At the head of the workshop is a chief, directly subordinate to the director of the enterprise. With the help of the workshop apparatus, the workshop manager carries out administrative, technical and economic management and selects personnel. He bears personal responsibility for the quality of products, implementation of the program, safety of material assets, compliance with safety regulations, and the introduction of new equipment.

In large thermal shops, the shop manager manages production through deputies and shop services; in small workshops - through senior and shift foremen

Control scheme for a large thermal workshop

For systems. Improving product quality and accelerating technical progress of production in the management structure of a modern thermal workshop provides for a special technological preparation service for production. The shop's CCI service is engaged in the introduction of new technological presses, provision of production areas with modern technological equipment, development of measures for the scientific organization of production, development and implementation of rationalization proposals, provision of workplaces with the necessary documentation, reconstruction of thermal departments and areas.

The Chamber of Commerce and Industry pays special attention to modern production in connection with the introduction of CAD and GPS.

Many of these functions are performed either by a technological bureau directly subordinate to OGmet, or jointly with the CCI service of the thermal workshop.

Deputy shop manager for production carries out operational management of production. He monitors the timeliness of the launch of parts for processing and the time of their delivery to the consumer, the distribution of products among areas and workplaces, and is responsible to the workshop manager for the implementation of the program. Planning and operational bureaus, heads of departments and sections report to him.

Planning and Operations Bureau draws up calendar plans and schedules for the launch and delivery of products by all departments and sections of the workshop by month, day and shift (shift-daily assignments), conducts operational regulation and monitoring of program implementation, provides workplaces with everything necessary for smooth operation.

Responsibilities dispatcher consist of: operational circulation of production progress, coordination of the activities of interconnected departments and areas, and elimination of emerging violations and deviations.

If there is a control point in the thermal shop with dispatching means (telephone, radio, tape recorder, televisions, etc.), as well as computer equipment for collecting, accumulating, processing and transmitting primary information, it is possible to more quickly monitor the progress of production and make timely decisions.

To control the quality of projections in thermal shops and departments, they organize technical control bureau(BTK), subordinate to the general plant quality control department. The functions of BTK include: checking the properties of finished products; control of technological modes; checking the condition of technological equipment and measuring instruments, monitoring compliance with technological discipline, systematizing and analyzing defects and developing recommendations for its prevention, timely execution of control operations, ensuring the reliability of inspection results, as well as high labor productivity of inspectors. BTK must coordinate its activities with other services of the thermal workshop.

The head of the BTK is obliged promptly notify the administration of the thermal workshop about all cases of mass defects and violations of technological discipline.

LAYOUT OF THERMAL DIVISIONS

1. Composition of thermal units

The composition of thermal departments at factories and production associations is determined by the specialization of enterprises, the nature and completeness of manufacturing processes, the specifics of heat treatment, the connection of thermal departments with adjacent workshops and the level of development of auxiliary production.

Termites carry out work to determine the composition of thermal units together with designers of related industries, and these tasks are often solved in several stages. First, in accordance with the nature of the general plant production process of manufacturing and processing (processing), the composition and initial layout of thermal units in the enterprise are outlined. Further, when developing a project for each thermal division, adjustments are made to this scheme.

The basis for designing the composition of thermal units is the volume and stability of product flows.

The location of thermal departments at the plant must correspond to the accepted production structure and layout of workshops and services, the nature of the general plant cargo flow and the types of available transport.

Each thermal division is geographically closer to those adjacent workshops with which they have the closest connections, or located on their territory.

When servicing a group of adjacent workshops, this thermal unit is located closer to those workshops whose products occupy the largest volume in its processing program.

The main thermal shops at some factories are organized together with forging, foundry and other hot shops in the form of the like. groups of hot shops located geographically on the leeward side. Such a combination makes it possible to reduce fire danger and improve hygienic conditions for the remaining workshops, to organize fuel warehouses, power stations, etc. more rationally. However, the zoning principle should not conflict with the requirement to ensure rational general plant cargo flows. Auxiliary thermal units are most often located in the corresponding workshops or colonies.

Thermal units should be located so that, if necessary, they can be expanded in the future, while maintaining existing utilities and transport routes.

