steels
382
' S.
Medium-Alloy Sheet Steels
388
6.
High-Alloy Sheet Stee.ls end Alloys
393
7
e-Deformed and Undefermed Sheet Steels
LittJ
.
8.
.
Sheet Steels Abroad
401
,
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- Chapter VII. Electroslag Castings
l. Mechanical Properties and Characteristics of Castings of
Various Steels
2. Electroslag Castings Abroad
= Chapter VIII. Heavy-Tonnage Blanks of Electroslag Steel
- 1. Areas of Applications
= 2. Materials Employed in Producing Blanks
3. Modern Methods of Producing Blanks
~ 4. Monoblock Blanks of Electroslag Steel
5. Blanks Obtained by Electroslag Sealing of an Axial Aperture
- 6. Blanks Obi:ained by the El-ctroslag Casting Method
7. Blanks Obtained by the Batch Electroslag Casting Method
- 8. Blanks Obtained by the EShSB [Electroslag...] Method
Chapter IX. E1e:ctroslag Cast Iron
l. Types of Cast Irons, Areas of Applic,'tion and Problems of
Improving Quality
2. Methods of Refining and Heating Cast Iron to Obtain Spheroidal
Graphite
3. Influence of Electroslag Working of Cast Iron (EShOch) on Its
Quality
4. High�Purity Electroslag Cast ~'ran
Chapter X. Electroslag Nonferrous Metals and Alloys
l. Titanium and Titanium Alloys
2, Aluminum
3. Copper and Copper-Base Alloys
Refractory Metals and Special Alloys
Chapter XI. Economic Effectiveness of EShP and EShL
1. General Methodological Statements
2. Economic Effectiveness of Production and Consumption of EShP
Metal
3. Comparative Analysis of Technical-Economic Indices of EStP and
Other Remelt Processes
4. EShL An Important Direction for Improving Efficiency Qf
Producing Blanks
5. Economic Appraisal of the State of Production of Electroslag
Metal Abroad
6. Prospects for Future Improvement in Economic Effectiveness of
Production of Electroslag Metal
= Conclusion
Bibliography
10
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416
416
466
477
477
478
480
494
506
511
512
528
542
542
547
548
556
565
565
572
573
584
595
596
598
625
629
633
640
646
648
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_ FOREWORD
Each year many hundreds of tho-lsands of tons of electroslag metal are produced
in this country. The EShP [Electroslag Remelting] metal product list today
embraces practically all types and grades of steels and alloys and all tyFes
of rolled products produced by the metallurgical industry. They include rolled
merehant shapes and wire, plate and sheet, tubes and rings, railcar tires, etc.
The assortment of electroslag forgings and drop forgings is quite extensive.
- More and more varieties of castings, including sectional shapes, are being ob-
tained from electroslag metal.
Bearing and tool steels, structural and high-strength steels, stainless and
heat-resisting steels, iron, nickel, nickel-cobalC and ir,on-nickel-cobalt base
alloys, copper and its alloys, transformer steels and alloys, including ferro-
- aluminum alloys are subjected to electroslag remelting. In recent years highly
- reactive and even refractory metals have been remelted.
- Alongside the remelting process, that is, EShP proper of a consumable electrode,
other areas of electroslag technology are also being developed, that is, a
technology which employs as heating source Jau?.e heat released in a synthetic
slag during the passage of an electric current through it.
Elactrosaag casting M is an important new manufacturing process, and particular-
= ly such types as shaped and centrifugal casting, based on pouring electroslag
metal into a stationary or rotating mold.
Electroslag processes are being developed in which consumaUle electrodes are
= used only partially or not at all (electroslag casting, including batch casting,
electroslag working electroslag heating, electroslag refining, electroslag
= feed, etc).
_ One new application of the electroslag process is its employment in electric fur-
nace melting of steel of inetallized iron pQllets, electroslag melting of
synthetic pig iron of products of direct reduction of iron (pellets, sponge
iror.).
- Whatever one might call a given variation of electroslag technology, its end
product is metal, in the form of an ingot or casting, or in the form of a
forging or drop forging. In all instances this product bears a common name
electroslag metal.
Electroslag metal is not only a product of ferrous or nonferrous metallurgy.
Therefore we must say afew words about the term special electrometallurgy,
- which until quite recently was defined rather narrowly, applying only to the
_ production of inetal in electroslag and other remelting furnaces. Obviously
the time has come to broaden the definition of this term somewhat, bearing in
mind that special electrometallurgy and its important subdivision electroslag
metallurgy should encompass all those processes in which the electroslag
= process is empYoyed to melt solid o-r refine liquid metal.
