Nikolaiev D. Determination of Optimal Ways of Remelting Various Nomenclature Charges to Obtain Black Alloys With Specified Properties Intended for Shaped Casting

Українська версія

Thesis for the degree of Doctor of Philosophy (PhD)

State registration number

0826U002985

Thesis Registration Form

0826U002985.pdf

Applicant for

Specialization

  • 136 - Металургія

28-08-2026

Specialized Academic Board

PhD 15090

National Technical University "Kharkiv Polytechnic Institute"

Essay

The subject of the study is the chemical composition of ferrous alloys obtained using various technological schemes based on mono- and duplex melting processes, taking into account the uncertain composition of charge materials and their possible heredity, in order to ensure quality requirements in the manufacture of shaped castings. The aim of the dissertation is to determine the optimal ways of remelting a mixed-material charge to obtain ferrous alloys with specified properties intended for shaped casting, based on a technological audit of serial industrial meltings, which are based on building a technological profile of mono- or duplex melting processes using the most common firing furnaces – cupola furnace, electric arc furnace, induction furnace. The introduction substantiates the relevance of the problem associated with the fact that the remelting of poor-quality charge materials to obtain an alloy with the possibility of its further use for the manufacture of shaped castings can lead to inadequate quality of the melt and castings. This requires the development of different technological modes of melting and out-of-furnace processing, depending on the quality of the charge. But determining the real quality of the charge, which is obtained from different sources, is very difficult, which requires certain assessment procedures, the results of which will be capable of predicting the chemical composition and properties of the alloy and making decisions on the rational management of melting processes. The experiments were carried out on the basis of the Kremenchuk Road Machinery Plant. The following scientific results were obtained as a result of the study: For the first time, a procedure for removing uncertainty associated with the chemical composition of the charge has been proposed, which is based on the construction of predictive kinetic equations to determine the chemical composition of the alloy at the time of its release from the furnace and pouring into the foundry molds. For the first time, a procedure for removing uncertainty associated with the possible heredity of charge materials has been proposed, which is based on the construction of mathematical models of the “composition - properties” type, where the properties are tensile strength and hardness, and the subsequent comparison of the density of the distribution of properties calculated by these models and the density of the distribution of properties obtained in actual melts on the charge, which is checked for the presence of heredity. For the first time, predictive models have been built to determine the composition of the alloy at the time of its release in the “cupola furnace – electric arc furnace” duplex process and indicators based on the data of the proposed technological audit of serial melts. The issue of determining the relationships of cupola melting parameters that can be used to develop optimal solutions for melting technology has been further developed. The issue of predicting the temperature regime of melting as a factor influencing the physicochemical processes that occur in the melting system and form the final composition of the alloy and slag has been further developed. The issue of assessing the stability of melting indicators in a cupola furnace, in an electric arc furnace, as well as in “cupola furnace – electric arc furnace” and “cupola furnace – induction furnace” duplex processes has been further developed. The practical significance of the results obtained is as follows: – recommendations have been developed for conducting a technological audit of serial meltings of cast iron or steel directly in the production process, which allows for a rational choice of melting modes, taking into account the instability of the charge quality and uncertainty regarding its chemical composition; – a method has been developed for selecting rational alloy processing modes by combined alloying and modification of cast iron in the process of melting by mono- and duplex processes in order to adjust the mechanical properties of alloys, taking into account possible negative consequences caused by the presence of heredity of charge materials, which manifest themselves in the deterioration of the mechanical properties of alloys; – a method has been developed for conducting an operational predictive determination of the chemical composition of cast iron and steel for the moment of issuing the melt for pouring into molds directly in serial meltings, which allows choosing in the production process such an option for using ferroalloys and such melt processing modes in “cupola furnace – electric arc furnace” duplex processes, which ensure high quality of alloys;

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Research papers

Nikolaiev, D. (2022). Procedure for selecting a rational technological mode for the processing of cast iron melt on the basis of graph-analytical processing of the data of serial smeltings. ScienceRise, 5, 3–13. https://doi.org/10.21303/2313-8416.2022.002774

Frolova, L., Barsuk, A., Nikolaiev, D. (2022). Revealing the significance of the influence of vanadium on the mechanical properties of cast iron for castings for machine-building purpose. Technology Audit and Production Reserves, 4 (1 (66)), 6–10. https://doi.org/10.15587/2706-5448.2022.263428

Nikolaiev, D. (2024). Construction of a cupola information profile for further modeling for the purpose of controlling melting processes. ScienceRise, 2, 3–14. https://doi.org/10.21303/2313-8416.2024.003674

Nikolaev, D. (2024). The choice of rational adjustment of the chemical composition of iron melted in an electric arc furnace on the basis of technological audit of serial films. Technology Audit and Production Reserves, 2 (1 (76)), 22–26. https://doi.org/10.15587/2706-5448.2024.301259