Location of thermal units in the workshops of a machine-building plant

.Organization of thermal enterprises in production associations

The association includes the main enterprise, a number of branch plants, design and technological institutes, scientific research laboratories, pilot workshops and factories, as well as various services and facilities. The presence of huge material, energy and labor resources in production associations provides ample opportunities to speed up the technical process of all production, including thermal production. Based on the deepening of the specifications of enterprises and workshops in production associations, specialization is also deepening, for example: in the automotive industry (production of crankshafts, springs, springs, valves), highly specialized thermal shops and departments of mass or large-scale production are formed for the processing of these parts and workpieces. At enterprises of technological specialization (forging, stamping, foundries), specialized thermal units are formed for processing forgings or castings with the widespread introduction of combined processes. When organizing factories or workshops with functional specialization within the framework of an association, they create a thermal division with a fairly high level of serial processing of auxiliary products.

PLACEMENT OF THERMAL DIVISIONS

Thermal workshops can be located in separate buildings, together with other workshops, in the areas of adjacent workshops.

In accordance with the fire hazard classification, buildings for thermal units belong to category G, in which non-combustible materials (metals) are processed in a hot or incandescent state, and solid, liquid and gaseous substances are also burned as fuel, and the processing process itself is accompanied by the release radiant warmth, sparks and flames.

Individual buildings when the nature of production or fire safety requires territorial separation of heat treatment from adjacent buildings. Separation from other workshops can be caused either by the large size of thermal equipment, for example, tower furnaces, for which the height of the building to the crane runways is 24-30 m, or by the need to process long products (aircraft parts, barrels, pipes, etc.) in a vertical position.

Block buildings

Interconnected workshops of the plant, including thermal ones, are often located in multi-bay buildings.

Layout of thermal units in a multi-span block building (shaded)

At the same time, production connections are improved, the cost of specific area is reduced, transport routes and the length of energy communications are reduced. To organize thermal shops in these premises, the outermost fire-resistant spans are most often allocated.

Two-span building

Each building has the following elements

1-column

2-longitudinal extension axis

Center axes(indicated by letters and numbers in circles - mutually perpendicular straight lines depicting a layout grid on the plan;

Column grid(black bold dots) show the layout of the columns on the workshop plan and is determined by the alignment axes;

span– part of the building between two adjacent columns and end walls;

Span width– distance L between two longitudinal alignment axes;

Heat treatment refers to processes the essence of which is the heating and cooling of products according to certain modes, resulting in changes in the structure, phase composition, mechanical and physical properties of the material, without changing the chemical composition.

The following types of metal heat treatment are carried out in the heat shop:

holiday (high and low)
cementation

Annealing

Annealing is a heat treatment consisting of heating the metal to certain temperatures, holding it and then very slowly cooling it along with the furnace. Used to improve metal cutting, reduce hardness, and obtain a granular structure. The purpose of annealing is to eliminate chemical heterogeneity of steels, reduce hardness to facilitate mechanical processing, etc. Annealing is of the 1st and 2nd kind.

Essence annealing of the 1st kind consists in heating the workpieces above the phase transformation temperature, followed by slow cooling. The following types of annealing of the 1st kind are distinguished:

Homogenization, used to level the structure, especially of large steel castings and forgings;

Recrystallization, eliminating changes in structure that occur, in particular, during the process of processing metals by pressure, during which they receive hardening, accompanied by a noticeable increase in hardness and a decrease in ductility;

Annealing, which removes or reduces residual internal stresses arising during various technological operations.

By using annealing of the 2nd kind, or full annealing, change the structure of the alloy and eliminate internal stresses. The billets are heated to a temperature exceeding the phase transformation temperature by 30-50 degrees C, and slowly cooled along with the furnace. This heat treatment process is carried out after stamping, casting of blanks, as well as after rough machining in order to reduce hardness.

Hardening

Hardening is heating to an optimal temperature of 900 – 950 o C, holding and subsequent rapid cooling in order to obtain a nonequilibrium structure. As a result of hardening, the strength and hardness of the steel increases and the ductility of the steel decreases.

Most structural steels are heated during quenching to a temperature of 850-900 degrees C, and cooled in water, oil or salt solutions. Cooling in molten salts is used for high-alloy steels, for example tool steels, high-speed steels containing a large number of alloying elements.

