In this reviews modern ways, examples of operational use of electron-beam technologies are shortly submitted. Also are described of its advantage and prospect for its development. In the article examples of successful operational use of electronbeam technologies in applied material science and industry are adduced.U članku su ukratko prikazani primjeri praktične primjene elektrono-lučne tehnologije. Dane su prednosti i perspektive razvitka. Navedeni primjeri njihove uspješne primjene u industriji

I. Mamuzić

N. Grechanyuk

P. Shpak

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METALURGIJA 41 (2002) 2, 125-128 125N. GRECHANYUK at all.: MODERN ELECTRON-BEAM TECHNOLOGIES OF MELTING ...Received - Primljeno: 2001-07-15Accepted - Prihvaćeno: 2001-11-15Professional Paper - Strukovni radISSN 0543-5846METABK 41 (2) 125 (2002)UDC - UDK 621.385.832.002=20. ECHANYUK, I. MAMUZIĆ, P. SHPAKN. Grechanyuk, P. Shpak, Scientific Production Enterprise, Gekont,Ukraine, I. Mamuzić, Faculty of Metallurgy, University of Zagreb, Sisak,CroatiaThe development of economics of any state bodilydepends on a level of development of science and appli-cation of high and modern technologies. One of newest,dynamically developing and perspective technologieswidely used in applled materials technology, is the elec-tron-beam technology.Modern concept the electron-beam technology are in-cludes:- electron-beam melting;- electron-beam evaporation (EB-PVD) and subsequentcondensation in vacuum of metallic and non-metallicmaterialss by covers or massive bars, unbound from asubstrate, of composite materials, powder and etc.;- electron-beam welding;- electron-beam treatment.The modern level of development of EB-technologies,which have used in the Research and Producing Company“GEKONT”, Ukraine has reviewed.ELECTRON-BEAM MELTINGElectron-beam melting is widely applied in the worldpractice to producing metals high-melting, high-reaction-MODERN ELECTRON-BEAM TECHNOLOGIES OF MELTING AND EVAPORATIONOF MATERIALS IN VACUUM, BY USED “GEKONT”-COMPANY, UKRAINEIn this reviews modern ways, examples of operational use of electron-beam technologies are shortly submitted.Also are described of its advantage and prospect for its development. In the article examples of successfuloperational use of electronbeam technologies in applied material science and industry are adduced.Key words: electron-beam technology, protective coatings, composite materials, electrocontacts materialSuvremene elektrono-lučne tehnologije topljenja i isparavanja materijala u vakuumu, rabljenih u tvrtki“GEKONT”, Ukrajina. U članku su ukratko prikazani primjeri praktične primjene elektrono-lučne tehnologije.Dane su prednosti i perspektive razvitka. Navedeni primjeri njihove uspješne primjene u industriji.Ključne riječi: elektrono-lučna tehnologija, zaštitne prevlake, kompozitni materijali, materijali za elektolučnekontakteary and precision alloys of high purity [1,2]. It is one ofthe most effective ways of increase of metal purity fromparasitic and non-metallic impurity, and also eliminationof a chemical and structural non-uniformity.In the “GEKONT”-company the industrial electron-beam equipment permitting to produce ingots of metalsand alloys by diameters from 60 up to 140 mm, length upto 2000 mm and slabs by the sizes 140x160x2000 mm.The new generation of the electron-beam equipment,designed in the “GEKONT” company, allows to produceingots by diameters up to 300 mm, length up to 2000 mmand slabs 300x300x2000 mm.Exploited in the “GEKONT”-company the electron-beam equipment will be widely used:- for producing ingots and slabs of copper of heightenedpurity used hereinafter for manufacturing of essentialparts of nuclear power engineering;- of ingots of zirconium also used in the nuclear powerengineering;- of ingots of alloys MeCrAlY, where Me-(Ni, Co, Fe),for protective coatings, used for deposition, on turbinesblades;- of ingots and slabs of titanium and its alloys by