Nikolaiev, D., Selivorstov, V., Dotsenko, Y., Dzevochko, O., Pereverzieva, A., Dzevochko, A. (2025). Identification of temperature in cupola furnace based on the construction of the “slag composition – slag viscosity” model. Technology Audit and Production Reserves, 1 (1 (81)), 29–33. https://doi.org/10.15587/2706-5448.2025.322458

Nikolaev, D., Selivorstov, V., Dotsenko, Y., Osypenko, I., Kuznetsow, E. (2025). Determination of conditions for preventing chemical wear of induction furnace lining in the “cupola furnace – induction furnace” duplex process. Technology Audit and Production Reserves, 6 (1 (86)), 43–47. https://doi.org/10.15587/2706-5448.2025.345473

Ніколаєв, Д. А., Дьомін, Д. О. (2023). Визначення раціональних технологічних режимів обробки чавуну на основі приведення даних плавок до єдиних умов. XХI Міжнародна науково-практична конференція «ІНФОРМАЦІЙНІ ТЕХНОЛОГІЇ: НАУКА, ТЕХНІКА, ТЕХНОЛОГІЯ, ОСВІТА, ЗДОРОВ’Я. MicroCAD-2023». Available at: https://www.kpi.kharkov.ua/archive/MicroCAD/2023/Секція%202.%20Актуальні%20питання%20механічної%20інженерії%20і%20транспорту/ВИЗНАЧЕННЯ%20РАЦІОНАЛЬНИХ%20ТЕХНОЛОГІЧНИХ%20РЕЖИМІВ.pdf

Ніколаєв, Д. А. (2024). Раціональне коригування хімічного складу чавуну електродугової плавки. XХII Міжнародна науково-практична конференція «ІНФОРМАЦІЙНІ ТЕХНОЛОГІЇ: НАУКА, ТЕХНІКА, ТЕХНОЛОГІЯ, ОСВІТА, ЗДОРОВ’Я. MicroCAD-2024». Available at: https://ndch.kpi.kharkov.ua/wp-content/uploads/2025/01/Zbirnik-tez-MicroCAD-2024.pdf

Ніколаєв, Д. А. (2024). Раціональне коригування хімічного складу чавуну на основі технологічного аудиту електродугової плавки. XX Ювілейна міжнародна науково-практична конференція «Литво 2024» ХIII Міжнародної науково-практичної конференції металургія 2024. Available at: https://ptima.nas.gov.ua/images/stories/Conf/Conf2024/Матеріали%20конференції.%20Литво.%20Металургія-2024.pdf

Ніколаєв, Д. А., Дьомін, Д. О. (2024). Технологічний аудит серійних плавок задля вибору раціонального коригування хімічного складу чавуну електродугової плавки. Неметалеві вкраплення і гази у ливарних сплавах: зб. тез 17-ї Міжнар. наук.-техн. конф. Available at: https://repository.kpi.kharkov.ua/items/6f043296-2b53-4a87-aecb-c0e3a3ab1d2f

Ніколаєв, Д. А. (2025). Систематизовані дані для побудови інформаційного профілю вагранки. Інформаційні технології: наука, техніка, технологія, освіта, здоров'я = Information technologies: science, engineering, technology, education, health: тези доп. 33-ї міжнар. наук.-практ. конф. MicroCAD-2025. Харків: НТУ "ХПІ", 401. Available at: https://repository.kpi.kharkov.ua/handle/KhPI-Press/90452

Ніколаєв, Д. А. (2025). Ідентифікація температурного режиму ваграночної плавки за аналізом шлаку. Литво. Металургія. 2025 = Foundry. Metallurgy. 2025: матеріали 21-ї Міжнар. наук.-практ. конф. Харків; Київ, 208–210. Available at: https://repository.kpi.kharkov.ua/handle/KhPI-Press/90580

Ніколаєв, Д. А. (2025). Визначення впливу режимів електродугової плавки на формування хімічного складу сталі. ХІХ Міжнародна науково-практична конференція магістрантів та аспірантів «Теоретичні та практичні дослідження молодих вчених». Харків: НТУ «ХПІ», 783–784. Available at: https://repository.kpi.kharkov.ua/items/6286002a-95da-4492-813f-ce18b044b00c

Ніколаєв, Д. А. (2026). Механічні властивості серійних плавок у вагранці, визначені систематизацією ретроспективних даних. Інформаційні технології: наука, техніка, технологія, освіта, здоров’я: тези доповідей ХXХІV міжнародної науково-практичної конференції MicroCAD-2026. Харків: НТУ «ХПІ», 486. Available at: https://zenodo.org/records/20205455

Ніколаєв, Д. А. (2026). Виявлення особливостей хімічного складу чавуну ваграночної плавки для подальшого аудиту в дуплекс-процесах за невизначеності якості шихти. Литво. Металургія. 2026: Матеріали XXІІ Міжнародної науково-практичної конференції. Харків: НТУ «ХПІ», 209–211. Available at: https://ptima.nas.gov.ua/images/stories/Conf/conf2026/Proceeding_Foundry_Metallurgy_2026.pdf

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