Depending on the heating temperature, a distinction is made between complete and incomplete hardening. When fully hardened carbon steels in cold water obtain a martensite structure, which has very high hardness and great brittleness. If cooling is carried out less intensively, then less hard and stressed troosite structures can be obtained. To reduce brittleness and internal stresses, steel is tempered.

Heating of the product for hardening to 950 o C is carried out in shaft and chamber electric furnaces and in an electric salt bath. Cooling - in water and oil tanks and baths to a temperature of 150 o C and in saltpeter baths to a temperature of 180 o C. Then the metal is cooled in air in the room.

Vacation

Tempering involves heating steel to different temperatures, holding it at this temperature, and cooling it at different rates. The purpose of tempering is to relieve internal stresses arising during the hardening process and obtain the necessary structure. By increasing the tempering temperature, it is possible to increase the plasticity and viscosity of the material while simultaneously reducing the hardness and strength. Tempering at high heating temperatures is called improvement.

There are low, medium and high holidays. Low Vacation, i.e. heating steel to a low temperature (150-200 degrees C), leads to a decrease in residual internal stresses while maintaining its high hardness and wear resistance. Average holiday, while maintaining increased hardness, provides sufficient strength, elasticity and endurance. It is often used in the manufacture of springs and leaf springs. At high holidays obtain a sufficiently high elastic limit with sufficient impact strength and hardness. As a result of high tempering, a structure is obtained that is necessary for machine parts exposed to high voltages and variable impact loads (for connecting rods, bolts, etc.). During high tempering, the products are heated in shaft furnaces to 600 o C, maintained at this temperature for a certain time, then cooled with the furnace to 300 o C. Low tempering is carried out in saltpeter baths at 300 o C, and then at this temperature the products are removed from the bath and cooled in air to the temperature of the working area.

Heat treatment is intended to impart certain physical and chemical properties to the metal - hardness, viscosity, elasticity, electrical conductivity, etc. - by heating to a given temperature (from 450 to 1300 ºC) and subsequent cooling in certain environments. There are thermal hardening, tempering, languishing, and annealing of metal. If necessary, various chemical elements and compounds are additionally introduced into the surface layer of the metal: carbon (cementation), nitrogen (nitriding), cyanide compounds (cyyanidation), etc.

The workpieces are heated in combustion furnaces operating on gaseous, liquid or solid fuels and electric furnaces. To ensure uniform heating, products can be placed in special baths with molten lead or salts of barium chloride and nitrate.

Cementation is carried out by heating in charcoal mixed with carbon dioxide or in baths with cyanide compounds; nitriding – in a stream of ammonia at a temperature of about 500 °C. Heat treatment of metal with high-frequency currents through the use of induction heating in a high-frequency electromagnetic field is common.

The most common method of heat treatment is immersion of products after heating in quenching baths with mineral oils.

Working conditions in heat treatment shops in terms of microclimate are in many ways similar to those in forge shops. Due to the high concentration of heating equipment, the air temperature in the premises of thermal shops may exceed established standards. Relative humidity is usually 30 – 60%. Radiant heat also reaches high levels, especially during loading of workpieces into the furnace and during unloading.

The air in the working area in thermal shops is polluted by various chemicals, the composition of which is determined by the production technology. When coal with a high sulfur content and high-sulphur fuel oil are used as fuel, the air environment is polluted with sulfur dioxide. Carbon monoxide also enters the air from heating and hardening plants; its concentration may periodically exceed the maximum permissible concentration.

Quenching in baths with mineral oils is accompanied by the release of hydrocarbon vapors and their pyrolysis products. If ventilation is poor, the concentrations of these substances can be significant.

When cementing products using sodium or potassium cyanide, as well as during cyanidation in baths with molten salts of cyanide, cyanide is released, however, with reliable operation of local exhaust ventilation, the concentrations of hydrogen cyanide and cyanide salts in the air of the working area usually do not exceed the maximum permissible limits.

Working in pig baths is accompanied by air pollution with lead vapor; lead is found in hand washes and on the workwear of heaters. During nitriding, the air is polluted with ammonia.

The use of heat treatment of metals with high-frequency currents in the absence of reliable shielding leads to exposure of operators to high-frequency electric fields.

