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Institute of Metal Science, Equipment and Technologies “Acad. A. Balevski”

Institute of Metal Science, Equipment and Technologies “Acad. A. Balevski”

with Hydro- and Aerodynamics Centrewith Hydro- and Aerodynamics Centre

2 Институт по металознание 2008 година

BULGARIAN ACADEMY OF SCIENCES

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• InternationalTrophyforTechnology-1981;• EuropeAwardforMostCelebratedTechnologyoftheFrenchChamberofCommerce-1983,1987;

• EncouragingAwardforEuropeanScienceDevelopmentofthe“Koerber”Foundation-1985;

• PrizeoftheWorldIntellectualPropertyOrganization-1986;

• DieselGoldenMedaloftheGermanInstituteforInventions-1990;

• AmericaAward1990-1991;• InnovationAwardtogetherwithM&T2001Ltd.CanadaattheAutomechanika,Frankfurt,Germany-2004;

• Varna2003,2007,2010Awards;• Significantnumberofmedalsatinternationaltechnicalandinnovationexhibitions.

The Institutehasbeencertifiedaccording toNATOand EU requirements to access to classifiedinformationonlevel“Secret”.

The Institute is one of the leading organizations inBulgariainthefieldofnationalsecurityanddefense.Considerable share of the Institute’s activities isrelated to investigation, design and production ofhigh-techdefenseequipmentandsystems,includingdevelopment of high-tech anti-terrorists systemsaccording to the NATO’s conceptions for defenseagainstterrorism.

MachinesandtechnologiesdevelopedintheInstituteareinoperationatpresentinGermany,France,Italy,Poland,Austria,Hungary,Romania,Russia,China,India,Canada,USA,Sweden,CzhechRepublic,Slovenia,Denmark,etc.Thetechnologyandcounter-pressurecastingmachinesfindwideapplicationintheautomotiveindustryandparticularlyinproductionofautomobilewheels.

The Institute’s Quality Assurance System has been certified according to ISO 9001:2008 and NATO AQAP-2110.

The Institute carries out fundamental research, applied studies and innovations in the field of:• metal science and heat treatment;• casting,crystallization,structureandcharacteristicsofmetalsandalloys;

• plasticityandfractureofmaterials:• thestructuralpropertiesofthemetalofnuclearreactors

pressure vessels and other important equipment of nuclear and thermal power plants and equipment in other industrial branches; • developmentofmethodsforassessmentoftherest-life

time of industrial equipment and constructions; • developmentofsteelusedinheavy-loadedmetalstructures

(incl. gas and oil pipelines);• interactionofgaseswithmetalsandnon-metalic

materials;• weldingprocesses:

• examinationandtestingoftheweldabilityofdifferentmaterials;• examinationandtestingofweldingmaterialsandwelded

joints;• developmentandapprovalofweldingtechnologiesand

procedures and equipment for special welding methods;• simulationandnumericalmodelingofweldingprocesses;

• developmentofnewhigh-nitrogensteels;• ceramicandcompositematerials;• electro-thermicandmagneto-hydrodynamicprocesses;• ecologicallyfreehigh-techprocesses;• machinesandinstrumentalequipmentforproductionofnewmaterialsandarticles;

• shiphydrodynamics,aerodynamics,watertransport,oceancoastalengineering,seaandrivercrisesanddisasters,environmentalprotection,renewableenergysources;

• high-techproductsandsystemsfordefenseandsecurity:• criticalinfrastructureprotectionsystems(incl.Border

security);• developmentofnewcompositionsofarmormaterialsand

new original constructions for protection of vehicles (light and heavyarmoredmachines,helicopters,etc.)againstvariousammunitions;• developmentofanti-diversionandanti-terroristdevices,

including devices for personal protection;• designandmanufacturingofsensorsanddevicesagainst

invasionsonland,seaandairforthenationalsecuritysystemsofEU-andNATO-membercountries,etc.

AWARDS

INSTITUTE OF METAL SCIENCE, EQUIPMENT AND TECHNOLOGIES “ACAD. A. BALEvSkI” WITH HYDRO- AND AERODYNAMICS CENTRE

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Microcrystalline blank of rapidly solidified strips and extruded powders

Structure of high damping alloy microcrystalline strip

Crystallization calorimetric thermograms of amorphous alloys Cu

100-xZr

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Bulk amorphous metallic alloys obtained via “suction casting method”

Institute of Metal Science, Equipment and Technologies “Acad. A. Balevski” with HydroAerodynamics Centre • 2010

In the Field of Metal Science

Research and Development

Fundamentalresearchinthefieldofmetalscienceofnewamor-phous,micro-crystallineandnano-crystallinemetalalloys;Examinationofphasetransformationsandtheirthermodynamicsandkinetics;Developmentofsurfacethinlayersandnewcompositeandnano-structurematerials;Creatingandapplicationofmathematicalmodelsofphasetransfor-mationsinopenthermo-dynamicalsystemsbymeansofinterdisci-plinaryapproach;Measurmentsofgasdiffusioninmetalsandalloys.Thegasdiffusinmodelingandtheconcomitantprocesses;Developmentofmethodsofrecoveryofusefulproductsfrommetallurgicalwastes.