used inan aeronautical and chemical engineering;- of ingots of a high-speed steel R6 (W6-Mo5-V2) foreffecting a high performance cutting tools [3, 4].METALURGIJA 41 (2002) 2, 125-128126N. GRECHANYUK at all.: MODERN ELECTRON-BEAM TECHNOLOGIES OF MELTING ...In stage of industrial approbation there are new tech-nology of production of ingots:- of alloys: nickel-chromium, nickel-chromium-aluminium- for the producing of strand for heating elements;- of alloys: a chromel-copel, chromel-alumel - for the pro-ducing of thermocouples strand.In a development stage there are also other technolo-gies of obtaining of ingots and slabs by the electron-beammelting.ELECTRON-BEAMDEPOSITION OF PROTECTIVE COATINGSIn economically developed countries electron-beamevaporating and the subsequent condensation of metallicand non-metallic materials in vacuum has used for cre-ation protective and, first of all, heat-protective coatingson turbine blades.The modern heat-protective coatings, having the great-est operational resource, put on a defended item basicallyby the two-steps of technology. On such ways, in particu-lar, there was the American company “Pratt and Whitney”.An internal metallic layer Ni(Co)CrAlYHfSi- deposits bythe plasma spraying, and external ceramic layer (ZrO2-Y2O3)- by electron-beam deposition.The similar engineering solution is conditioned alsoby that until recently indispensable quantity of yttrium,hafnium, silicon and zirconium in an internal metallic layerby electron-beam technology, vaporization from one cru-cible was not possible. The new generation of the elec-tron-beam equipment was designed by “GEKONT”-com-pany for a deposition of heat-protective coatings (Figure1.) allows to decide a problem of the introducing practi-cally of any quantities of addition elements in standardheat-resisting alloys MeCrAlY, including Hf, Si, Zr, Y etc.It opens new feasibilities of electron-beam technology forperfecting heat-protective coatings:- at the approximately equal cost of the plasma spray andelectron-beam equipment and material inputs on a depo-sition heat-protective coating, the application of EB-PVD technology will be more economically expedient,as the deposition of composite two-layer coating, suchas MeCrAlYHfSi/ZrO2-Y2O3 implements on one typeof equipment and, probably, for one work cycle;- this type of facility allows to obtain the concentrationgraded heat resistant metallic layers more easier in com-parison with plasma spraying technique;- in the case of getting two-layered coatings the EB-PVDtechnology allows also to obtain the dispersion strength-ened metallic first layer with oxide, carbide or borideparticles;- it is possible to obtain heat-protective multi-layer coat-ings with alternating micro-layers such as Me/Me, Me/MeO, Me/MeC, Me/MeB2, MeO/MeO, MeO/MeC witha micro-layer thickness within a range 0.001 ... 10.0 -30.0 µm;- the available equipment allows to start the developmentof new types ceramic materials for thermal barrier coat-ings with an increased toughness and with a self curingeffect at the expense of fine particles and micro-layersto cure the micro-cracks formed during thermal cyclesin a ceramic top layer;- using this EB-unit type gives a possibility to developEB-PVD technology, to deposit new metallic materials(for example, Cr alloys) as the heat resistant coatings. Itis also important direction of our further investigations.Now the “GEKONT”-company has produced heat-pro-tective coatings on turbines blades by electron-beam evapo-rating of ingots MeCrAlY, MeCrAlYHfSiZr and ceramicson the basis ZrO2, stabilizing Y2O3. [5]Three classes coatings are designed:- single-layer metallic such as MeCrAlY, MeCrAlYHfSiZr;- single-layer micro-laminate composite such as with al-ternation of layers MeCrAlY (MeCrAlYHfSiZr)/MeCrAlY(MeCrAlYHfSiZr + MeO), where MeO-A12O3 or ZrO2 + 6 ... 