Russian Federal Nuclear Center –

1. Russian Federal Nuclear Center – Lisbon, December 2002 Presentation Development of Advanced Materials and Manufacturing Processes Alexander Korshunov

2. 500oC <130oC 32 minutes 500oC 20oC 7 minutes 80 225 370 460 Fire-Proof Heat-Insulating Material Distribution of a Temperature Field Inside of Sandwich-Elements in Their Joint Point steel Heat-Insulating Material 5.1 cm 1.9 cm 2 cm 13.5cm Material Specifications: Density 400 - 550 kg/m3 Compressive Strength 1.3 - 3.6 MPa Coefficient of Thermal Conductivity 0.093 - 0.171 W/m·К

3. Polymer-based ecologically clean materials X-ray protective material based on silicone rubber • Characteristics: • provides protection at tube pressure of 85 kV , • density, 2800-2900 kg/m3, • tensile strength 3.0-3.5 МPа, • lead equivalent at thickness of 1.8 mm 0.45 мм. • Purpose: • is designed to manufacture protective materials for medical personnel and patients in medical radiology. Toxicological tests have been performed, and the permission of the RF Ministry of Public Health for the development and manufacture of protective clothes and shutters used in X-ray facilities.

4. Alloy , g/cm3 в, MPa 0,2, MPa , % А, J/cm2 VNJ 90 16.9-17.1 950-1000 650-700 ~20 4-5 VNJ 95 17.9-18.1 930-950 680-700 ~ 10 3-5 VNJ 97,5 18.5-18.7 700-750 700-730 1 1 VNJ-3-2 18.0-18.1 700-720 620-630 3-4 3-5 W-Cu 16.8-17.1 690-720 670-680 1 1 PRODUCTION TECHNOLOGY FOR PLASTIC TUNGSTEN ALLOYS AND ITS PRODUCTS (1)

5. USE OF EXPLOSIVE ENERGY For Welding of Heterogeneous Metals • Production of bimetal joints of various range has been run in. Products may be exposed to different machining methods: cutting, rolling, bending... • Advantages: • high strength of a joint welded; • improved structural rigidity; • high economical efficiency Used in thermoelectric conductive systems, non-ferrous metallurgy, power engineering, laser technique, instrument making, machine-building etc.

6. DIFFUSION ZINC PLATINGof structural steels instead of cyanic cadmium plating • Technology allows production of thin (5-30 µm) non-porous coatings on any complex shape parts. • Corrosion resistance of diffusion zinc coating is in a par with resistance of coating with galvanic cadmium. • Technological process is economical and environmentally friendly. • Method is used in production of fixing parts and other parts in different machine-building industries (avia-, automotive industry, etc.)

7. Summary: Bearing ability of 190 MPa for undemountable joints; 55 MPa for demountable joints. After 20 thermal cycles at the temperatures from -50 to +50 С a joint didn’t loose its tightness. Advantages: possibility to join pipes of different materials including ones being unjoinable by conventional methods (welding, soldering and others); fire- and explosive safety in work performance; simplicity and a short time needed for assembly; absence of areas of thermal and electric exposure DEMOUNTABLEPIPELINE JOINTS with couplings of titanium nickelide - shape memory alloy Used in : Aviation, spacecrafts, oil- and gas pipelines, construction, medicine, ship-building, chemical industry, automobile industry, etc.

8. New Electrohydraulic Pulsed Forming Technology Project #1593 Approach: Multiple-step application of a workpiece material on the punch, with the punch being in discrete motion Advantages: • Friction of the workpiece against the punch is technologically active • Minimum elongation ratio: 3 • Thinning is four times as good as against conventional technology Applications: • Machine building • Aircraft industry • Instrument manufacturing Collaborator: Ford Company, USA

9. Devices to Enhance Thickness, Speed and Quality of Gas-Assisted Laser Cutting of Metals Project Proposal #1670 Objective: Enhanced quality and technological efficiency of gas-assisted laser cutting as applied to great-thickness metals Approach : Develop methods and devices to provide optimal formation of the process gas flow and generation of optical radiation in the cutting area Project Milestones: • Develop new samples of cutting heads to allow cutting in inert atmospheres • Develop a laboratory cutting head model for cutting in oxygen • Develop a quantitative gas-assisted laser cutting model and corresponding software

10. Efficient Technology for Aluminum Foam Materials Production Project Proposal#2272 Objective: Lower cost of aluminum foam production Advantages: • Considerable cost reduction as compared with powder metallurgy • Availability of scrap aluminum as a source material Applications: • Construction (lumber substitute) • Fireproof partitions • Shipbuilding, pontoon platforms • Automobile industry • Sound-absorbing casings

11. Ion Plating Facility Prototype Project Proposal #2527 Objective: Develop a next-generation facility based on theoretical and experimental investigations Advantages: • Production of smooth coating surfaces due to excluding the drop phase • The coatings produced need neither finishing nor superfinishing such as polishing or honing • The coatings applied using the new technology will allow the service life of cutting and forming tools to be extended by several times

12. Corundum Powder Production Technology Project Proposal #2535 Objective: Develop a new technology to produce corundum powder with a particle size between 20 and 1 micron from scrap aluminum by spark-erosion dispersion Advantages: • Considerably reduced production costs • Availability of scrap aluminum as a source material • Small-size equipment Applications of fine corundum: • Abrasive materials • Fireproof materials • Casting molds