Department of Physical-Metallurgical Problems of Electroslag Technologies

The laboratory of the department is equipped with modern scientific and production equipment and facilities.

The basis of the laboratory is an industrial electroslag remelting furnace of the P-951 type, which allows smelting solid and hollow ingots with a diameter of 110/180/320/390mm and a length of up to 1500mm. The furnace is controlled by a modern unique process control system, which allows smelting ingots from various steels, special alloys and non-ferrous metals. There is a possibility of remelting in a protective atmosphere of inert gases. The furnace is equipped with a fleet of water-cooled molds, both for drawing the ingot and by the filling method. This installation is equipped with a unique tool – a current-supply mold (CSM), which makes it possible to melt non-compact materials (chopping, shavings, liquid metal) and prefabricated consumable electrodes, which allows recycling of expensive steels, alloys and pure metals.

The laboratory also houses an A-550 flux-melting furnace with a fleet of graphite crucibles. The  furnace with a lined crucible, with a mass of accumulated metal up to 550 kg, has a fleet of lined crucibles of a wide range and a tilter for electroslag chill casting.

All metallurgical units are powered by two furnace transformers, each with a capacity of 720 kVA, and have smooth voltage control via thyristor regulators, which allows for flexible adjustment of the electrical parameters of the process and smelting of the highest quality ingots.

For the production of ingots weighing up to 2 kg, the workshop has a laboratory electroslag installation USh-114, which has a water-cooled mold for ingots measuring 50x200mm, and graphite crucibles for working with liquid metal and slags.

– Development of a new generation of fluxes for advanced electroslag technologies to produce structural materials with predetermined properties (2012-2016)

 – Development of electroslag remelting technology to produce modern railway rails with improved weldability (2015-2017)

– The development of scientific substantiation and the creation of a through-technology for the production of modern high-strength steels for welded structures is based on special electrometallurgy and composite electrodes (2017-2021)

– Development of electroslag technologies for controlling the crystallization of modern austenitic heat-resistant steels and alloys (2018-2020)

– Development and creation of a prototype of a modern computerized system for automatic control of the technological process of melting at an electric slag remelting furnace (2019)

– Development of aseptic technologies for the utilization of consumable medical instruments made of high-alloy steels (2020)

– Development of melting, out-of-furnace treatment and electroslag remelting methods for nitrogen martensitic steel (2021)

– Development of theoretical and technological bases for the production of microalloyed boron steels for the needs of power engineering (2021-2023)

– Development of the process technology for the production of ferrovanadium (2022-2023)

– A series of works on the development of technology and production of experimental ingots of nickel alloys and alloyed steels under electroslag melting conditions, including for alloy recycling (2023-2024)

– Study of electroslag and arc slag metallurgical processes to produce Fe-Al-x system alloys with aluminum content greater than 20% (2023-2026)

– Development and implementation in industry of technologies for the production of large ingots, including ESR of high-alloy steels with a minimum level of segregation for the needs of power engineering

– Development of hybrid electrometallurgical technologies and equipment of increased energy efficiency for the production of new steels such as 20Мn-10Al

– Development of carbon-free technologies for the utilization of long products into high-quality billets, ready for processing by forging or rolling

– Development of highly efficient modes of slag treatment, deoxidation and modification of steel in a ladle furnace involving the analysis of large databases and oxidation of the intermediate product

– Development and implementation in industry of technologies for the production of large ingots, including ESR of high-alloy steels with a minimum level of segregation for the needs of power engineering

– Development of hybrid electrometallurgical technologies and equipment of increased energy efficiency for the production of new steels such as 20Мn-10Al

– Development of carbon-free technologies for the utilization of long products into high-quality billets, ready for processing by forging or rolling

– Development of highly efficient modes of slag treatment, deoxidation and modification of steel in a ladle furnace involving the analysis of large databases and oxidation of the intermediate product

– Development and implementation in industry of technologies for the production of large ingots, including ESR of high-alloy steels with a minimum level of segregation for the needs of power engineering

– Development of hybrid electrometallurgical technologies and equipment of increased energy efficiency for the production of new steels such as 20Мn-10Al

– Development of carbon-free technologies for the utilization of long products into high-quality billets, ready for processing by forging or rolling

– Development of highly efficient modes of slag treatment, deoxidation and modification of steel in a ladle furnace involving the analysis of large databases and oxidation of the intermediate product

