INSTITUTE OF TECHNOLOGY OF METALS
  
 



LANGUAGE
  • Russian

  • INSTITUTE
  • Institute
  • Main directions of scientific research work
  • Structure
  • Contacts
  • Cooperation

  • DEVELOPMENTS OF THE INSTITUTE
  • Continuous casting
  • Freezing-up casting
  • Bimetals
  • Silumins
  • Simulation of casting processes
  • Water analog simulation of die casting
  • Electroslag casting

  • CORROSION
  • Development of diagnosis system of the metal surface damage
  • Development of prognosis system of the steel surface damage by the Light Section Profiling System (LSP system) in high-speed production process
  • Development of prognosis system of the steel bulk property claim by the magnetic detection method in continuous production process
  • Diagnosis system of quality control and process control by digital image analysis
  • Universal magnetic thickness gage
  • Development of anti-corrosive active polymer film for steel packing

  • COATINGS
  • Magnetic Impulse Hardening
  • Cladding
  • IMM (Induction Metallurgical Method) Surface Hardening
  • Thermal Spray Coating Process
  • Flame Spray
  • Detonation Flame Spraying
  • Nontransferred Plasma Arc Spraying
  • Electric Arc Spraying
  • Activated arc spray- Hypersonic metallization
  • High-Frequency Pulse Hardening of Surfaces
  • Wire Arc Coatings
  • Metallization Of Ferrites And Creation Of Fixed Compositions Ferrite-metal

  • TECHNOLOGIES AND EQUIPMENT
  • Equipment For Surface Metallization And Blazing Of Oxide Materials
  • for continuous casting of cast iron and nonferrous metals
  • for battery grid casting
  • for continuous casting of CuCl belt
  • Plant for continuous casting of copper, aluminum, gold, silver, solder wires
  • DEVELOPMENTS OF THE INSTITUTE :: Development of prognosis system of the steel bulk property claim by the magnetic detection method in continuous production process

    Abstract

    This project is dedicated to development of diagnosis system of the mild steel surface damage or deformation and compatibility solutions to enable high productivity due to protect surface damage in advance and save production loss by automatic surface quality control system. The basic technical objective of this project is research and development of major compatibility issues between surface condition of low carbon steel surface and it’s digital image analysis by morphological interpretation of color, shape, and texture of surface damage in real time. This project is to demonstrate, by way of simulation tests of image analysis by the Light Section Profiling System (LSP system) in high-speed production process for surface defects, the tradeoffs associated with conflicting requirements of surface condition, for surface deformation from high stress or temperature of production process, surface defect from corrosion inhibition and materials fatigue life, wear resistance and corrosion resistance with lubricant for process of milling, forging, pressing, etc. The anticipated results of the project comprise key components of an advanced technology of diagnosis system of surface damage analysis and methodology of study of surface defect with mechanical properties. The project will result with: image capture and database establishment procedures for surface damages, data expert system with data query management, methodology of digital image analysis of morphological defects, classification methods of defined images, automatic on-line prognosis system for surface damage. The methodologies and experimental data that are conceived for the proposed investigation will allow selection of optimal condition of surface quality control and shape deformation up to 1,000 m/min of process speed.

    Anticipated Benefits

    This system can apply to the continuous high-speed steel production process for detection and prevention of surface damage or outside defect of products. It will prevent the claim of products and increase the productivity of company, which are producing final stage of steel sheet relating to surface. The superiority of this system is that 3 main digital image elements (color, texture, and shape) can combine for image detection case by case and define by multi-dimensional classification method for preparation of optimal decision. And it can adapt easily to user's hardware with low cost of image capture system. LSP system in on-line will be powerful for detection of surface damage and automatically can save all data to user's main computer that are interpreting data of database.

    Key words

    Digital image analysis, Image capturing system, Export system, Morphology, Surface damage, On-line Diagnosis, Multi-dimension classification, Light Section Profiling System (LSP system), Corrosion

    Technical objectives

    The Light Section Profiling System (LSP system) is intended for in-process detection topographical irregularities of plane steel sheets. The principle scheme of the system is presented on the Fig..1.a. The steel sheet 1 is illuminated by gapped light source 2. When the object is illuminated in the field of vision of object lens a reflected gap image is observed. If the surface is flat and smooth the gap image is looking as a straight line (Fig.1.b). In case of presence irregularities such as cracks, scratches, tear out of metal or holes, the shape of the line is changed (Fig. 1.b). As result the reflection position of light source on the investigated surface is changed. The optical system receives the reflected light and projects it on the diode matrix 3. If the reflected light came from the some peak on the surface it fall on the area above middle line of detectors. In case of reflecting from a cavity the beam is come to the area below the middle line. The position of detectors can be adjusted to fit a range of normal deviations of surface defects. In that case any signal coming from the upper or lower lines of detectors will inform about out of size range of surface defects. The information can be used for future processing by control system.

    The described base system can be modified for processing information about color heterogeneity of controlled surface. Corrosion, oil stains or temper color can cause such heterogeneity. For detection these defects the reflected passed throw optical split system (4,5). Additional detectors 6 analyze the spectrum of reflected light. The conclusion is made by analysis of relative intensity of red, green and blue spectral components of reflected light.

    The system is fully designed on analog electronic components. It is allow achieving data processing in real time with speed of steel sheet movement up to 1000 m/min.



     

    Fig.1 a) General scheme of LSP system: 1 – steel sheet; 2 – light source; 3 – detectors of position of reflecting surface; 4 – light beam split system; 5 – dispersion prism; 6 – detectors of reflected light dominant color; b) – view of gapped light source on smooth and flat surface; c) – view of gapped light source on rough surface.

    If we want to evaluate more micro-surface damage by using this system, we can combine with the linnik double microscope system as following;

    The Linnik double microscope with two separate mutually facing oblique parts, one is illuminating and the other is optical, supports a significantly broader range of analysis of the depth of damage (Fig.2).

    When an object is illuminated through the slot diaphragm in the lens field of vision a surface shadow profile is observed. This method allows measuring damage 3 to 100 mm deep with accuracy of the order of 3-5%. Special optical attachments may expand the upper range of measurements to 1 mm.
     

    Fig. 2. Linnik optical double microscope configuration: 1, 2 – tube; 3 – lens; K – ocular; a – slot collimator; HH – plane of observation; а1 – image of slot а; а2 – projection, а1'; a2’ – same when plane НН shifts to distance d; j -- angle of deviation of tubes 1 и 2 from normal С.

    Scope of project

    Refer to proposal 1.
     

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