Health activities. Normalization of the microclimate is achieved by rational organization of ventilation. The easiest way to remove large volumes of superheated air is to use aeration lamps. If it is impossible to carry out aeration to remove excess heat, local natural exhaust ventilation is used in the form of umbrellas over heat sources and shafts, as well as mechanical general supply and exhaust ventilation.

As in other hot shops, in thermal production it is effective to use thermal insulation of heat sources, shielding workplaces, installing water curtains in the windows of heating furnaces, painting heating equipment in light colors, etc.

Air showering contributes to improving the heat exchange of workers; its organization at the workplaces of thermal operators is mandatory.

To prevent air pollution by harmful chemicals, it is necessary to provide maximum cover for hardening and other baths with the obligatory arrangement of local exhaust ventilation with air intakes such as on-board exhaust units. Exhaust air contaminated above permissible levels with lead vapor, cyanide compounds and other harmful substances must be cleaned before being released into the atmosphere.

A promising way to prevent air pollution of the working area and the surrounding atmosphere by vapors and products of thermal destruction of hydrocarbons is to replace mineral oils with aqueous solutions of non-toxic synthetic substances. Production tests of such substitutes provide encouraging results. One of the effective ways of hygienic rationalization of heat treatment processes of products is the use of vacuum processes.

Automation and mechanization of processes is of great technical, economic, sanitary and hygienic importance.

At large machine-building enterprises, in conditions of mass production, continuous furnaces with pusher conveyors or other mechanisms operate. All basic processes are automated: loading into furnaces, transfer to quenching baths, unloading, washing, etc.

To protect operators of high-frequency metal heating installations from the possible adverse effects of electromagnetic fields, radiation sources are shielded using a metal mesh or sheet metal.

The most common method of heat treatment is immersion of products after heating in quenching baths with mineral oils.

Working in pig baths is accompanied by air pollution with lead vapor; lead is found in hand washes and on the workwear of heaters. During nitriding, the air is polluted with ammonia.

The use of heat treatment of metals with high-frequency currents in the absence of reliable shielding leads to exposure of operators to high-frequency electric fields.

Air showering contributes to improving the heat exchange of workers; its organization at the workplaces of thermal operators is mandatory.

Automation and mechanization of processes is of great technical, economic, sanitary and hygienic importance.

To protect operators of high-frequency metal heating installations from the possible adverse effects of electromagnetic fields, radiation sources are shielded using a metal mesh or sheet metal.

Thermal workshop

General characteristics and purpose of the workshop.

The heat shop is designed to perform all types of heat treatment, mainly large forgings, castings and welded metal structures. The thermal shop at NKMZ is equipped with unique equipment for the production of thick-walled slabs and other parts. The workshop has one bay.

The thermal equipment is represented by three horizontal furnaces with a sliding hearth (G1, G2, G3) for annealing and normalization by tempering, two vertical gas furnaces (B1 and B2) with oil and water tanks and two vertical electric furnaces (E1 and E2). The dimensions of the working space of the heat shop furnaces are given in the following table:

Symbols ovens	Dimensions of working space, m			Cage weight
Symbols ovens		Height under vault	Arch height	Cage weight

The operating temperature of furnaces G1, G2 and G3 is 950 °C. The workshop is also equipped with a sand pit for slow cooling of forgings after tempering.

To cool the workpieces during quenching, quenching tanks are located near the furnaces: one with mineral oil, tank diameter 4.2 m; tank depth 32.0 m. The tank is installed near furnace E1; another tank - with water, tank diameter 2.7 m; depth 32.0 m.

Thermal furnaces in the thermal shop are unique; they are designed for heat treatment of long (up to 30 m long) parts, as well as large-scale forged, cast, welded and welded parts.

A characteristic feature of the annealing mode in the heat shop is the transfer of forgings for final cooling into a closed sand pit, which increases the productivity of the furnaces.

Gas furnaces use natural gas as fuel. In electric ovens, heat is created by passing electric current through powerful heaters placed in the walls of the workspace.

To straighten products after heat treatment, the workshop has a hydraulic press with a force of 3000 tons.

Most products after heat treatment require mechanical testing; to take samples, the workshop has two cutting machines on which samples are cut and sent to the Central Factory Laboratory (CPL), where all tests are carried out.

