International Projects
Device for semi-industrial simulation of the process of regulated solidification and refining of metal alloys
Start: 2027-01-01 / End: 2028-06-30
Full name:
Device for semi-industrial simulation of the process of regulated solidification and refining of metal alloys
Objectives:
The aim of the investment is to gain the possibility of carrying out advanced research and simulation on a laboratory scale of the processes of production of metals and alloys with high metallurgical purity and regulated internal structure intended for responsible semi-finished products and construction products, as well as to develop advanced refining slags. As a result of the investment, a unique on a national scale experimental comprehensive technological line will be created, consisting of vacuum electric furnaces in which electrode ingots will be smelted and cast, and an electroslag remelting device in which these electrodes will be melted into slag with high refining properties and subjected to re-regulated solidification in a crystalliser will be constructed.
Materials obtained as a result of electroslag remelting are characterised by high metallurgical purity (small amount and size of non-metallic inclusions), high homogeneity of elements on the cross-section and high mechanical properties. These types of materials are used in structural components of the aviation, automotive, armaments, and space industries. The device for electroslag remelting of steel and alloys together with the research infrastructure will allow to produce newly designed materials at Łukasiewicz – GIT laboratories, and then for the determination of their utility properties and implementation for production in local or national industrial companies, increasing their market competitiveness.
Budget:
Total cost of the project: PLN 7,109,258.33
EU co-financing: PLN 5,462,744.58
Target group:
Research and experience conducted at the Institute on the purity of materials and the solidification structure of ingots, conditioning the production of advanced construction materials, fall within the scope of engineering and technical sciences in the following disciplines:
- materials engineering,
- mechanical engineering,
- environmental engineering, mining, and power industry.
The planned research investment will expand the resources of research infrastructure in the region and will allow, together with universities, to apply for research and development projects in advanced fields of science and technology, such as: incremental technologies (3D printing) and technologies for the production of components operating under heavy load for the aerospace industry. The investment will expand the Łukasiewicz-GIT research offer, as well as the market sale of semi-finished products for SMEs from the Silesian region and certified reference materials (analytical standards) for customers from Poland and abroad (USA, China, Japan, Germany, France, Spain, and others).
The obtained research results will be implemented on an industrial scale in the process of electroslag remelting of metals, which will allow to produce ingots with a compact structure, without axial scarcity and segregation of elements and with a specific direction of crystallisation.
The project will allow to achieve a positive economic effect by small and medium-sized enterprises of the Silesian region as a result of the possibility of producing a wide range of metal alloys of high metallurgical purity intended for responsible structural components in the automotive industry (parts of the drive and steering system), medical (implants, dentistry), energy (wind turbines), aviation and defence, currently not produced in the country. The technology of producing high purity materials from metal alloys fits into the scope of intelligent specialisations of the Silesian Province in such areas as:
- power engineering,
- medicine,
- emerging industries.
The investment will allow to expand cooperation with enterprises producing finished products or components for the armaments (MESKO S.A., Zakłady Mechaniczne Bumar Łabędy S.A., Rosomak S.A. in Siemianowice Śląskie, ZM Tarnów), energy (Zakłady Remontowe Energetyki ELKO in Racibórz), automotive (Stelantis Gliwice, Fiat factory in Tychy, Nexteer Automotive – Gliwice and Tychy branch, Alstom Konstal Chorzów plant), medical (BHH Mikromed) and aviation (Margański & Mysłowski aviation plant in Bielsko-Biała) industries.
The planned investment is in line with the operational goal of increasing the innovativeness of the economy by supporting the ability of companies to generate and implement innovations and modern technological solutions, support for universities, research institutions and organisations, including the development of human resources in the field of creating innovative and creative solutions, as well as patents and their commercialisation in cooperation with the economic sector and the networking of regional entities in the process of creating innovation and interdisciplinary cooperation. The ESR device will also allow for the recycling of decommissioned parts of machines and devices operating under heavy loads without the need to scrap them and resmelt them in an electric arc furnace. ESR electrodes made in whole or in part, e.g. decommissioned drive shafts of windmills or working rollers of rolling mills and subjected to electroslag remelting will allow to obtain a raffinate that meets the physicochemical requirements for a new material.
Description:
The ESR device will be an essential element of the Łukasiewicz-GIT research and scientific infrastructure and equipment. First, it will complement the LPS-A steelmaking technology line consisting of two electric vacuum furnaces. The raffinates obtained as a result of electroslag remelting will constitute a batch for the LPS-B line for semi-industrial simulation of advanced processes of regulated hot rolling and cooling of sheet metal or bars and will provide a high-quality material base for testing using the Gleeble Technological Process Simulator. In addition, ESR raffinates will constitute high-quality semi-finished products to produce finished products in armament, automotive, tool, aviation, and many other plants.
The material scope of the investment includes the purchase of ESR equipment equipped with crystallisers with cross-sections of 72 square mm, 100 square mm and 250 square mm, allowing for the remelting of semi-finished steel and alloys of adjustable length in the range of 0.5 to 1.5 m.
It was planned that raffinates with a cross-section:
- of 72 square mm will be intended for scientific research at Łukasiewicz-GIT in the field of designing new grades of steel and alloys for the needs of the Gleeble 3800-GTC Metallurgical Process Simulator and further plastic processing at the BGH Katowice rolling mill (production of analytical standards and semi-finished products for the medical industry),
- of 100 mm will be a batch for forging and rolling on the B-LPS line for semi-industrial simulation of advanced processes of regulated hot rolling and cooling of sheets or bars (with the possibility of producing small-sized semi-finished products for the automotive, aviation, defence, aerospace, energy, medicine industries), and
- of 230 mm: they will be a charge for the Łukasiewicz-GIT forging plant for responsible semi-finished products for the tool, automotive, armaments, and aviation industries.
The scope of the planned construction works includes the adaptation or construction of a technological hall on the premises of Łukasiewicz- GIT for the operation of the ESR device. It will be necessary to adapt the existing or to build new electrical, water, and IT infrastructure, install exhausts and filters for the discharge of process gases, purchase and instal containers for consumables and auxiliary materials, construct and equip a warehouse for spare parts, etc.
Project results
The effect of electroslag remelting will be obtaining ingots (raffinates) of high metallurgical purity and a reduced degree of micro-segregation of elements, which directly affects the plastic properties and strength of steel products, i.e. elongation, reduction of area, torsional and tensile strength, impact strength, etc.