11
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It should scarcely be necessary here to discuss in detail the great importance
for scientific and technological advances of inetal of high quality, high
reliability, homogeneity, with high indices which are constantly reproduced
from one melt to the next, characteristics which describe electroslag metal.
One cannot even imagine what would have happened in a number of areas of new
technology and the most modern production facilities if inetal were the same in
a.ts qualitati,ve indices and level of properties as 1.5 to 20 years ago. Today
it is well known that the principal result of electroslag remelting of inetal,
just as of other refining remelting processes which purify metals of harmful
- impurities and nonmetallic inciusions, which improve its structurP, is a sub-
stantial improvement in plasticity and toughness indices with a practically
unchanged level of strength properties. This remarkabl2 property of inetal
freed of contaminating impurities, metal which is sufficiently dense and
- homogeneous, possessing the required structure, makes it possible, utilizing
- its margin of toughness and plasticity, appreciably to increase the strength
- of a steel or alloy. It is precisely this which has made it possible to
supply modern machine building with steels possessing very high strength (100-
200 kg/mm2) in fairly large sections, with the required margin of plasticity
and toughness. In a number of instances, however, when precisely these two
indicators are of decisive significance for the operating properties, reliabili-
- ty and durability of a structural componAnt, machine or machinery part, it
makes sense not to seek to obtain the greatest possible strength but rather
- to utilize in full measure the excellent plasticity and toughness properties of
= refined metal.
Twenty years ago, during the period of farmation of special eJ.ectrometallurgy,
only costly steels and alloys were remelteci. In recent years, initially in
this country and subsequently abroad as well, there was noted a clearly-
marked trend toward empYoyment of EShP in the production uf relatively inex-
= peresive medium- and low-alloy, and sometimes common carbon steel. EShP has
= come into large-scale production, although of course even 10 or 20 years hence
electroslag steel will scarcely comprise more than 1-2 percent of the world's
total metal production.
We know that party and government decisions call for rapid development of
J electroslag technology (remelting and casting) in our country. No matter how
rapidly this branch develops, however, it is highly unlikely that i.n the
= foreswable future it will fully satisfy the swiftly growing needs of the economy
for electrnslag metal. This metal is not expensive, but at the present time
; it is still i.n short supply. Therefore it should be employed only in those
instances where it is truly essential and produces considerable technical and
- economic effect, that is, when electroslag metal is truly indispensable.
Electroslag metal should.be employed when it genuinely increases the durability,
- reliability, and efficiency of a structural component or product. It hardly
- makes sense, for example, to make engine cylinder liners of EShP metal when
- total engine life is determined not b} the service life of this liner but
rather the efficiency and life of the crankshaft or the t3.me to failure of
- other engine components. It hardly makes sense to make the rolling contacts
- of bearings of electroslag metal if the rings are made of conventional-process
metal. Many such examples could be cited.
- iz
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_ When specifying elec[roslag metal to be utilized in a given structural com-
ponent, machine or in a given mechanism, designers, process eng'Lneers, and
production people should consider not only the performance characteristics of
this metal but also the economic advisabi.lity of such a decision. It is very
important here to take the end result into consi.deration. Frequently the em-
- ployment of electroslag metal can and does lead to higher product cost, es-
= pecially in those cases where the cost of the metal proper determines to a
significant dFgree the price of a product. An increase in the service life of
a product or improvement in its performance charac*_eristics, however, caused
by employment of electroslag metal can and in practice in fact does bring sub-
stantiai benPfits in the area of utilization of this product (machines,
mechanisms, structures). Only such a comprehensive appraisal of the ef-
' fectiveness of employment of electroslag metal will enable us to util3ze it
most intelligently in industry and construction.
The Communist Party and Soviet Goverziment devote great attention to the prob-
lem of improving the quality of metal products and efficient utilization of
_ metal on the basis of adoption of little-waste technology. El-ectroslag re-
- melting is one of the most efticient means of improviiig the quality of inetal.
Other electroslag processes, such as heating, feed, and casting help solve the
- problem of impraving usable metal yield in metallurgical production, that is,
- in the final analysis foster maximum efficient utilization of inetal. Such
electroslag technology variants as casting into water-cooled molds, shaped
- casting and centrifugal casting help solve the problem of reducing "labor
expenditures in the metalworking industry, of rc:lucing metal l4sses in the form
of chips, trimmings, flash, etc.
