The main stages of research on the development of technology for obtaining cast A34‑grade solder in the form of rods are presented. It is shown that, taking into account the basic patterns of structural heredity, up to 100 % of preprepared various scraps and waste can be effectively used to prepare the working alloy. The results of melting and solidification kinetics, chemical composition and microstructure analysis, mechanical testing, and density analysis showed that the A34‑grade solder obtained using the developed technological scheme fully meets the requirements of regulatory documentation. The possibility of using A34 solder as a filler material for welding plates (2 mm thick) made of aluminum alloys AK7ch (casting) and AMg5 (deformable) has been established. Argon was used as the gas shielding medium. A technological instruction for preparing A34 solder alloy has been developed. The production of A34 cast solder in the form of rods has been organized.

The article outlines the advantages of medium‑frequency induction crucible furnaces in comparison with industrial‑ frequency furnaces. It presents the economic efficiency achieved by transitioning from industrial‑frequency induction furnaces to medium‑frequency units. Additionally, the paper describes the method of multi‑station melting, highlighting improvements in energy efficiency, metal quality, and production flexibility.

The article presents a thermodynamic calculation of the modifi ation of hypereutectic silumin by cerium, beryllium and antimony. It has been shown that in the melt of hypereutectic silumin, cerium, beryllium and antimony refine elementary silicon nanocrystals from adsorbed oxygen atoms. The process of modifying primary silicon microcrystals with cerium, beryllium and antimony has been studied. These metals increase the concentration of elementary silicon nanocrystals free of oxygen atoms in the melt of hypereutectic silumin. This process increases the concentration of crystallization centers and increases the dispersion of primary silicon microcrystals.

Examples of the implementation of additive technologies in the current foundry production are considered. Using the example of the furan process, it is shown that additive technologies in their content can differ significantly from traditional technol gies. Casting cores obtained by the Binder Jet technology differ from cores obtained by the traditional furan process in their increased strength and gas emission. This must be taken into account when designing gating systems to prevent the occurrence of gas defects in castings.

The process of centrifugal casting of AMg5 and AMg6 alloys was tested under gravitational load coefficients (GLC) of 300g and 500g. It was found that the positive effect of increased GLC on melt crystallization is more pronounced when casting alloys with higher alloying element content. This promotes not only grain refinement and melt purification from brittle iron‑silicon compounds but also enhances the solubility of alloying elements in α(Al). Thus, castings from AMg6 obtained at 500g, compared to those at 300g, showed 1.1 and 1.3 times higher strength and ductility, respectively. Compared to the best samples of cast AMg6 alloy produced according to GOST 1583–93, centrifugal casting at 500g yielded an AMg6 alloy with strength, ductility, and hard‑ ness increased by 15–25, 10–50, and 40 %, respectively. Moreover, the alloy exhibits a structure equivalent to that obtained through solution heat treatment. Using the rolling method, the process of plastic deformation of AMg5 and AMg6 aluminum‑ magnesium alloys with structures obtained via casting at 500g was studied. As a result of developing various rolling routes, the AMg6 cast alloy obtained at 500g was strengthened, achieving a 1.6‑fold increase in strength and hardness at a total deformation of 60 %. The resulting AMg6 material had a strength ranging from 411 to 435 MPa and an elongation of 10 to 13 %, de‑ pending on the tensile direction. The results demonstrate the promise and necessity of further research into producing AMg alloys via centrifugal casting under GLCs of 300–500g followed by plastic deformation.

The study investigates the influence of shrinkage processes in the mold of a continuous casting machine on the formation of surface defects during the casting of a 200 mm diameter round billet. The necessary shrinkage criteria for the continuously cast billet were determined to form an optimal shell by selecting molds with a specific geometric configuration and by using slag‑forming mixtures of customized chemical composition.

Under the control of plastic properties, the reliability of a preliminary assessment of the unevenness of plastic deformation during repeated drawing of high‑strength wire was compared using the calculated geometric parameter of the wedge‑shaped zone and the experimentally determined metal lift at the entrance to the working cone of the drawing. The geometric parameter of the wedge‑shaped zone does not characterize the effect on the formation of plastic properties of increased strength, the ratio of compressive and tensile stresses in the deformation zone with a change in a single compression, and therefore cannot be used as an indicator of the unevenness of plastic deformation during repeated drawing of high‑strength wire made of pearlite steel. The rise of metal at the entrance to the deformation zone of the drawing tool, determined by drawing on split lugs, is highly sensitive to changes in the main technological parameters of the drawing process and meets the criterion of uneven plastic deformation. To increase the uniformity of deformation during repeated drawing of high‑strength wire, it is necessary to reduce single compressions and reduce the angle of the working cone of the drawing as the total degree of deformation increases, as well as to carry out deformation by drawing with counter‑tension and in the mode of hydrodynamic friction.