1. Electroslag remelting of variable cross-section electrodes using a two-circuit scheme / O. Pedchenko, V.L. Petrenko, Yu.V. Kostetskyi, G.O. Polishko, V.A. Zaitsev // Conference on Welding and Related Technologies (WRT 2024, 7-10 October 2024, Yaremche, Ukraine) (1st ed.). – 2025. – London, CRC Press.– P. 25-28 https://doi.org/10.1201/9781003518518-5
2. Aluminothermic reduction of vanadium-containing waste under conditions of electroslag smelting / M.O.  Vdovin, Yu.V. Kostetskyi, Ye.O.  Pedchenko, G.O. Polishko, V.L.  Petrenko, V.A.  Zaitsev // Welding and Related Technologies: Proceedings of the VII-th International Conference on Welding and Related Technologies (WRT 2024, 7-10 October 2024, Yaremche, Ukraine) (1st ed.). –2025. – London, CRC Press.– P. 44-47. https://doi.org/10.1201/9781003518518-9
3. Отримання ферованадію в умовах електрошлакової плавки / Ю.В. Костецький, Є.О. Педченко, М.О. Вдовін, Г.О. Полішко, В.Л. Петренко, В.А. Зайцев // Сучасна електрометалургія. – 2024. – № 4. – C. 11–17. https://doi.org/10.37434/sem2024.04.02
4. Specifics of Creating Joints from Modern Boron-Microalloyed High-Strength Steels Utilizing Laser, Contact Spot, as Well as Argon-Arc Spot Welding Technologies // H. Polishko, Yu. Kostetskyi, V. Kostin, Ye. Pedchenko, A. Bernatskyi, M. Sokolovskyi, Honcharov,  V. Zaitsev // Metallofiz. Noveishie Tekhnol. – 2024. –  V. 46. – No.9. – P. 893-914. https://doi.org/10.15407/mfint.46.09.0893
5. Energy and Environmental Savings by and for Steel Lightweight / Ganna Stovpchenko, Lev Medovar, Danylo Stepanenko, Zhouhua Jiang, Yanwu Dong, Yuxiao Liu // ISIJ International. – 2024. – V. 64. – No.1. –  P. 165-173. https://doi.org/10.2355/isijinternational.ISIJINT-2023-230
6. Electroslag welding and related technologies: Chapter 3 / L. Medovar, G. Stovpchenko // Welding of Metallic Materials: Methods, Metallurgy, and Performance. – Elsevier, 2023. – P. 73 – 111. https://doi.org/10.1016/B978-0-323-90552-7.00005-5
7. Дослідження якості металу легованої алюмінієм і хромом високомарганцевої сталі після електрошлакового переплаву / В.А. Зайцев, Ю.В. Костецький, Г.О. Полішко, В.А. Костін, В.Л. Петренко, Є.О. Педченко // Сучасна електрометалургія. – 2023. – № 4. – C. 1-11.  https://doi.org/10.37434/sem2023.04
8. Комп’ютерне моделювання процесу сифонного відливання крупного сталевого циліндричного зливка / Ю.В.Костецький, Є.О. Волченков, Г.П. Стовпченко, Є.В. Тацький // Метал та лиття України. – 2023. – vol.31. – №1(331). – С.19-27.  https://doi.org/10.15407/steelcast2023.01.019
9. Features and Restrictions of Electroslag Remelting with Silica-Bearing Slags for Lightweight High Manganese Steel / Medovar, G. Stovpchenko, L. Lisova, Zh. Jiang, Y. Dong,  C. Kang // Steel research. – 2023. – V. 94. – No.11. – 2300161. https://doi.org/10.1002/srin.202300161
10. Electroslag Hollow Ingots for Nuclear and Petrochemical Pressure Vessels and Pipes / L. Medovar, G. Stovpchenko, A. Sybir, J. Gao, L. Ren, D. Kolomiets // Metals. – 2023. – 13(7). – 1290. https://doi.org/10.3390/met13071290
11. Thermodynamic and Physical Properties of CaF2–(Al2O3–TiO2–MgO) System Slags for Electroslag Remelting of Inconel 18 Alloy / G.P. Stovpchenko, L.O. Lisova, L.B. Medovar, I.O. Goncharov // Materials Science. – 2023. – V. 58. – No. 4. – P. 494 – 504. https://doi.org/10.1007/s11003-023-00690-6
12. Формування зони з’єднання шарів в композитному зливку, наплавленому електрошлаковим процесом з рідким металом, для роторів енергетичних турбін / Г.О. Полішко, Г.П. Стовпченко, В.А. Костін, А.Ю. Тунік, Л.О. Лісова, Л.Б. Медовар // Сучасна електрометалургія.– – №1. – С. 24-33. https://doi.org/10.37434/sem2022.01.03