8 mas. % Y2O3;- two-layer coatings with internal metallic MeCrAlY(MeCrAlYHfSiZr) and external ceramic (ZrO2-Y2O3)layers;- two-layer coatings with internal composite layerMeCrAlY (MeCrAlYHfSiZr) + MeO dispersible-hard-ened or micro-layer types and external ceramic (ZrO2-Y2O3) in layers;- three-layer coatings with internal and intermediate in lay-ers on the basis of alloys MeCrAlY (MeCrAlYHfSiZr)and external ceramic layer on the basis of ceramics(ZrO2-Y2O3);- three-layer coatings with internal metallic MeCrAlYFigure1.Slika 1.General view of electron-beam equipment for deposition of protective coveringsPogled na elektro-lučno postrojenje za nanošenje zaštit-ne prevlake na lopatice turbineMETALURGIJA 41 (2002) 2, 125-128 127N. GRECHANYUK at all.: MODERN ELECTRON-BEAM TECHNOLOGIES OF MELTING ...(MeCrAlYHfSiZr), intermediate composite MeCrAlY(MeCrAlYHfSiZr) + MeO dispersion-hardened or micro-layer types and external ceramic (ZrO2-Y2O3) in layers;The application of protective coatings allows:- to increase durability of the workers and guide vanes in2 ... 5 times;- to increase an operation temperature of gas and efficiencyof the turbine;- to supply(ensure) more complete combustion of fuel;- to use low-cleaned fuel.Productivity exploited in the “GEKONT”-company ofthe industrial electron-beam equipment: 20 ... 50 thousandscoated blades annually, depending on their geometricalsizes. The sizes of coated blades: length up to 400 mm;diameter up to 220 mm.PRODUCING OFMATERIALS FOR THE ELECTRICAL CONTACTSDespite of broad application of an electron-beam tech-nology for deposition of protective coatings of a differentfunctionality, until recently there were no claimed uniquecapabilities of the given technology for obtaining massivematerials, semifinished items, sheet bars, powders, metalpaper and etc.The modern electron-beam aggregates allow to receiveup to 10 ... 15 kg a vapour per hour and consequently quiteactual is obtaining items from the vapour up to 100 kg andmore are powerful.The “GEKONT”-company has designed and patentedthe new industrial technology of obtaining of materials forelectrical contacts, which are not having of clones in theworld [6, 7]. General view of the industrial electron-beaminstallation for obtaining materials for electrical contacthas shown in a Figure 2..The materials (Cu- 8 ... 4 mas. % Mo- 0.05 ... l mas. %Zr- 0.05 ... 0.l mas. % Y), not keeping extremely scarceargentums, tungsten, cadmium oxide, receive by highvelo-city electron-beam evaporating of dilute coppers alloy andmolybdenum and subsequent condensation of a blendedsteam flow in the vacuum on the substrate, heated up to580 ... 600 °C. The previously marked adherent providesmild separation of the condensed sheet from a substrate.The condensed materials represents disk sheet bar a diam-eters up to 1000 mm and depth up to 4 mm, from whichone was carving the working section of a contact and sol-dering on the its basis. The specificity of new technologyis formatting special micro-layer structures with depth ofalternating layers from 0.1 up to 0.4 microns, owing towhat the contacts have higher complex physical-mechani-cal and service properties as contrasted to by used nowmaterials has received powder metallurgical techniques.The main advantages of new materials:- it do not contain argentums and consequently are rathercheap;- its durability surpass in 1.5 ... 3 times compositions anargentums-cadmium oxide;- provide high reliability of actuation of contacts;- its maximum switched current up to 4200 A.The materials are well treated by cutting, extrusion,drilling, are easily soldered by any of known ways of sol-dering with usage standard argentums and non-argentumsof solders.General view of contacts, which has produced by“GEKONT”-company, has shown in the Figure 3..Most effective fields of application of contacts, whichhas produced on the basis of new materials for electricalcontacts:Figure 2.Slika 2.General views of electron-beam installation for obraining composite materials for electrical contactsPogled na elektro-lučno