Activity lines :

1. Physical-Technical Institute of National Academy of SciencesBelarus, Minsk Activity lines: http://www.phti.belhost.by Е-mail:phti@tut.by Tel/fax:(+375-17-263-76-93) Founded - 1931 Personnel- 370 Laboratories- 30 1. New materials for machine building 2. Newtechnologies for thermal anddeformation processing of materials

2. Physical-Technical Institute ofNational Academy of Sciences, Belarus, Minsk Presents one of the investigation lines

3. Physical-Technical Institute ofNational Academy of Sciences, Belarus, Minsk «Deformed ironsmake up a new class of materials» A. I. Pokrovsky (Example of unusual action ontraditionalmaterial)

4. Iron,classical approach: • Excellent casting material • Hardly deformable • Material only for non-critical items New view oniron: • Deformed iron enters the class ofmaterials of high quality • Has superior properties 3. Its area of applications is wider

5. Iron benefits as compared to steel • Higher thermal conductivity results in rapid heat sink(cylinder sleeves, guide valve sleeves) • Antifriction properties(camshafts, crank shafts, piston rings) • Quicker damping of vibrations and sounds(valve pushers) • Lighter by 10% (casings, pallets)

6. Drawbacks of iron: • Low mechanical properties • Casting defectsdegrading the properties

7. Traditional means of increasing mechanicalproperties of iron: • Alloying • Modifying • Thermal treatment Quality of a casting, Castingdefects: Problemsdo not vanish

8. Advantages of deformation processing : 3. Accuracy of shaping 2.Increase of strength characteristics 1.Guaranteed quality of metal

9. Physical-TechnicalInstitute of NationalAcademy of Sciences, Belarus, Minsk Why we turn to deformation of iron : • Casting defects such as pores and cavities are avoided • Mechanical properties are enhanced up to the level of alloyed steel (strength is 1200 MPa, elongation 15%) • Antifrictioncharacteristics are increased by a factor of 1.5

10. Control of graphite shapeTraditional approach: Change of graphite shape from branchy to compact and spherical ones

11. Control of graphite shape on deforming And vice versa, from spherical shape to fibers

12. Wetested thefollowing classes of irons : Gray iron Mottled iron Malleable iron High-strength iron And have foundthe most ADVANTAGEOUS ONES

13. Conditions of iron deforming There are 5 groups of «know-how» : • Alloying diagrams • Preliminary thermal treatment forimprovement of deformability • Design of press-forging tool • Temperature-forceparameters of deforming • Finishing thermal treatment

14. Example of deliberate selectionof parameters for iron deforming Part:body of drill chuck Press forging from a solid billetFOR ONE STROKE

15. Example ofviolating the irondeforming conditions Part: Cylinder of jack plungerfor MAZ truck Spoiled product (press-forging temperature is violated) High-quality semi-finished product Finished part

16. Schematic diagramof iron deforming 1 – Iron billetheated tohigh temperature 2 – Body of press tool 3 – Intermediate medium 4 - Punch 5 – Die 6 - Guide bush

17. Making the samples forinvestigations Incomingcastingbillet Longitudinal samples: Transverse samples: Press-forged rod

18. Wearing weight loss during dry friction, deformed condition: (Decrease by a factor of 1.5 as compared that in casting condition) In order of decreasing wear resistance: 1. Mottled iron, (MtI) 2. High-strength iron, (HSI) 3. Malleable iron, (MI) 4. Gray iron, (GI)

19. Significant feature of deformation isanisotropy ofstructure and properties Longitudinal section Cross section

20. Anisotropy ofwear duringdry friction • The selection is made • of optimum relationships between: • Deformation • parameters • Microstructures • Friction directions Longitudinal sample Transverse sample

21. DryFriction: Coefficient offriction can be decreased by a factor of 2.5 Longitudinal sample Transverse sample

22. Probable factors that causeimprovement of deformed ironcharacteristics: • Refinement of austenite grain • Change in pearlite morphology • Change in graphite morphology • Origination of new graphite inclusions

23. 1. Refinement of austenite grain Grain number 3-4 Grain number 8-9

24. 2. Changes in pearlite morphology х 10000 х 10000 х 15000

25. 3. Changes in graphite morphology

26. 4. Formation ofnewgraphiteinclusions

27. Physical-TechnicalInstitute of NationalAcademy of Sciences, Belarus,Minsk Industrial testing ofdeformed iron Various parts have been offeredbut the greatest interest has been shown in 2 lines (that will be discussed below):

28. Physical-TechnicalInstitute of NationalAcademy of Sciences, Belarus,Minsk High-quality billets ofpistonandsealing ringsmade fromdeformed iron • Their mechanical properties • are 2 times higher than those of cast rings • Any failures are absent • 7-fold decrease of lubricant bleeding • No wear increase of mating part • Stable and one and the same quality throughout the whole height

29. Appreciation in Belarus and Russia

30. Physical-TechnicalInstitute of NationalAcademy of Sciences, Belarus,Minsk High-quality billets ofgears made fromdeformed iron • Strength is at the level ofalloyed steel • Noise in trucks is lower by 3 to 4 db • Weight of gears is lower by 9 % (the economy for one set is 700 g)

31. Disadvantagesof technology • High power requirements.A billet is to be heated. • Some time is required for designing, fabricating andadjustment of press-forging tool. • Costly press tool. • Economically sound are: Both mass production from 50 thousand pc per year (e. g., gears for MAZ) and pieceproduction (e. g.,piston rings «Formula-1»).

32. Present-day investigationproblems: 1. Technological directional thrust is ahead of fundamental knowledge.2. The factors that cause iron hardeningare still not completely cleared up.3. The role played by structure factorsin hardening is ambiguous.

33. We are in search of potential partners for: • Performing joint scientific investigations • Cooperation in delivering billets made from deformed iron.

34. From the scientific viewpoint weare interested in: • Physical factors and mechanisms responsible for iron hardening during hot deformation • Computer simulation of iron hardening processes; • Tribotechnical tests • Investigation of iron physical characteristics • Construction of mathematical models of structure formation • Investigation of fine structure (dislocations and point defects).

35. From the practical viewpoint we are interested in: • Widening the area of deformed iron use as an effective competitive alternative to steel roll stock for manufacturing automotive and machine-building parts • Joint realization of our technological developments during production of items from deformed iron with improved characteristics • We are now prepared to produce rods for investigations as well as gear and sealing ring billets of various typical sizes

36. Contacts: • Physical-Technical Institute of National Academyof Sciences of Belarus • 10 Kuprevich St., Minsk, 220141, Belarus • Artur I. Pokrovsky, Cand. Tech. Sci., Leading Scientific Worker • Tel.: +10375-29-663-58-38 • Е-mail: arturu@tut.by

37. Thank you for attention!