Among the thermal equipment in the workshop, there are units such as cooling wells, designed for slow cooling of products after heat treatment in order to obtain minimal stresses.

Crane equipment in the workshop is presented:

– two electric bridge cranes with a lifting capacity of 150/75 t, there is also one overhead crane with a lifting capacity of 50/10 t

The thermal shop is connected by rail to many workshops of the plant. The train enters directly into the workshop.

The following new technological processes are widely used in the thermal shop of NKMZ:

1. Accelerated cooling from the standardization of parts such as axles made of LOKHN steel;

2. Shortened mode for squeezing propeller shafts from st. 35;

3. Stepwise hardening of propeller shafts made of high-alloy steels;

4. Water hardening of propeller shafts.

In total, the workshop employs 150 people, incl. 25 people ITR. The workshop is managed by its manager. Directly subordinate to him are: senior foreman of the thermal workshop, senior foreman of the electroslag welding section and deputy head of the production preparation workshop.

The deputy head of the workshop is directly subordinate to the production areas, as well as the technical and technological bureau: armored personnel carriers, industrial safety departments, accounting, standardization officers, mechanics and electricians of the workshop.

Workshop technical services

The quality control service is subordinated to the head of the plant quality control department and, through him, functionally to the chief engineer.

Quality control inspectors report to the head of the section, they promptly identify defects in the workshop and the reasons for its occurrence (as in other armored personnel carriers), determine ways and methods to reduce it. When carrying out heat treatment and welding modes, quality control workers are required to monitor the exact adherence to the technology, the correct cutting of samples for mechanical properties and the tear-off sample to the laboratory for making samples and testing mechanical properties, taking hardness measurements on parts, gauging parts to determine the need for straightening.

BTR is a technological processing bureau, its responsibilities are: development of technological operations based on instructions and standard technological documents for heat treatment and electroslag welding, acceptance of technological documentation, issuing sheets of mechanical tests, drawing up a charge with sketches of parts, keeping records of properties.

PRB - planning and distribution bureau - plans and distributes work to parts, sections, counts for the work carried out by the workshop for a month, a year. Receives documentation from different workshops of the plant: as one of the procurement workshops of the plant, the thermal workshop serves all workshops of the plant with heat treatment. So, for example, hot forgings after forging are supplied to the thermal processing center No. 2 to perform isothermal annealing. From mechanical shops No. 6, 8, 11, etc., workpieces are received after rough mechanical processing (“blowing”). For final heat treatment – hardening and tempering. Large steel castings arrive from the cutting shop for annealing or normalization.

From the thermal shop, after checking the compliance of the actual properties of the heat-treated blanks with the parts required according to the drawing, the blanks are sent to the machine shop for final machining and cutting.

Mechanical assembly shop No. 11

Brief description of the workshop and its equipment.

Mechanical assembly shop No. 11 is one of the last mechanical assembly shops of the plant put into operation (launched in 1977). Of the plant’s mechanical shops, this is one of the largest.

Purpose of the workshop: production of ore-grinding equipment for various purposes, shears for cutting metal, spare parts for rolling equipment. The main machining equipment: gear hobbing, turning-boring, turning-screw-cutting, longitudinal-milling, longitudinal-planing, transverse-planing, slotting, cylindrical grinding and other machines.

The workshop has 6 spans and one overpass. Four bays are machining bays, two bays are machining bays, bays 1–4 carry out the full cycle of metalworking parts, bays 5–6 – assembly of parts. There is mutual cooperation between machining spans.

On the first bay there are lathes (with center heights of 200 - 500 mm), milling machines with a universal table, grinding machines (circular, flat, internal grinding), slotting, boring (with a spindle diameter of up to 160 mm) with digital display , longitudinal - planing, longitudinal - milling, rotary.

On the second span there is a large fleet of rotary machines on which parts up to 4000 mm in height are processed. Lathes with a spindle diameter of 160mm, milling drilling machines with a largest drilling diameter of 100mm, slotting machines. In terms of the mass of processed parts and dimensions, the machines of the second span are larger compared to the machines of the first span.