_ In the llth Five-Year Plan emphasis will be placed on intensive development
- both of inetallurgy and machine bu'Llding, and on all-out improvemPnt in the
- quality characteristics of metal and its economical utilizat3.c'n. A thrifty
- attitude toward metal and complete utilization of available reserve potential
: and possibilities of achieving metal economies are the biisiness of the entire
party and the entire people, stresses the CPSU Central Committee decree en-
titled "On the Performance of the Metallurgical, Machine Building and
- Construction Ministries in the Area of Tmproving Quality of Metal Products and
= Efficient Utilization of Metal fln thp Asis of Adoption of Little-Waste
Technology in Light of the Demands of the November (3.979) CPSU Central Com-
mittee Plenum" (see the 8 June 1980 issue of the newspaper PRAVDA).
The many years of experience in the production and utilization of electroslag
metal attest to the great prospects for further development and improvement
- of electroslag technology in the interests of our country's economy.
- As electroslag metal production increases, thP number of publications per-
- taining to the quality and properties of this metal is growing both in this
country and abroad. Today we are familiar with many thousands of such
articles. Idowhere in the world, however, has there yet been published a study
synthesizing the countless data pertaining to the physical, mechanical and
other properties of steels and alloys which have undergone EShP. This cir-
cumstance significantly hinders the task of achieving correct selection of
- metal and intelligent utilization of its potentiaZ.
13
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This team of authars, from the Electric Welding Institute (IES) imeni Ye. 0.
Paton of the Ukrainian SSR Academy of Sciences and several ottier organiza-
tions which have taken part in writing this volume, was faced with the dif-
ficult task of critiCally interpreting and synthesizing z vast amount of in-
formational material, which is fairly conflictive.and sometimes insufficiently
,reliable. Nevertheless this has been accomplished, and we hope that this book
will be of use to the large communitp of specialists engaged in the production
and consumption of electroslag metal.
. The authors decided to depart from the standard arrangement general.ly eanployed
in any book dealing with physical metallurgy or metalworking, that is, from
arrangement of the material according to types or classes of steels and
alloys. We adopted what we feel is a more suitable arrangement merchant
_ shapes, forgings and drop forgings, tubes, sheet and plate, castings, and
large-tonnage blanks. Within each ofthese large divisions the material is
arranged according to the traditional scheme from common and low-alloy
steels to complex and high-alloy steels and, finally, to alloys. The only
~ exception has been made for cast iron and nonferrous metals and alloys.
Inasmuch as the "Naukova 4umka" Publishing House comparatively recently put out
a book entitled "Elektrosh]alcovMe pechi" [Electroslag Furnaces], equipment for
EShP and EShL is treated very briefly in this volume At the same ti.me con-
siderable aCten.tion has been devoted for the first time to the general
mechanisms of influence of EShP on chemical composition, physical, mechanical,
- and corrosion properties, as well as on such purely process characteristics as
_ deformability, workability, and weldability.
Chapter I was written by B. I. Medovar, G. A. Boyko and L. M. Stupak; Chapter
- II G. A. Boyko, A. B. Kuslitskiy, Yu. G. Yemel'yanenko, and N. I. Pinchuk;
= Chapter III L. M. Stupak, L. V. Chekotilo, B. I. Medovar, and A. B.
Kuslitskiy; Chapter IV A. E. Ku',,litskiy, S. A. Lebenzon (deceased), Yu. G.
Yemel'yauenko, and L. M. Stupak; Chapter V-- A. B. Kuslitskiy, S. A. Lebenzon,
~ A. K. Tsykulenko, L. V. Chekotilo, L. M. Stupak, I. I. Kumysh (deceased),
V. Ya. Sayenko, and V. L. Artamonov; Chapter VI V. A. Sayenko and A. G.
Bogachenko; Chapter VII G. A. Boyko; Chapter VIII A. K. Tsykulenko;
Yu. G. Yemel'yanenico, Yu. V. Latash, A. Ye. Voronin, and V. P. Andreyev;
Chapter IX L. M. Stupak and I. Yu. Lyutyy; Chapter X-- I. Yu. Lyutyy,
: L. M. Stupak, and T. V. Novikova; Chapter XI B. I. Medovar, I. N. Ivanov,
- G. V. Bergauz, and A. M. Brechak.
It took more than 2 years from the time the manuscript was ready and the book
- was published. During this time numerous new data have appeared in the Soviet
- and foreign technical literature, dealing with the quality of matal materials
- obtained by electroslag methods.
Of course the authora could not include thie data in the text of thia volume.
J Nevertheless, seeking to assist the readers in gaining their bearings in the
- large flow of new information, the authors of this volume felt that it was
necessary to provide at thP end of each chapter a bibliography of the most im-
- portant supplementary literature on electroslag metal published during the time
- it took for this bcok to be published.
- The authors would be grateful for critical comments which they can utilize in
the future.