The article presents software implementation of Poka‑yoke principle and introduction of torsion bar rotation control system on cabling machines, which can significantly reduce production costs caused by the influence of equipment and human error. The aim of this project is to improve software of cabling machine, allowing to identify hidden defects (including along the length of steel cord) in order to reduce share of technically unavoidable waste at the customer, and to reduce share of non‑conforming products in production. The solutions for improving breakage detection system, introducing additional triggers to eliminate “short‑length” during production of steel cord, reducing amount of non‑conforming products (correctable and non‑correctable), calculating and promptly eliminating machine failures and monitoring unintentional operator errors are considered. During the process software for monitoring and counting length of steel cord and a torsion bar rotation monitoring system were developed and implemented.

This article examines the priority requirements for bead wire as a key component of tires. It outlines various factors affecting the processing of bead wire and the actions taken by manufacturers to improve it. The most critical challenges encountered in designing new bead wire constructions are highlighted, along with possible solutions. The main stages of developing new bead wire designs are reviewed. The important role of a multifunctional team in promptly resolving emerging issues and reducing design timelines is described. Emphasis is placed on the importance of customers providing complete information about the intended design, including its area of application. The use of DFMEA methodology is discussed as a potential tool to address the issue of insufficient input data during the design phase.

The article discusses the issues of non‑metallic inclusions analysis in steels. The article examines optical effects arising in polarized light on non‑metallic inclusions, artifacts of metallographic sample preparation, and some details and defects of the microstructure. It is shown that at maximum magnifications of up to 1500 times it is not always possible to visualize crystalline non‑metallic inclusions. The article illustrates the similarity of optical effects on crystalline inclusions, water droplets, pores, and etch pits. It is shown that in this regard, the role of additional options of optical microscopes increases, expanding the possibilities of optical contrasting, which makes it possible to recognize various metallographic artifacts. At the same time, equipping laboratories with modern metallographic equipment, primarily high‑magnification objectives, as well as various means of optical contrasting is of paramount importance.

Heat‑resistant alloys and steels are a specialized class of stainless materials designed for operation under elevated temperatures and in aggressive environments. These materials are intended for use in applications where conventional steels would lose their properties due to high temperature exposure, oxidation, or corrosion. This study analyzes the equivalence of domestic heat‑resistant steels and alloys to their international counterparts in EN, AISI, ASTM, and AFNOR standards. The mechanical properties of steels within the AISI system are examined. A comparative review of the primary application fields of heat‑resistant steels produced in the CIS and those of the AISI system is also provided.

Over the past 15–20 years, a substantial amount of imported equipment for various purposes has been acquired. When such equipment breaks down, there is often a need to replace damaged components. However, with the imposition of international sanctions, certain difficulties have arisen. One of the major challenges involves the inability to accurately determine the equivalency between the materials used in original foreign components and those available in the CIS, including their heat treatment methods and mechanical properties. This issue complicates the selection of suitable domestic alternatives.