Research Achievements•Amorphousandmicro-crystallinemetalsandalloys;•Environmentalfriendlyandenergysavingtechnologiesandbio-conformablenewmaterials.

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Thermo-analytical complex Mass-spectrometer with vacuum programmable furnace

Thermo-gravimetric analysis (TGA) system

Computerized apparatus for internal friction studies


Research Results Implemented

•Amorphousandnano-crystallinemetalalloys,nano-fibersandnano-materials;•Investigationonthebehavioroflow-alloyFepowderscoatedwithnano-sizedhydrocarbonlayersinthepro-cessoftheirsintering,aswellasobtainingoflow-alloyFe-powderscoatedwithnano-sizedhydrocarbonlayers;•Alumothermal(micro-and/ornano-)compositesaboundinginAlN;•CompositematerialsbasedonAl-Si-Zralloysintendedforbiomedicalapplication;•EnvironmentalfriendlyandenergysavingtechnologiesforrealizationofTenifer-processesforprotectivecoat-ings;•Investigationsonthecompositionandstructureofmetallurgicalslagafterthermalandchemicalinfluences.

Research Methods and Apparatuses

•Thermo-analyticalsystem“PerkinElmer”;•Mass-spectrometerMI12018;•High-vacuumdeviceB30.2;•Thermo-magneticscale“SETARAM”;•Differentialthermo-analyzer“SETARAM”;•OpticalmetallographicmicroscopeReichertMeF2andNeofot2;•Computerizeddevicefortestingofinternalfriction;•ComputerizeddilatometerNetch;•Computerizeddevicefortestingonlow-cyclefatigue.

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Институт по металознание 2008 година

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Installation for pressure casting IFP 001

1 - cover; 2 - hole; 3 - control desk; 4 - mould;

5 - autoclave; 6 - induction furnace (pressure up to 5 MPa;

capacity - 10 kg)


In the Field of Technologies and Equipment for Special Steels and Alloys


•Engineeringofnewclasseshigh-nitrogenconstructional,tool,stainlessandwear-resistantsteels,aswellassteelswithhighmechanicalandoperatingcharacteristicsunderhighpressure;•Fundamentalresearchonthesolubilityofgasesinmeltsofmetalsandalloysunderpressureofupto50MPa;•Investigationofcrystallization,mass-andheat-exchangeprocessesontheboudarysurfacesteel-solidphase;•Applicationofnano-modifiersforimprovingthestructureofmetalsandalloys;•Obtainingofcompoundsofmetalswithnon-metalsandgases-hydrides,nitrides,borides,etc.;•Designandmanufacturingofaggregatesforproductionofsteelsandalloysunderpressure.

Research Achievements

•Mechanicsofrealfluids;•Mathematicalmodelingofheat-andmass-transferinsystemscasting-mold;•Methodsandprogramsforlocalizationandpredictionofdefectsduringformationofcastings;•Approaches,algorithmsandcomputerprogramsformonitoring,optimizationandcontrolofcastingtechnologies.

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Induction furnace under pressure of 5 MPa for producing of 10 kg steel ingots

Construction of reservoirs for petroleum products using alloys developed by the Institute



•Flowofmeltinareaswithcomplexgeometryunderconditionsoflaminarandturbulentflows;•Fluid-andgas-dynamicsofmachinesforcastingundercounter-pressureandlowpressure;•Ventilationinthemouldcavity;•Thermalandconcentrationconvection;•Movementofmeltininter-dendritespaces;•Solvingof3-Dproblemofheat-transferduringfillingofcastingsystembymeltandduringthecrystallizationprocess;•Crystalnucleusformation,phaseevolutionandphasetransformations;•Transferofheatunderconditionsofcontact,radiationandconvectionheat-transfer;•Modelingofcontactphenomenaduringfillingofmouldcavitieswithcomplexgeometrybyrealfluids,crystallizationandcooling;•Phasetransformationsunderconditionsofreactivediffusion;•Modelingofprocessesofinitiation,growthanddistributionofgaspocketsduringcrystallization;•Methodsandnumericalalgorithmsformodelingofstress-deformablestateofthesystemcasting-mould;•Calculatingofresidualstressincastingandform;•Methodsandalgorithmsforsolvingofinversetechnologicalproblemsandproblemsforcastingparametersidentification;•Methodsforcontrolofthemouldcavityfilling;•Approachesforinteractiveandautomaticoptimizationofcastingtechnologies.