COPYRIGHT: Izdatel'stvo "Naukova dumka", 1981
- 3024 14
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~ MISCELLANEOUS
~
! UDC: (669.27+542.65):66.021.31
FLUORIAE PROCESS FOR PRODU'CTNG TUNGSTEN ,
- Mascow FTORIDNYY PROTSESS POLUCHENIYA VOL'FRAMA: FIZIKO-KHIMICHESKIYE OSNOVY,
- SVOYSTVA METALLA in Russian 1981 (signed to press 29 Sep 81) pp 2-4, 259-260
- [Annotation, table of contents and introduction from book "Fluoride Process
of Obtaining Tungsten: Physicochemical Principles, Properties of the Metal",
by A. I. Krasovskiy, R. K. Chuzhko, V. R. Tregulov and 0. A. Balakhovskiy,
- edited by Academician V. I. Spitsyn, Izdatel'stvo "Nauka", 750 copies, 261
pages]
[Text] This monograph presents the physicochem3.ca1 principles of the process
of reduction of tungsten hexafluoride by hydrogen and the properties of the
: obtained tungsten, and examines the physicochemical mechanisms of deposition
of alloys of tungsten with rhenium and tungsten carbides.
On the basis of the authors' data, citing the results of studies by other
_ investigators, the authors examine in detail the thermodynamics of the process,
its kinetics and crystallization features.
The authors present'in sufficient detail the physical and chemical properties
- of tungsten fluoride as well as the properties of W-Re alloys and tungsten
_ carbides.
This volume is intended for scientific workers, engineers, process engineers,
and faculty members of higher educational institutions specializing in the
; field of gas-phase crystallization of inetals.
Contents Page
Introduction 3
Chapter 1. Tungsten 5
- Physicochemical Properties of Tungsten 5
Interaction With Elements of the Periodic System 13
Interaction with Chemical Compounds 17
- Obtaining Metallic Tungsten from Tungsten Articles 18
' Chapter 2. Physicochemical Properties of Fluoride Compounds of Tungsten 28
= 15
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- Fluorides
28
40
' Tungsten Oxyfluorides
44
Methods of Obtaining Tungsten Hexafluoride
lmpurities in Tungsten Hexafluoride
45
- Chapter 3. Physicochemical Princigles of the yrocess of Reduction of
- Tungsten Hexafluoride by Hydrogen
47
= Thermodynamic-Fundamentals of the Process
47
ICinetics of Deposition of Tungsten Fluoride
51
- Chapter 4. Crystallization of Tungsten Fluoride
75
General Analysis of the Process uf Crystallization ................e..
75
= Initial Stage of Crystallation
77
Grain Texture of Tungsten Fluorine
83
~ Microstructure of Tungsten Fluoride
105
116
of Tungsten Fluoride
Fine Structure
,
= Mechanism of Crystallization of Tungsten Fluoride
121
Chapter 5. Cohesion of Tungsten Coatings With Various Substrates
123
- Chapzer 6. Physicochemical Properties of Tungsten Fluoride
132
Purity of Tungsten Fluoride
132
134
Corrosion and Erosion Properties of Tungsten Fluoride
� Diffusion Interaction of Tungsten Fluoride With Nuclear Fuel and
Refractory Metals
137
144
= Permeability of Hydrogen and Nitrogen Through Tungsten Fluoride
Emission Properties of Tungsten Fluoride
149
Chapter 7. Physical-Mechanical Properties of Tungsten Fluoride
161
161
Hardness
Density
163
163
RecrystaZlation ar_d Recovery of Properties
Temperature Bependence of Mechanical Properties
173
- Plastic Deformation
181
- Mechanical Pxoperties of Deformed Tungsten Fluoride
184
- Recovery of Properties of Deformed Tungsten Fluoride
185
Chapter 8. Equipment for Producing Coatings, Articles and Semi-
manufactures of Tungsten Fluoride
186
Chapter 9. Physicochemical Principles of Obtaining Tungsten-Rhenium
Alloys of Fluorides and Their Properties
190
Physicochemical Properties of Rhenium Fluorides
190
Process Thermodynamics
192
Kinetics of Deposition of W-Re Alloys
193
Kinetics of Deposition of Rhenium in W-Re Alloys
196
16
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Kinetics of Deposition of Tungstet in W-Re Alloys 198
Structure and Mechanical Properties of Alloys 205
Chapter 10. Synthesis of Tungsten Carbides 219
Obtaining Coatings 219
Obtaining Tungsten Carbide Powders 229
Conclusion 232
Bibliography 234
INTRODUCTION
The swift pace of development of various fields of new technology demands that
we seek and find new technological processes of obtaining coatings and
structural materials capable of operating at high temperatures in active cor-
rosive and erosive environments. Among metals which in many cases meet these
demands, a privileged position is occupied by tungsten as the uaost refractory
metal, which well withstands variable high-temperature loads and which re-
tains sufficiently high meGhanical properties at high temperatures. Another
valuable attribute of tungsten is its electroemissive properties.
