Vol 26, No 3 (2024)

Introduction. The modern oil and gas industry requires the development of high strength materials for well casing. Changes in rolled steel production technologies are one of the urgent tasks. Reducing the cost of high quality steel well casing is becoming a major challenge for the oil and gas industry. Multiphase microstructures containing acicular ferrite or an acicular ferrite-dominated phase exhibit good complex properties in HSLA steels. This paper focuses on the results obtained using modern methods of thermomechanical rolling. Results and discussion. This work analyzes the characteristics of thermomechanical rolling technologies and its impact on the microstructure of rolled steel for well casing. It is shown that predicting mechanical properties based on the microstructural characteristics of steel is complicated due to the large number of parameters involved. This requires an optimal microstructure of the steel. A satisfactory microstructure depends on several factors, such as chemical composition, hot work processing, and accelerated cooling. Alloying elements have a complex effect on the properties of steel, and alloying additives are usually introduced into the steel composition. From a metallurgical point of view, the choice of alloying elements and the metallurgical process can greatly influence the resulting microstructure. Conclusion. This review reports the most representative study regarding thermomechanical rolling technologies and microstructural factors in well casing steels. It includes a summary of the most important process variables, material properties, regulatory guidelines, and microstructural and mechanical properties of the metal for well casing production. This review is intended to benefit readers from a variety of backgrounds, from non-metal forming or materials scientists to various industrial application specialists and researchers.

Introduction. The operation of rail grinding is used in railway transport as a preventive measure for the formation and development of defects of contact and fatigue origin, wave wear and deformation of transverse profile rails. Currently, JSC Kaluga Plant “Remputmash”, together with Siberian State University, is developing a new high-capacity rail train named PHSP 2.0. PHSP 2.0 is 3.5 times more productive than existing analogues. PHSP 2.0 technology is based on high-speed rail grinding, which requires cutting speed up to 100 m/s. The rotation of grinding wheel is controlled by an electric motor. Todaу there is no industrial electric drive capable of implementing the required characteristics (7,000 rpm, 45 kW, 60 H·m). The aim of this work is to study the modes of rail grinding using a new high-speed electric grinding wheel containing a synchronous electric motor with permanent magnets and frequency converter, which feeds motor with an AC voltage with an increased frequency and provides control of the grinding wheel rotation speed. Research methods. In order to obtain results of operation of the new electric drive in conditions as close as possible to real-world operating modes and the possibility of implementing high-speed grinding technology, research tests were carried out on a specially designed rail-welding machine. The measurement of grinding wheel speed was carried out by the laser tachometer “Megeon 18005”; the assessment of metal removal after mechanical processing was carried out by the profiler rail PR-03; the pressure in pneumatic system was measured with pressure transducers of measuring units VDH 100I-DY1,6-111-0.5. Results and discussion. According to research results, new high-speed electric drive was found to have increased performance due to increased performance and ability to adjust speed of grinding wheel, thus providing the necessary removal of rail head metal with a significant increase in the speed of rail train movement.

Introduction. In modern manufacturing, the product life cycle comprises various stages, from conception to disposal. Among these stages, machining plays a significant role, as it directly influences the durability and functionality of the finished product. With increasing competition and the need to reduce production costs, optimizing machining processes has become a crucial task. Traditionally, conservative technological approaches have been used to ensure processing quality. However, this often leads to decreased productivity and higher costs. Modern monitoring and diagnostic techniques can significantly improve process control, particularly through tool condition monitoring. The subject. This paper discusses the stages of the product life cycle and emphasizes the importance of monitoring machining processes. It explores the potential of using vibroacoustic signals to continuously monitor equipment and product conditions. Special attention is paid to the use of vibroacoustic signals for diagnostics and quality control. Modern approaches to filtering these signals, including the use of the fast Fourier transform and various window functions, are analyzed in order to improve the accuracy of the analysis and identify potential defects. The purpose of this work is to develop an algorithm for an online monitoring system that will monitor the condition of cutting tools based on the creation of a digital shadow using a vibroacoustic complex. The main tasks to be solved are to establish the ranges of applicability of frequency response of acoustic signals and optimal window functions, as well as to establish the relationship between the degree of wear on the cutting tool and the results of vibration diagnostics and surface roughness. The methods and technologies for filtering vibroacoustic signals and their application in real–world production settings are discussed. Special attention is given to the role of digital twins in integrating monitoring and filtering data, allowing for the creation of a virtual model of a product to predict its behavior and optimize processes throughout the life cycle. A comparison of various monitoring methods and technologies is conducted, as well as an analysis of practical examples of digital twin implementation in production processes and its impact on improved control. Results and discussion are presented, identifying current research and practical advancements, while also proposing existing challenges and promising areas for future research in the fields of monitoring, signal filtering, and the use of digital twins in mechanical manufacturing.