13. Effect of deformation of molten metal droplets on their motion and heating in liquid slag / I. Krivtsun, V. Sydorets, G. Stovpchenko, G. Polishko, A. Sybir, L. Medovar // The Paton Welding Journal. – 2022. – 6. – p.41-48. https://doi.org/10.37434/tpwj2022.06.06
14. Рециклінг відпрацьованого некомпактного інструменту зі швидкоріжучої сталі способом електрошлакового переплаву / Є.О. Педченко, Ю.В. Костецький, В.Л. Петренко, Л.Б. Медовар // Сучасна електрометалургія. – 2022. – №3. – С.23-28. https://doi.org/10.37434/sem03.03
15. Оцінка економічної ефективності електрошлакових технологій з витратним електродом і переробкою рідкого металу / Г.П. Стовпченко, Г.О. Полішко, Д.В. Коломієць, Л.Б. Медовар // Сучасна електрометалургія. – – №4. – C. 20-26. https://doi.org/10.37434/sem2022.04.04
16. Electroslag remelting as a method of recycling non-compact high-speed steel tools / Y. Pedchenko , L. Medovar , Yu. Kostetsky // Proceedings 31st International Conference on Metallurgy and Materials METAL 2022, Brno, Czech Republic, EU, May 18-19, 2022. – P. 142-148. https://doi.org/10.37904/metal.2022.4455
17. About Place of Desulphurization at ESR / L. Medovar, G. Stovpchenko, A. Sybir // Proceedings of the Liquid Metal Processing & Casting Conference 2022 Held September 18–21, 2022 in Philadelphia, Pennsylvania, USA – P.17-18.
18. Predictive models for molten slags viscosity and electrical conductivity based on directed chemical bonds concept / G. Stovpchenko, D. Togobitskaya, L. Lisova, D. Stepanenko, L. Medovar // Ironmaking & Steelmaking – 2022. – V. 49. –   6. – P.572-580. https://doi.org/10.1080/03019233.2022.2026043
19. Improvement of the Mechanical Characteristics, Hydrogen Crack Resistance and Durability of Turbine Rotor Steels Welded Joints / A. I. Balitskii, V. V. Dmytryk, L. M. Ivaskevich, O. A. Balitskii, A. V. Glushko, L. B. Medovar, K. F. Abramek, G. P. Stovpchenko, J. J. Eliasz, M. A. Krolikowski // Energies. – 2022. – No. 15. – 6006. https://doi.org/10.3390/en15166006
20. Електрохімічні процеси при електрошлаковому переплаві (огляд) / Стовпченко Г.П., Кадильникова А.В. // Сучасна електрометалургія. – 2021. – № 1. – C. 9-16. https://doi.org/10.3743/sem01.01
21. Experimental study of the influence of vibration on the microstructure of the weld of a pipe billet / V.F. Balakin, T.M. Kadylnykova, S.V. Savkyn, A.V. Kadylnykova // Modern engineering and innovative technologies. – 2021. – No 16. – Part 1. – P. 94-104. https://doi.org/10.30890/2567-5273.2021-16-01-001
22. Additive manufacturing of massive parts by the ESR and ESR hybrid processes / L. Medovar, G. Stovpchenko, G. Polishko, A. Sybir, D. Kolomiets // Intern. Conf. on Joining Welding Additive Manufacturing JWAM 2020, 29–31 January 2020, Tel Aviv, Israel.
23. Сучасні електрошлакові технології переплаву електроду та переробка рідкого металу (огляд) / Л.Б. Медовар, Г.О. Полішко, В.Л. Петренко, Г.П. Стовпченко // Теорія і практика металургії. – 2020. – №2. – с. 17-25
24. Порівняння умов масообміну при електрошлакових процесах з витратним електродом і з рідким металом / Л.Б. Медовар, Г.П. Стовпченко, А.В. Сибір, Г.О.Полішко, В.Л.Петренко, Я.В. Гусєв // Успехи физики металлов. №4. 2020. с 481-500. https://doi.org/10.15407/ufm.21.01.001
25. Термодинаміка взаємодії та фізичні властивості шлаків 30CaF2/30CaO/30Al2O3 (SiO2, MgO) при електрошлаковому переплаві / Л.О. Лісова, Г.П. Стовпченко, І.О. Гончаров, Я.В. Гусєв, Л.Б. Медовар // Сучасна електрометалургія. – 2020. – №1.– C. 8-13. https://doi.org/10.37434/sem2020.01.01