Until recently the technology of producing tungsten aA:ticles was based solely
on the widely known metal ceramic method.
Methods of plasma deposition, electric arc melting and electron beam melting
are presently be:ing developed. The list of industrial methods of applying
tungsten coatinf;s is even shorter. Methods of applying coatings bv
electrolysis of molten tungsten salts, which have been under developmer.t for
many years, have failed to produce the desired results, because of high tem-
peratures of the melts on the one hand and their aggressive action on the
coated surfaces on the other. Application of tungsten coatings by methods of
vaporization by electron beam in vacuum chambers or by cathode vaporized
coating produces good results in many cases, but difficulties which arise
when coating large articles of complex configuration considerably narrow the
field of application of these methods.
Methods of deposition of tungstan from vapar-gas phases have recently begun
- developing at a rapid pace. As has been demonstrated by the experiments of
a large number of irvestigators, employment of these methods makes it pos-
- sible, with a comparatively simple process, to obtain both high-quality
tungsten coatings and tungsten-coated articles. For this reason there has now
aisen an urgent need to synthesize material on industrial procesaes of obtain-
ing tungsten and certain of its alloys by the method of deposition from
~ vapor-gas phase. This is particularly essential because the most promising
' method of depositing tungsten by reduction of tungsten hexafluoride by hydrogen,
which has already produced important practical reaults and which was first
I initiated by the authors of this monograph under the direction of Academician
= V. I. Spitsyn and Professor Yu. N. Golovanov, has been discussed very
little in the literature.
17
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_ The principal ai.m of thiG monograph is to acquaint the broad community of
researchers and people in industry working with processes of deposition of
metals and metal compounds from vagor-gas phase with neaz results in obtaining
coatings and articles of tungsten and witfi deposition from a mixture of
hexafluoride and hydrogen, and its properties. The material on deposition of
tungsten from other volatile tungsten compounds is presented more concisely
and is necessary for a full understanding of the advantages and drawbackS of a
gzven methad. The description of deposition of a W-Re alloy and tungsten
carbide is justified both by its newness and by a common initial raw material
tungsten hexafluoride.
The book consists of 10 chapters. .Chapters 1 and 2 synthesize data in the
literature on the properties and methods of obtaining tungsten and tungster.
- fluorides.
Chapters 3 and 4 examine the phys ico chemical. (thermodynamics, kinetics) and
crystallization (structure, grain texture, initial stages of nucleation)
aspects of the process of reduction of tungsten hexafluoride by hydrogen and
the mechanism of crystallization.
- Chapters 5-7 present the physi.cochemical and physical-mechanical properties of
- tungsten f luoride, which are of importance for pxactical utilization of
tungsten fluoride.
- Chapter 8 deals with the equipment employed in the fluoride process of obtain-
- ing tungsten. Chapters 9 and 10 examine the physicochemical principles of
obtaining W-Re alloys and tungsten carbides, which in turn demonstrates the
broad possibilities of the fluoride process for obtaining not only metals but
also for synthesizing metal compounds.
In a number of instances this volume presents differing opinions of various
investigators on the substance of the fluoride process of obtaining tungsten.
- This is due to the newness of the presented material and the authors' desire
~ to present the readers with the opportunity critically to analyze existing
ideas on the mechanism of the process of hydrogen reduction of tungsten hexa-
fluoride.
Individual chapters of this volume have been written by the following authors:
= chapters 1-3 A. I. Krasovskiy and V. R. Tregulov; Chapter 4-- R. K. Chuzhko;
chapters 5 and 6-- A. I. Krasovskiy and V. R. Tregulov; chapters 7, 8-- 0. A.
Balakhovskiy; chapters 9, 10 A. I. Krasovskiy and R. K. Chuzhko.
The authors will be grateful to the readers for comments and suggestions per-
= taining to the presented material and would like to give thanks to their
- collegues who took part in work on the individual items discussed in this
- volume: I. V. Kirillov, Yu. N. Tokayev, I. L. Sinani, V. P. Kuz'min, Yu. V.
Lakhotkin, M. A. Khusainov, Z. G. Mendeleyev, as well as the following persons,
- who were very helpful in prepar3ng the manuscript: Ye. F. Sorokin, T. V.
- Rubkin, T. K. Titov, T. K. Maksimov, and M. V. Malandin.