The third span is equipped with machines with numerical indication (spindle diameter up to 160 mm), longitudinal touching machines (table dimensions 3200 x 8000 mm), and transverse touching machines. The purpose of this span: manufacturing of body parts.

The fourth span is equipped with seven Czech-made boring machines (spindle diameter 200 - 250 mm), three foreign machines - of which two are models “PPL - 750L” and one from the Japanese company “MAAD” for cutting gears (diameter up to 10,000 mm). A longitudinal milling machine and rotary machines for processing parts (with a diameter of up to 2000 mm) are also installed.

On the flight there is equipment for processing teeth on parts of the shaft-six type.

The fifth span consists of two sections: assembly and machining. The assembly area has stands for drilling and assembling mill drums (crushing and ore-grinding equipment). At the second site, two machines and grinding rollers are installed.

The sixth span is the assembly one. It is equipped with assembly stands and drying chambers. On this span, rolling equipment is assembled.

Almost in the workshop, any parts are processed in a closed cycle according to the range of manufactured products. The workshop successfully develops and applies new advanced technological processes for forming parts, using part processing using a CNC program, using a jig, using USP, and using a sole. The movement of parts along the bays of the workshop is carried out by overhead cranes. The crane's lifting capacity is 20 - 25 tons. To move goods between spans, electric trolleys, electric cars, and hand trolleys are used. The workshop is used by railway transport and automobiles to move parts and finished products around the plant. The workshop cooperates with almost all mechanical workshops, manufacturing and manufacturing workshops, FLC, thermal, steel and steel workshops, etc.

From mechanical workshop No. 11, parts go to other workshops for cutting teeth of small modules and chrome plating. For heat treatment, parts are sent to a heat treatment shop.

Block diagrams of machine shop management.

Services and departments of the workshop:

The following technological and technical services operate in the workshop:

BTR (Technological Development Bureau) carries out work on technical preparation of production, introduces new technological processes, makes changes to factory technologies, coordinates them with the department of the chief technologist, carries out technical training of workers and retraining of personnel in accordance with frequency and in coordination with the technical training department;

PDB (planning dispatch bureau) draws up equipment loading schedules, participates in the preparation of shift and daily assignments;

PEB (planning and economic bureau) carries out technical economic planning, carries out payroll calculations and accruals for them.

Accounting - organizes accounts for all items of incoming and outgoing material and raw materials, compiles statements, maintains a card index, monitors the correct completion of documents related to the expenditure of material assets and wages;

The workshop power engineer service ensures the operability and technical serviceability of power equipment, monitors the correct and rational use of electricity;

The tool department (IHO) provides production areas with fixtures, tools (cutting and measuring), repairs tools for manufactured orders and non-standard tools;

Mechanical services – ensures the serviceability of mechanical equipment, maintains the workshop building in working order, repairs the workshop roof, ensures cleaning of lanterns;

Production sites carry out all work aimed at high-quality production of products in accordance with established plans and schedules.

Central factory laboratory

General characteristics of the unit

TsZL is a research and development structural division of the plant. Functionally subordinate to the chief metallurgist. As a division, it is part of the department of the chief metallurgist. Purpose of the Central Plant: carrying out research work primarily in the metallurgical industry, introducing new technological processes, new steel grades and efficient types of equipment into procurement production. Also performs supervisory functions to assess the quality of products. Establishing the causes of defects that arise during current production, as well as among customers.

TsZL – located in a separate building. The laboratory staff consists of 300 employees, mainly engineers - researchers, laboratory assistants, and support workers. The CZL includes the following divisions: mechanical testing laboratory, technical processing laboratory, metallographic laboratory, spectral analysis laboratory, roll laboratory, forging and pressing laboratory, foundry laboratory, electroslag remelting laboratory (ESR), ultrasound laboratory and X-ray gamma flaw detection, production phase .

The central laboratory is managed by the head of the laboratory, who has two deputies: one for research work, the other for control. Each department is headed by the head of this laboratory.