26. Сучасні датчики рівня рідкого металу для ЕШП в короткому кристалізаторі / В.Л. Петренко, Г.П. Стовпченко, В.А. Ткаченко, Д.В. Коломієць, Л.Б. Медовар // Сучасна електрометалургія. – 2020. – №2. – C. 10–17. https://doi.org/10.37434/sem2020.02.02
27. Дослідження технологічності та ефективності нового шлаку для електрошлакового переплаву / Г.П. Стовпченко, С.В. Давидченко, Л.О. Лісова, Я.В. Гусєв, Л.Б. Медовар // Сучасна електрометалургія, – 2020. – №3. – C. 11–17. https://doi.org/10.37434/sem2020.03.01
28. О применении ЭШП для рециклинга отработанных прокатных валков и роликов МНЛЗ / Л.Б. Медовар, А.В. Сибирь, А.П. Стовпченко, Е.А. Педченко, В.А. Зайцев // Металургійна та гірничорудна промисловість. – 2020. – № 4. – C. 40-51
29. Towards Prediction of the ESR Ingot Composition / G. Stovpchenko, L. Medovar, L. Lisova, I. Gusiev, A. Sybir // 2019 Liquid Metal Processing & Casting Conference (LMPC-2019), September 8-11, 2019, Birmingham, UK.
30. Ways of increasing the energy efficiency of electric arc furnaces/ S.N. Timoshenko, A.P. Stovpchenko, Yu.V. Kostetsky, M.V. Gubinsky // Electrometallurgy Today (Sovremennaya Elektrometallurgiya). – 2019. – №1. – P.46-56. https://doi.org/10.15407/sem2019.01.06
31. Self-disintegrating slag for the electroslag remelting of hollow ingot / G. Stovpchenko, L. Medovar, G. Polishko, I. Goncharov, L. Lisova // Ironmaking & Steelmaking. – 2019. – V. 46. – No. 8. – P. 782-788. https://doi.org/10.1080/03019233.2018.1428418
32. Physicochemical comparison of electroslag remelting with consumable electrode and electroslag refining with liquid metal / Ganna Polishko, Ganna Stovpchenko, Lev Medovar, Lyudmila Kamkina // Ironmaking & Steelmaking. 2019. – V. 46. – No. 8. – P.789-793. https://doi.org/1080/03019233.2018.1428419
33. Innovative solutions for manufacturing high-quality rails in Ukraine /L. Medovar, G. Stovpchenko, G. Polishko, A. Sybir, D. Kolomiets, Yu. Kostetsky // Science and Innovation. – 2019. – 15(6). – P. 35–45. https://doi.org/10.15407/scine15.06.035
34. Energy efficient solutions for the EAF steelmaking / S.N. Timoshenko, A.P. Stovpchenko, Yu. V. Kostetski, M.V. Gubinski // Journal of Achievements in Materials and Manufacturing Engineering. – 2018. –V. 88. – No 1. – P. 18-24. https://doi.org/10.5604/01.3001.0012.5867
35. Physico-chemical properties of the ESR slags system CaF₂-Al₂O₃-(MgO, TiO₂) / G.P. Stovpchenko, L.O. Lisova, I.O. Goncharov, I.V. Gusiev, // Journal of Achievements in Materials and Manufacturing Engineering. – 2018. – V. 89. – No. 2. – P. 64-72. https://doi.org/10.5604/01.3001.0012.7110
36. Refining of iron-carbon melts from copper by the method of sulphurizing / Yu.V. Kostetsky //Electrometallurgy Today (Sovremennaya Elektrometallurgiya). – 2017. – №4(129). – С. 28-36. https://doi.org/10.15407/sem2017.04.04
37. Modeling of continuous casting by combined process of MCCB + ESR / L.B. Medovar, A.P. Stovpchenko, A.V. Sibir, Ye.A. Volchenkov, E.A. Pedchenko, A.A. Polishko, V.A. Lebed // Electrometallurgy Today (Sovremennaya Elektrometallurgiya). – 2017. – №4(129). – P. 3-4. https://doi.org/10.15407/sem2017.04.01
38. Conception of microplants for producing premium quality products by using electroslag remelting / L.B. Medovar, A.P. Stovpchenko, Yu.V. Kostetsky // Electrometallurgy Today (Sovremennaya Elektrometallurgiya). – 2017. – №3(129). – P. 3-8. https://doi.org/10.15407/sem2017.03.01