A. I. Krasovskiy
- COPYRIGHT: Izdatel'stvo "Nauka", 1981
3024
= CSO: 1842/100
- 18
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,
i
, UDC : 620.22
SCIENTIFIC FUNDAMIINTALS OF MATERIALS SCIENCE
Moscow NAUCHNYYE OSNOVY MATERIALOVEDENIYA in Russian (signed to press 30 Oct 81)
pp 2-4, 252-253
[Annotation, foreword and table of contants from book "Scientific Fundamentals
- of Materials Science", edited by USSR Academy of Sciences Corresponding Member
Ch. V. Kopetskiy, Izdatei'stvo "Nauka", 1000 copies, 254 pages]
~ [Text] This volume deals with the scientific grinciples of materials science.
- The articles present a picture of the various areas of materials science and of
- the research being conducted ia these areas. The articles are written by
leading experts in various areas of materials science. They examine general
; problems of materials science, its developmeat prospects, and advances in
investigation o� the properties of various materials_. '
- This volume is intended for a broad group of investigators in various areas of
materials science, faculty and graduate students at physics and technical
higher educational institutions, as well as engineers working in plant labora-
tories.
TABLE OF CONTENTS Page
Foreword 3
I. General Problems of Materials Science. Development Prospects 5
M. M. Shul'ts. Contemporary State of Physicochemical Principles of
Obtaining Silicate Materials
S. T. Mileyko. Prospects of Heat-Resisting Composites
I. D. Tykachinskiy. State and Prospects of Research and Development
of Glasses and Sitalls
D. S. RuCman, Yu. S.Toropov, Yu. N. Polezhayev, N. M. Permikina, and
S. Yu. Pliner. Direction of Development of the Cliemiatry and
Technology of Highly Refractory Oxide Materials
A. G. Romashin. Radiotransparent Mbterials
I. N. Frantsevich. Ways of Studying the Electron Energy Spectrum
and Phase Transition in Refractory Substances
S. M. Brekhovskikh. Scientific Principles of the Taxonomy of
Materials
19
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5
12
19
27
39
46
63
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- II. Investigation of the Properties of Materials 76
V. P. Pukh. The Nature of Strength and Prospects for Obtaining High-
_ Strength Glass 76
V. Yu. Aristov, Ch. V. Kopetskiy, and L. S. Shvindlerman. Movement
of Large-Angle Inclination Boundaries in Aluminum 84
B. S. Baks'hteyn and L. S. Shvindlerman. Effect of Internal Adsorption
= in Solids 115
= Ye. M. Savitskiy, K. B. Povarova, P. V. Makarov, and Ye. K. Zavarzina.
Phase Composition, Structure and Properties of Vacuum-Melted Alloys
- W-C-Me(Zr, Hf, Nb, Ta, Re) 136
- A. P. Mokrov and P. N. Zakharov. Diffusion in Multiconstituent Sys-
_ tems 151
G. A. Semenov, A. N. Belov, Ye. N. Nikolayev, and K. Ye. Frantseva.
Prospects of Mass-Spectrometric Investigations of the Processes
- of Vaporization of Heat-Resisting Oxide Materials 167
= T. A. AnisimoLa, V. V. Dem'yanov, Ya. F. Ushatkin, Ye. Ye. Chigryay,
- Ye. I. Suzdal'tsev, L. P. Ivanova, A. D. Buravov, and A. G.
Romashin. Frequency Absorption Spectra of Some Ceramic Materials
in the Superhigh-Frequency and Submillimeter Bands 173
- G. B. Manelis, A. V. Rayevskiy, L. G. Shcherbakova, and L. P.
Lyashenko. Dislocation Mechanism of Chemical Trarsformations in
- Solid Phase 17$
III. Methods of Creating Materials 193
= A. G. Merzhanov, I. P. Borovinskaya, V. I. Yukhvid, and V. I. Ratnikov.
_ New Methods of Obtaining High-Temperature Materials Based on Com- �
- bus tion 193
V. Y e. Ivanov [deceased], V. M. Amonenko, and A. S. Tron'. Creation
of Laminated Materials Based on Refractory Metals 207
M. S. Aslanova. Reinforcing Glass Fibers 209
- K. A. Andriyanov, A. G. Romashin, V. F. Sokolov, V. P. Paranosenkov,
- M. A. Sipyagina, and Ye. I. Voronina. Scientific Principles of
- Creating Polyceramic MatErials 220
B. I. Pokrovskiy. Monitoring, Modeling and Controlling Ceramic
Manufacturing Processes Employing Computers 22$
M. M. Sychev and L. B. Svatovskaya. Obtaining High-Temperature
Corrosion-Resistant and Heat Resistant Composite Materials by
Condensation of Inorganic Bonding Agents 239
FOREWORD
As recently as 30-40 years ago the term "materialovedeniye" [materials
science] for all practical purposes meant "metallovedeniye" [physical
_ metallurgy]. And although t h i s volume does not touch upon even half the
- problems and questfons pertaining to the scientific principles of materials
science, neverth.eless it does give a certain picture of the main features of
development of this science.