Mechanical Testing Laboratory

Performs control functions by testing metal products for tension, compression, bending, hardness, impact strength, and also determines the quality of springs. The laboratory is equipped with three hydraulic universal testing machines with maximum force: two machines of 50 tons and one of 50 tons, two machines of 150 and 250 tons, respectively. The machines allow tensile testing of special samples and recording of the tensile diagram, as well as cold bending: one machine is equipped with a tubular electric heating furnace, which allows short-term tests at high temperatures. The laboratory has two MK30 pendulum impact drivers for testing standard samples for impact bending, including at temperatures of 180 °C. The laboratory presents a large range of hardness testers for testing metals according to Rockwell, Brinell, and Winkers. A number of portable devices are available. All tests are performed according to state standards.

Chemical Spectral Laboratory

They carry out work to determine the content of all basic elements in metals (C, M, Mn, P, C, Mo, Ti), and the determination is carried out both during the smelting process in the open-hearth furnaces and in the chemical process. composition entering the metal plant. The laboratory completely abandoned chemicals. methods for determining chemical compositions using chemicals. reagents. Now Spanish spectral method using spectrometers of the PECTPOIAB type. Special samples with a diameter of 25 mm and a height of 15 mm are subjected to spectral analysis (during the melting process). From the open-hearth shop, samples arrive through special pipes: under pressure (pneumatic mail). Each incoming sample is marked, including the heat number, furnace number, steel grade and the time of sending the results of the computer programs according to a special computer program, the results of the analysis are transmitted via teletype to the open-hearth shop, and are received by the master of the steel-smelting furnace. Analysis duration is 6-7 minutes. This allows the melting furnace master to adjust the composition of the steel produced as the melt progresses. To determine the content of gases (C, H, O) in the metal, gas analyzers are used in the laboratory.

X-ray-gamma-ultrasound laboratory

They mainly perform monitoring functions: they determine the presence of defects in the workpieces that violate the continuity (cracks, pores, cavities, non-metallic inclusions) using non-destructive methods, ultrasonic flaw detection (USF), X-ray and gamma ray scanning, and magnetic flaw detection.

Ultrasonic flaw detection allows you to detect the location of internal defects in various, preferably large sections of simple shapes.

The NKMZ laboratory uses the pulsed ultrasonic reflection method, using special devices such as 86-IM-3, V4-7Ts. Ultrasound signals are irradiated using a pyzoelectric quartz plate (vibrator), which converts electrical vibrations excited by high-frequency alternating voltage into elastic vibrations of the same frequency. Ultrasonic inspections are sent to the part being tested through a special sensor; when they encounter a defect in the part on their way, they are reflected from it and the contours of the defect can be observed on the electro-ray tube.

The magnetic defect method is based on the fact that in a magnetized product, the magnetic flux encounters obstacles with low magnetic permeability (cracks, non-metallic inclusions) that are dissipated and, if the obstacles are not located deeply, then on the surface of the product, instead of the exit of field lines, magnetic polarization is created, which is detected by magnetic indicators . The NKMZ laboratory uses magnetic flaw detectors MD7 and MD8.

X-ray and gamma flaw detection

X-rays for flaw detection are passed through the object being scanned and directed onto photographic film (photographic flaw detection). Rays weakened in the object cause blackening in the film or glow of the screen, respectively. The image on the screen or film is a geometric projection of the sample being examined and the defects present in it. The image of defects will appear darker on film than other areas, but lighter on screen. X-ray flaw detection is used to control the quality of welding.

Heat Treatment Laboratory

New technological methods for processing parts are being developed. Equipment: thermal heating furnaces, hardening tanks, hardness testers. The metallographic laboratory performs the functions of research and quality control of metal by examining the microstructure. Metallographic microscopes provide useful magnification of up to 4000x.

Forging laboratory

Performs research functions aimed at the development and implementation of new technological forging processes and carries out work to develop forging technologies for standard parts.

Foundry laboratory

Performs research functions to introduce new technologies for producing steel and cast iron castings into production, and also controls the quality of molding sands.

Roll laboratory

Performs research work on the introduction of new steel grades and technologies in the production of cold rolling rolls.

ESR Laboratory

Conducts experimental research on the development and implementation of electroslag remelting. The mechanical workshop (MW) is equipped with metal-cutting machines for making samples.

CZL production base

Designed for conducting experiments related to the development of technological processes. The base is equipped with electric heating furnaces and two induction furnaces for 100 tons of liquid metal (induction steelmaking furnaces). The production area is served by mobile floor-mounted equipment.

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