A database of chemical compositions of ausferritic ductile irons (ADI) was created based on publications in reputable scientific journals (Materials and Design, Materials Science and Engineering A, Journal of Materials Engineering and Performance, Journal of Materials Research and Technology (Elsevier), Metallurgical and Materials Transactions A, International Journal of Metalcasting (Springer), Materials, Metals (MDPI), Materials Transactions JIM, ISIJ International и др.). The search was carried out for 35 years (1990–2025), with the greatest attention paid to publications for the period 2020–2025. A statistical analysis of the chemical compositions of ADI from the database was carried out, which revealed a number of patterns. The values of average concentrations, standard deviations from averages, and confidence interval boundaries for average values of chemical element concentrations were determined using the Student’s distribution at a significance level of 0.05. The limiting ranges of ADI alloying with the main elements were established: carbon from 2.78 to 3.87 %, silicon from 0.28 to 4.69 %, manganese from 0.07 to 1.01 %, copper from 0.01 to 1.4 %, nickel from 0.001 to 2.0 %, molybdenum from 0.001 to 0.5 %. Graphs of the dependencies of the distribution frequency of the studied ADI alloys on the content of carbon, manganese, copper, nickel, molybdenum and magnesium were constructed. Characteristic maxima of the distribution frequency of the alloys were found, falling on the ranges of concentrations of the following elements: carbon 3.40–3.55 % (42 % of alloys), silicon 2.03–2.91 % (90 % of alloys), manganese 0.22–0.41 % (41 % of alloys). For copper, nickel and molybdenum in ADI, statistically significant concentration maxima were not revealed. The distribution frequency of ADI alloys was analyzed depending on the concentration combinations of the following pairs of chemical elements: С–Si, Si–Mn, Cu–Ni, Mo–Ni, P–S, Mg–C. Combinations of C–Si and Si–Mn concentrations, characteristic of most alloys, were revealed and displayed on the diagrams as local, clearly defined zones. Somewhat less defined areas of stable concentration combinations were found for the pairs: Mg–C and P–S. A number of groups of stable combinations of Cu–Ni, Mo–Cu, Mo–Ni concentrations were established and displayed on the diagrams as several corresponding zones. ADI groups were revealed: molybdenum‑free, low‑copper, low‑nickel; the most widely represented group is complex‑alloyed ADI: 0.6–1.4 % Cu, 0.5–2.0 % Ni, 0.15–0.3 % Mo. Statistical analysis allowed us to identify the most frequently used ADI alloying ranges: carbon 3.50–3.59 %, silicon 2.44–2.66 %, manganese 0.29–0.38 %, copper 0.39–0.62 %, nickel 0.46–0.81 %, molybdenum 0.13–0.24 %, magnesium 0.042–0.051 %, phosphorus 0.024–0.035 %, sulfur 0.011–0.015 %. As a result of statistical processing of the entire data array, the weighted average chemical composition: 3.54 % C, 2.55 % Si, 0.33 % Mn, 0.51 % Cu, 0.64 % Ni, 0.18 % Mo, 0.046 % Mg, up to 0.03 % P, up to 1.1% S. This composition is recommended as optimal. An analysis and comparison of chemical compositions of a number of patents on ADI compositions of the authors with the identified average statistical composition was carried out. Directions for creating groups of economically alloyed ADI based on the concept of economical alloying are proposed.

The service life of components with metallic or ceramic overlay coatings directly depends on a number of their mechanical and physical properties. For parts operating in friction assemblies, the strength of the applied coatings – closely linked to their hardness – is of particular importance. This study presents an analysis of hardness variation across the cross‑section of the coatings and substrate materials. A comparison is made between heat‑treated samples and their untreated counterparts, highlighting notable differences in hardness. The susceptibility to failure of low‑ and medium‑entropy coatings applied via plasma spraying onto cast irons, copper alloys, and composite materials is examined. The work also demonstrates the potential for optimizing the substrate to enhance coating performance.

This paper presents a brief review of the results previously obtained by the authors in their studies of the chemical and granulometric composition of zinc‑containing dispersed waste (zinc dust) generated during the galvanizing of pipes and subsequent steam blowing. It also examines the influence of technological parameters such as the mixture composition and the temperature of thermodiffusion galvanizing on the thickness, structure, and properties of zinc coatings produced using thermodiffusion galvanizing in saturating mixtures based on zinc‑containing waste. Since the primary function of zinc coatings is corrosion protection, samples of zinc coatings based on both standard zinc powder and production waste were fabricated ina rotating container unit for comparative corrosion resistance testing in a salt spray chamber. It is well known that to enhance corrosion resistance, zinc coatings are commonly passivated and coated with paint materials. Some of the zinc‑coated samples were also subjected to additional treatments. The comparative salt spray chamber testing (ongoing at the time of writing) revealed that after 300 hours of exposure, the coatings produced from zinc‑containing waste only slightly underperformed in terms of protective properties compared to those made with standard zinc powder. Additional treatments, specifically passivation, nearly eliminated white rust formation. Furthermore, the use of a combined paint coating system (passivation + painting) ensured complete corrosion resistance for no less than 300 hours in the salt spray chamber.

The results of the assessment of working conditions at the workplaces of the mold collector are presented, the factors of the production environment determining them are determined. The working conditions of the mold assembly worker are considered in comparison with the standard values. It has been established that when assessing the working conditions of an assembler in foundries, it is necessary to take into account the equipment and hand tools used, and the duration of stay at the working equipment