20
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First ot all, thi.s development is unusually dynamica The most diversified
materials and methoda of obtaining and proceseing them are becoming an ob-
ject of investigation. And this diversity is resulting in new materials and
technologies, the growth of which, just through possible combinations, should
_ take place in a geoLletric progression.
Secondly, a physical, quantitative approach to the problem. This distinguishes
uaodern materials science from the descriptive physical metallurgy of the 1930's
and 1940's.
Thirdly, employment of modern and ultramodern methods of investigation, the
resolving power of which is today at the atomic level.
: Fourth, materials science today is a proving ground where the latest ideas and
advances in mathemati.cs and computer technology, physics (particularly solid-
- state physics), physical chemistry, chemistry, and a great many other fields
of knowledge are tested and :tncorporated. If it is correct to state that one
= can expect the most unusual discoveries at the point of juncture between sci-
ences, it is applicable in full measure to materials science. One should mere-
ly consider the fact that the cor.tinuous stream of new materials with an amaz-
ing combination of what would seem to beuutually exclusive properties (high-
strength and heat-resisting allo.rs, amorphous metals, hard alloys, com-
posites, high-strength cerami.cs, superconducting materials) and methods of
- producing and processing them (high-vacuum and zone melting, numerous i.ypes of
crystallization, quenching at cooling rates of millions of degrees per second,
_ rolling in a vacuum, internal oxidav.ion and nitriding, combustion and ex--
- plosion, combined heat treatment anki mechanical working) has dulled our
ability to be amazed. And finally, we must particular'ly note that the
- successes of modern materials science are to a significant degree due to
_ development of theory of imperfectians in solids. Sequential enthusiastic
- interest in vacancies, dislocations and, today, grain boundaries and phase
= interfaces has ffiade it possible to concei!.trate considerable scientific man-
power on theory of imperfections. The pieture of an actual crystal has become
considerably more complex, but this does not move us further from the truth
b ut rather brings us closer to it.
This volwme contains articles by leading experts on numerous aspects of
physical materi-als science. Considerable attEntion has been devoted to the
~ development prospects of materials science of setallic, composite, and
, ceramic materials, new methods of producing and studying them, results of ex-
= perimental study and theory of imperfections in volids. This volume contains
' papers presented at the 16th Session of "Scientif.?.c Principles of Materials
Science," dedicated to the 60th anniversary of the Great October Socialist
Revolution, organized by the Scientific Council on the Problem "Physico-
chemical Princigles of Obtaining New Heat-Resisting Inorganic Materials" and
the USSR Academy of Sciences Institute of Solid-StatE Physics in Chernogolovka
on 14-16 June 1977.
~ COPYRIGHT: IzdateT.'stvo "Nauka", 1981
- 3024
- ' CSO: 1842/124
21
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A
FOR OFFICIAL USE ONI.Y
UDC: 669.018.6-154
INTERACTIOI3 OF MOLTEN METAL WITH CARBON MATERIALS
Moscow VZAIMODEYSTVIYE METALLICHESKIKH RASPLAVOV S UGLERODNYMI MATERIALAMI in
Russian 1981 (signed to press 26 May 81) pp 2-4, 183
- [Annotation, introduction and table of contents from book "Interaction Between
= Metal Melts and Carbon Materials", by Valeriy Ivanovich Kostikov and Anatoliy
Nikolayevich Varenkov, Izdatel'stvo "Metallurgiya", 1150 copies, 184 pages]
[Text] This velume prESents modern concepts of the processes of interaction
between carbon materials and molten metals. The authors examine the infliience
= of carbon on density, viscosity, surface tension and other properties of
liquid meta.ls. They present the fundamentals of theory and results of ex-
perimental investigation of the propexties of inetal melts. They present at
- ^ontemporary scientific level theory of wetting and flow, as well as factors
influencing the wettability and spread of molten metal on the flat surface of
- carbon materials. The authors present experimental data on wetting and spread
of molten metals on carbon materials. They examine the kinetics and
mechanisms of the processes of interaction of carbon with molten metal.
This volume is intended for personnel of scientific research institutes and
industrial enterprises. It may also be useful to graduate students and
- undergraduates specializing in the area of physicochemical investigati.ons of
metallurgical processes and obtaining heterogeneous materials.