Introduction. The paper presents the results of a study of the use of a tool electrode (TE), manufactured by selective laser alloying from MS1 maraging steel powder for copy-piercing electrical discharge machining (EDM). Purpose of the work: experimental study of the features of the use of additively manufactured TE in the EDM of critical products. Research methods. The specimens were prepared using a ReaLizer SLM 50 system. The starting material was spherical MS1 powder with an average particle size of 30 μm. To test the modes and select a TE sample with the least number of surface defects, four manufacturing modes were tested, and the best TE sample was selected for further research. The EDM was carried out on EMT Smart CNC equipment in a dielectric oil environment. The specimens were installed in a clamp with straight polarity and were used as TE; a 0.12C-18Сr-10Ni-Тi steel plate served as the workpiece electrode. The study was conducted using a factorial experiment (type 23) with a central design. The input data of the factorial experiment is the current I (A), voltage U (W), pulse on time Ton (μs). The output parameters were the roughness parameter Ra and tool electrode wear γ. The roughness parameter Ra was measured using a Mahr Perthometer S2. Results and discussion. TE samples were made from MS1 powder using the SLS method; the highest quality TE sample No. 4 was selected for EDM. Empirical equations are obtained that describe the relationship between the roughness parameter Ra and tool electrode wear γ, depending on the EDM modes. At the minimum mode with a current I = 4 A and a voltage U = 50 V, the tool electrode wear is γ = 0.0063875 g. The maximum tool electrode wear is γ = 0.13938 g with a current I = 8 A and a voltage U = 50 V. It is established that at a constant pulse on time Ton = 75 μs, the smallest roughness Ra = 2.83 μm is obtained at a current of I = 4 A and a voltage U = 100 V, and the maximum roughness is Ra = 4.1568 μm at I = 8 A and U = 100 V.

Introduction: in present scenario, light and high strength aluminium metal matrix composite are extensively used due to its high mechanical and tribological properties. Aluminium metal matrix composite reinforced with ceramic and industrial waste can customize its mechanical-chemical behavior. The purpose of the work: to create an aluminum matrix composite material using ceramic (primary) and industrial (secondary) waste represented by red mud and coconut shell ash, respectively. The mass fraction of the strengthening phase varied from 5 to 12.5 wt. % respectively with the residual mass percentage of the aluminum alloy. Method of investigation: nine specimens of composite materials were prepared by stir casting. Stirring was carried out at a speed of 50 to 100 rpm for 20 minutes at a temperature of 800 °C. Result and Discussion: the hardness behavior of the aluminum metal matrix composite was studied at an indentation load of 10, 15 and 20 kN. Taguchi method with L27 orthogonal array was selected to conduct analysis of variance (ANOVA) and regression analysis by selecting the mass percentage of red mud and mass percentage of coconut shell ash. The indentation load was used as an input parameter, and the hardness behavior was taken as an output parameter. The signal-to-noise ratio, response rank table, contour plot, and normal probability plot are investigated and it is found that hardness values improve with the addition of both reinforcing components and indenter load. The results show that the hardness value varies from 33.34 HB to 53.44 HB, and the effect of red mud mass percentage is more significant than the indenter load and coconut shell ash mass percentage.

The paper presents an analysis of studies related to the monochromatization of X-ray radiation (XR) at synchrotron radiation sources. A review of monochromators based on of X-ray diffraction on crystals is given, and the peculiarities of their technical realization are considered. The ideas about monochromators which include multilayer structures are examined. The authors also study technical problems arising during designing devices and its possible solutions. Introduction. The possibilities of using X-rays in scientific research are described. The high efficiency of synchrotron radiation sources is noted, and its characterization is given. Elementary information about diffraction of X-rays. The paper describes the properties of X-ray radiation and the possibilities of its using while studying various materials. Degree of monochromaticity. The degree of monochromaticity is an important characteristic of the synchrotron radiation (SR). Depending on the width of the wavelength band, “white”, “pink” and monochromatic beams are distinguished. Monochromators based on multilayer structures are used to obtain “pink” beams. Monochromatic radiation is formed using monocrystals. When conducting experiments with “white” beams, the monochromator is not used. The authors also describe the factors that violate the ideal fulfillment of the Wolf-Bragg condition and affect the degree of monochromaticity (heat, vibration). The reflectivity values at different beam grazing angles are noted to have different widths. Monochromators based on multilayer structures. Periodic structures combining thin layers of two heterogeneous materials make it possible to obtain “pink” beams. The wavelength bandwidth of such devices is one or two orders of magnitude greater than that of monochromators using crystals as optical elements. Configurations and geometry of optical elements. There are two types of X-ray diffraction on a crystal: Bragg and Laue diffraction. Bragg diffraction refers to reflective geometry, Laue diffraction is based on the passage of beams through the crystal. The section provides examples of monochromators with different configurations of crystals and X-ray mirrors. The arrangement of optical elements in a monochromator plays an important role in the geometry of the beam path. When designing monochromators, it is necessary to take into account the methods of fixation and orientation of the rotation axes of optical elements. Examples of monochromators with different configurations of crystals and X-ray mirrors are given. Focusing monochromators. It is possible to provide sagittal and meridional types of deformation by bending the optical element of the monochromator. Due to the curved crystal surface the beam is not only monochromatized but also subjected to focusing. Modern focusing monochromators are equipped with adaptivity elements allowing it to change the radius of curvature of the optical element. Examples of practical realization of such monochromators are presented. Thermal load of SR on optical elements. The SR is characterized by high brightness and a wide spectrum of emitted wavelengths. While operating optical elements of SR stations absorb a large amount of thermal power. The problems of heat dissipation have a fundamental influence on the quality of synchrotron radiation monochromatization. Additional information about monochromators. Examples of special design solutions for monochromators are given. Conclusion. The design of monochromators is relevant to the synchrotron radiation source 4+ “SKIF” under construction in Novosibirsk.

