By March 2014, when the United States and the European Union imposed the first package of economic sanctions against Russia, the share of domestic equipment in our oil and gas sector was 43%. The forced restriction of imports stimulated domestic production growth, and this share increased to 62%. The goal for 2035 is 90%.
Competing with China's manufacturing industry is difficult. After the introduction of virtually prohibitive import duties by the United States, China is more eager than ever to supply the Russian market. The only solution is to find innovative technological solutions that reduce costs and improve the performance characteristics of products. Let's talk about one such solution.
Scientists at Empress Catherine II Saint Petersburg Mining University have proposed an efficient surface alloying technology for casing products made of steel, such as pumps, compressors, or other equipment working in aggressive environments where corrosion and wear resistance are required.
This development can be used not only in the production of equipment for the oil and gas sector but also in other sectors of mechanical engineering, as well as for modernizing industries like the chemical industry. It allows for the production of casing elements from relatively inexpensive carbon steel. The protective layer enables the product to successfully compete in quality with more expensive grades of steel without coatings, which is what domestic industry currently purchases for serial production of equipment.
The wide application of surface alloying is hindered by the need to use costly vacuum furnaces in the technological process. These are necessary to eliminate oxidation processes on the treated products.
«We propose to carry out surface alloying using an open method. We dissolve the refractory alloying elements in a low-melting transport medium, such as a lead and bismuth alloy. The product is immersed in a container with the molten medium, and during the diffusion process, a surface-alloyed layer is formed on it» – said one of the authors of the development, Assistant Professor of the Department of Materials Science and Technology of Artistic Products, Andrey Mikhaylov.
In the university laboratories, scientists have assembled an experimental setup. With its help, the effectiveness of the proposed technology has been confirmed, and the intellectual property rights for the invention are protected by several patents.
«Surface alloying is carried out at temperatures between 800-1000 degrees Celsius. At such temperatures, carbon steels undergo oxidation processes. Vacuum equipment, which is currently used for surface alloying both in Russia and abroad, prevents the access of oxygen.
We achieve the same effect using a high-temperature flux, a kind of liquid membrane on the surface of the melt. We have developed a unique flux composition that successfully prevents air penetration. Additionally, for extra protection, we carry out the pumping of inert gas through the furnace throughout the process» – explained Andrey Mikhaylov.
The development attracted great interest at the Hi-Tech exhibition in St. Petersburg. The jury awarded it a "gold" prize. The same high evaluation was given to the work of the scientists from the Mining University at the Moscow International Salon of Inventions and Innovative Technologies "Archimedes." Industrialists are also showing interest, such as the St. Petersburg company LLC "Metallresurs."
The research team, comprising both renowned scientists, postgraduates, and students, is currently working on the possibility of increasing the size of the processed products. In particular, the alloying of internal surfaces of pipes in the oil and gas sector.