- Table of Contents Page
Introduction
3
Cr.aprer I. Structure and Properties of Carbon Graphite Materials 5
~
, 1. Structure of Carbon Materials. Description of Ideal Structures
- of Graphite 6
, 2. Three-Dimensional Structuxe of Graphite 9
, 3. Imperfection Structure of Actual Graphite Structures 11
4. Carbon-Containing Materials, Their Technology and Properties 13
, Chapter II. Influence of Carbon on the Structure and Physicochemical
- Properties of Molten Metals 21
1. Structure and Physicochemical Properties of Molten Metals 21
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- 2.
Density of Molten Metals
27
3.
Methods of Determining Density of M~alten Metals
29
~ 4.
Effect of Carbon on Density of Molten Metals
35
5.
Viscosity of Molten Metals
41
6.
Methods of Determining Viscosity of Molten Metals
46
7.
Viscosity of Molten Metals and Alloys Based on Molten Metals
53
8.
Effect of Carbon on the Viscosity of Liquid Titanium and
Zirconium
60
9.
Surface Tension of Molten Metals
63
- 10.
Methods of Determining the Surface Tension of Melis
73
11.
Effect of Carbon on the Surface Tension of Melts
80
12.
Diffusion of Impurity Atoms and Injcction Atoms in Liquid Metals
84
13.
Carbonization of Molten Metals
89
14.
Effect of Carbon on the Melting Point of Some Refractory Metals
98
_ Chapter III. Contact Interaction in a Carbon Material-Liquid Metal System 105
1.
Basic Terms and Definitions of Wetting
105
2.
Spread of Liquid Metals Along the Surface of Carbon Materials
117
3.
Impregnation of Porous Carbon Materials with Liquid Metals
129
4.
Equipment Employed to Determine Contact Angles of Wetting of the
Surface of Carbon Materials by Liquid Metals
135
5,
Wetting and Flow of Liquid Metals on the Surface of Carbon
Materials
145
6.
Wetting of Graphite With Liquid Metals Which Do Not Form Com-
-
pounds With Carbon
145
- 7.
Wetting of Graphite by Carbide-Forming Transition Metals of
Groups IV-VI
146
8.
Wetting of Graphite by Liquid Metals Containing Carbide-Forming
Elements
150
, 9.
Wetting of Graphite by Titanium-Containing A7.loys
153
10.
Impregnation of Carbon Materials by Molten Metals
160
- Bibliography
179
INTRODUCTION
- The la
st decade has been characterized by considerable intensification
of sci-
entifi
c research in the area of development of heterogeneous materials.
Such
materi
als, which consist of components differing in composition and pro
perties,
- posses
s elevated strength, hardness, unit strength, as well as a number
of
specia
l properties which enable us to view them as anong the most promising
in the
development of various structures.
In developing metal-base heterogeneous materials containing carbon material as
one of the constituents, great significance is attached to the physicochemical
processes taking place at the interface between the various constituents of
these materials. The most intensive course of such processes is observed under
the condition where liquid metals and metal-base melts, which wet the solid
surfaces of reinforcing materials,are employed as matrix material.
23
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_ With incorrect conduct of manufacturing processes aimed at obtaining hetero-
_ geneous materials, certain constituents of the composite, which are in contact
with the liquid metal, may partially or completely dissolve in the metaZ melt,
- thus Yeducing the level of properties of the heterogeneous materials. .
- Therefore employment of a liquid-phase process for producing heterogeneous
materials requires knowledge of a number of physicochemical characteristics,
- as well as the structure and constitution of carbon materials and liquid
metals. Such information is essential for studying and understanding the
- processes which take place at the phase interface between constituents of
_ heterogeneous materials in the process of their manufacture.
- Practical experience shows that in order to obtain high-quality metal-base
heterogenecus materials with a carbon filler it is essential to have process
= conditions which provide the possibility of occurrence on the phase interface
- of processes accompanied by insignificant dissolving of carbon materials in
- the liquid metal. The occurrence of such reactions, however, should not be
= accompanied by .loss of the properties of the carbon filler. Therefore essential
for a directed process is a quantitative estimate of the interacti4n between
the carbon material and liquid metal, which in large measure is determined
- by the physicochemical properties, structure and constitution of the solid and
liquid materials in contact.
- This book reflects the results of the research conducted by the authors, and
_ basic concepts on the structure and constitution of carbon materials and
liquid metals are presented at a contemporary scientific level. The authors
_ examine general questions pertaining to capillary and contact phenomena at
~ phase interfaces. Fxperimental data are presented on the processes of inter-
action between liquid metals and carbon material.
The authors would like to express their deep gratitude to Doctor of Technical
Sciences Yu. V. Naydich, corresponding member of the UkSSR Academy of Sciences,
- for reviewing the manuscript.
- COPYRIGHT: Izdatel`stvo "Metallurgiya", 1981
3024
CSO: 1842/125 END
~ 24
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