Introduction. Multilayer high-temperature coatings obtained using plasma spraying, are studied. The combination of layers of different chemical and phase compositions made it possible to increase wear resistance by 1.5–2.0 times. The purpose of this work is to study the influence of the chemical composition of sprayed coatings on the phase composition, structure, micromechanical and tribological characteristics under conditions of dry sliding friction of surface layers. Materials and methods of research. Coatings A and B consist of sequentially sprayed layers. The first and second layers were sprayed in a reducing atmosphere: the first layer was a heat-resistant self-fluxing powder of two systems: 1 – Fe-Cr-Si-Mn-B-C for coating A and 2 – Fe-Ni-Si-Mn-B-C for coating B; the second layer was a mixture of self-fluxing powder with iron powder in a 1:1 ratio. The third layer was obtained by spraying iron powder in an oxidizing atmosphere to form a metal oxide coating. To create a layer of scale on the surface, coated specimens were subjected to high-temperature annealing at a temperature of 1,000 ?. The chemical composition and nature of the distribution of elements over the thickness of the coatings were determined by micro-X-ray spectral analysis using a TWSCAN scanning electron microscope with an Oxford energy-dispersive attachment. Microhardness and micromechanical properties were studied using an instrumental microhardness tester of the Fischerscope HM2000 XYm system at a load of 0.980 N. Determination of tribological properties was carried out on a laboratory installation using the “finger-disc” scheme at loads of 30, 75, 100 and 130 N. To measure roughness parameters and obtain 3-D profilometry of surfaces after testing, a non-contact profilometer-profiler Optical profiling system Veeco WYKO NT 1100 was used. Results and discussion. Metallographic studies have shown that the formed multilayer coatings consist of an internal metal layer and an external oxide layer with a total thickness of the entire coating up to 800–850 μm. It is established that the first sprayed layer has the highest level of microhardness, which is due to the high-volume fraction of the strengthening phases contained in it (~ 95 %). It is shown that the coating A has increased wear resistance, which is expressed by minimal weight loss (~ 1.5 times less than that of the coating of the coatimg B), the friction coefficient was f = 0.3 for coating A and f = 0.4 for coating B. The study of wear surfaces has shown that for all selected test loads under sliding friction conditions, the coating of both compositions was preserved, even at a maximum load of 130 N.

Introduction. Development of Ni-Al intermetallic compounds is one of the priority directions of modern machine building. Due to such characteristics as high heat resistance, high temperature strength, and low density, nickel aluminides are used as functional coatings in the aerospace industry. The main methods of Ni-Al coating surfacing are High-Velocity Oxygen-Fuel and High-Velocity Air-Fuel spraying (HVOF and HVAF), atmospheric plasma spraying (APS) and its modification such as High-Velocity Atmospheric Plasma spraying (HV-APS) which provides non-equilibrium cooling conditions. Since there are eight different intermetallic compounds, as well as martensite transformation, Ni-Al coatings is quite interesting to study. The work purpose is to study the features of the martensitic structure in HV-APS coatings, and also to establish the effect of heating temperature on its decomposition. Materials and methods. Ni-Al coatings were surfaced onto a low-carbon steel substrate using the HV-APS method. Studies of the fine structure of the coatings were carried out using transmission electron microscopy (TEM). In addition, the influence heating temperature on structural transformations of the coatings was analyzed. Results and discussion. Two types of particles are formed in HV-APS coatings: with a dendritic and granular structure. The most part of HV-APS coatings consists of particles with a two-phase grain structure (NiхAl1-х and γ'-Ni3Al grains). Only NiхAl1-x grains undergo martensitic transformation at cooling. Martensite in large grains (sizes greater than 500 nm) has a lamellar structure, while small grains are completely transformed into one martensite plate. In addition, the coatings contain grains in which martensite plates (NiхAl1-х) and β-phases alternated. It is shown the behavior of martensitic plates at colliding with each other, as well as with the γ′-Ni3Al grain. Heating up to 400 °C contribute the begins of martensite decomposition in individual grains with the release of a secondary phase; after heating up to 600 °C all martensite dissolves.