Previous experience achieved with two of the leading systems,namely the VAIron closed-loop expert system of Siemens VAI MetalsTechnologies and the VAIF blast furnace expert system are describedfor several installations. The advantages of both systems havesince been combined into an advanced, state-of-the-art systemreferred to as VAIron–The Next Generation. This paper outlines thestructure and highlights of this new expert system.

Coke production capacity within AM FCWE is not self sufficient forthe total HM production. PCI was started up in 2004 at Bremen BF2and Eisenhüttenstadt BF5, with a ramp up to 180 kg/thm in one year.A working group defined the BF operating conditions leading to stableand efficient operation at high PCI. At Florange BF3 PCI trials at220 kg/thm were successful. At Dunkerque BF4 and Gent BFA andB, the PCI rate exceeds regularly 210 kg/thm.

During 2006 four chilled blast furnaces were recovered using theoxyfuel lance technology. All recoveries were successful andbrought the blast furnace back to full production within 200 hours.This recovery method has been under constant development since1990 and has now been applied over 25 times. It is considered safer,faster, easier and cleaner than the traditional recovery methods forchilled hearths.

The feasibility of direct thin strip casting of various steel grades forfurther metallic coating has been investigated. The surface evolutionis described for each processing step. Special attention to steelcleanliness and scale formation was given, since local surfaceheterogeneities of grain structure and chemical composition maydisturb the coating process. Low alloyed cast strip can be coatedwith little to none difference to classical coating routes, however,some highly alloyed steel grades require further optimization.

Production of pipes and tubes in Russia reached 7.9 Mt in year2006. The share of welded pipes has raised up to 58% and is expectedto grow further in the future. Russian tube producers are involvedin a steady effort of modernization of equipment andcommission of new facilities with a view to offer larger volumes ofhigher quality products that meet the requirements of internationalstandards.

A new image analyzer, Thixomet®, has been developed with the abilityto create “panoramic” images of material microstructure forinvestigations. Capabilities of the Thixomet image analyzer for materialmicrostructural characterization are demonstrated with examplesof nickel-based superalloys. Practical use of the Thixomet forcontrolling material properties by characterizing their microstructureis demonstrated.

The technology of mono-metals has reached maturity and furthertechnological developments are impeded by some natural limits.Basic resources have been largely investigated and major innovativesteps should not be expected in this area. Further progress in thescience and technology of metallic materials will rather concerncomposite metals, layered composites in particular.