postrojenje za pridobivanje kom-pozitnih materijala za elektrolučne kontakteFigure 3.Slika 3.General view of contacts made with application of com-posite materials for electrical contactsPogled na kontakte prigotovljene s rabljenjem kompo-zitno elektrokontaktnog materijalaMETALURGIJA 41 (2002) 2, 125-128128N. GRECHANYUK at all.: MODERN ELECTRON-BEAM TECHNOLOGIES OF MELTING ...REFERENCES1. S. Schiller, U. Heisig, S. Panzer: Elektronenstrahltechologie, VEBVerlag Technik, Berlin, 1976.2. B. E. Paton, N. P. Trigub, D. A. Trigub, D. A. Kozlititin: Elektrono-lučevaja plavka. Naukova dumka, Kiev 1997., 265 (original in Rus-sian language)3. M. I Grečanjuk, P. O. Špak, I. B. Afanasjev, D. F. Černega: Strukturata vlastivosti švidkorizaljnoi stali R6M5 optimalnoi šljahom ele-ktrono-promenevogo pereplavu promislovih vidhodiv. Materialimeždunarodnoj naučno-tehničeskoj konferencii “Proizvodstvo staliv XXI veke. Prognoz, processi, tehnologii, ekologija”, Kiev-Dnipro-petrovsk, 2000, 380-384 (Original in Ukraine language)4. M. I. Grečanjuk, I. B. Afanasjev, P. O. Špak, V. O. Osokin, M. M.Švedčikov: Sposib vigotovlennja zagotovok dlja instrumentu iz švid-korizaljnoj stali ta pristrij dlja iovo zdijenennja. Patent Ukaini, No37658 A, 2001. (Original in Ukraine language)5. M. I. Grečanjuk, P. P. Kučerenko, V. O. Osokin, I. B. Afanasjev, S.S. Belik, V. O. Akrimov, I. M. Grečanjuk, E. L. Pijuk: Zahisne pokri-tija dlja lopatok gazovih turbin. Patent Ukraini, No 97084126, 2001.(Original in Ukraine language)6. N. I. Grečanjuk, V. O. Osokin: Kompozicionnij materijal na osnovemedi dlja električeskih kontaktov i sposob evo polučenija. PatentUkaini, UA 17204 A, 1997. (Original in Ukraine language)7. M. I. Grečanjuk, V. O. Osokin, I. B. Afanasjev, I. M. Grečanjuk:Kompozicionnij materijal dlja električeskih kontaktov ta sposib iovootrimannja. Patent Ukaini No 3475A, 2000. (Original in Ukrainelanguage)8. M. I. Grečanjuk, M. M. Paščenko, V. O. Osokin, I. B. Afanasjev, I.M. Grečanjuk: Kontaktnij materijal dlja dugogasnih kamer ta sposibjovo otrimannja. Patent Ukraini No 2368A, 2000. (Original inUkraine language)- the electrical transport (contacts used in electric loco-motives, trams, trolley buses, underground trains);- lifts facilities (passenger and goods lifts);- ports and ships cranes and other handling gears;- electric carts of all types;- mining equipment;- industrial and household electrical devices, keeping re-lay assemblies, contactors, single-switches etc.;- welding rods of contact welding machines.The new generation of the industrial electron-beamequipment for producing materials for electrical contactshas designed by the “GEKONT”-company. It allows tomake up to 10 tons of the condensed materials annually,from which one it is possible to produce up to 2.5 millionspieces of contacts.Built in the “GEKONT”-company the new generationof the industrial electron-beam equipment is universal andcan be utilised for obtaining sheets of composite materialswith the unique physical-mechanical charcteristics on thebasis of copper; aluminium, chromium, iron, cobalt, tita-nium, molybdenum and other materials, and also for depo-sition wear-resist and high-hard of coatings on a cuttingtool, title block, etc.Now already designed materials on the basis of cop-per, which one under the physical-mechanical character-istics surpass beryllium bronze. Also has designed the ma-terials on the basis of copper and chromium for electricalcontacts for arc-extinguish chambers, [8] on the basis ofaluminium and boride of zirconium for an aeronauticalengineering and etc.This not full list of different directions of an electron-beam technology indicates its sufficient universality andeconomic feasibility of its application in different branchesof science and engineering.

Suvremene elektrono-lučne tehnologije topljenja i isparavanja materijala u vakuumu, rabljenih u tvrtki “GEKONT”, Ukrajina

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