•Installationfornon-cruciblemelting;•High-temperatureinductionfurnaceoperatingundervacuumandpressureofupto50MPa(uniqueinBulgariaandintheworld)forinvestigationontheprocessofobtainingofsteelsandalloyswithhighphysicalandmechanicalpropertiesintendedforspecialoperationconditions;•Inductionfurnace(designedandmanufacturedintheresearchdepartment)forproductionof10-kgingotsofspecialsteels.

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Sheme of Gas Counter Pressure Casting Machine

Machine for Casting under High Pressure and Aluminum Castings Produced under High Pressure


In the Field of Technologies and Equipment for Casting of Metals and Alloys


•Newrelationshipsconnectedtogas-dynamics,hydro-dynamicsandheat-exchangeprocessedduringsurfaceandvolumeformationofAl-alloycastingsundertheconditionsofgascounter-pressurecastingprocess;•MathematicalmodelsdescribinginfluenceofsometechnologicalparametersonthestructurehomogeneityandmechanicalpropertiesofAl-alloycastingsundertheconditionsofgascounter-pressurecastingprocess;•Determinationoftheinfluenceofconvectiveheat-transferbetweentheliquidmetalinthemouldandthepotonthequalityofaluminumalloyscastings;provingthenecessityofpreservationoftheheat-transferoritsinitiationatminimumthermallossandrapidrestorationofthesystem’initialstate;•Discoveringofnewcapabilitiesofthemethodforcastingundergascounter-pressurethroughcontrolledprocessesoffillingofcasting’thinsectionsusingdif-ferentialalterationofpressureinthemould;•Processesofcastingandcrystallizationofbig-sizecastingsmadeofhigh-strengthaluminumalloyswithwidecrystallizationrangeatcastingundergascounter-pressureandoptimizationofconditionsforobtainingofqualityproducts;•Structuresandcharacteristicsofgreatnumberofcastinganddeformablealuminumalloyscrystallizedunderhighpressureatsqueezecastingprocess;


•Investigationandfurtherdevelopmentofthecre-atedintheInstituteandworld-recognizedwidespreadMethodforcastingundergascounter-pressure;•Investigationontheprocessofsqueezecastingofmetalsandalloysanditsapplicationforobtainingofcompositematerialswhichimprovethealuminumcast-ingscharacteristics;•Investigationanddevelopmentofprocessesofcast-ingunderlowandhighpressure,centrifugalanddie-castinginmetallicandcombinedmoulds;•Developmentofnewmethodsandequipmentforob-servationandcontrolofcastingprocesses;•CreatingofnewAl-andFe-basedalloysandinvesti-gationsoftheirproperties;•DevelopmentoftechnologiesforobtainingofqualityproductsofAl-andFe-alloysandcompositeswithhighmechanicalandoperationalcharacteristics;•Developmentandinvestigationofthepropertiesofhigh-strengthandcorrosion-resistantnitrogenalloyedsteels.

Simulation of the Crystallization Processes in Aluminum Castings Obtained by the Casting with Gas

Counter-Pressure Method

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Automobile Supports and Pistons for Heavy-loaded Diesel Motors Reinforced with Composite Materials

Castings Made of Corrosion-resistant, Wear-resistant and Cavity-resistant Steels and Multilayered Tubes Obtained by Centrifugal Casting

Aluminum Alloy Reinforced with Ceramic Fibers and Metal Frame Structures


•Provingofpossibilityforobtainingandstudyingofcompositematerialsbasedonaluminumalloysrein-forcedwithceramicfibersand/orporousmetalandceramicstructuresatsqueezecastingprocess;•Mathematicalmodelsofcentrifugalcastingprocessofmono-andpoly-metalcastingsofsteel,ironandheavynon-ferrousmetalsandcompositematerials.


•Technologiesforgascastingundergascounter-pres-sureofheavy-loadeddetailsforapplicationinautomo-tiveindustry(wheelsformotorcarsandtrucks,elementsofcarsuspension,bodydetails,etc.),hydraulicsandpneumatics(covers,bodies),defenseindustry(wheelsforheavytransportvehicles);•Machinesandcastingcomplexesforcastingundergascounter-pressureofaluminumalloysparts;•Industrialapplicationoftechnologiesforproductionofcastingsforkeyaluminumalloypartsbysqueezecast-ing,includingfullyorlocallyreinforcedwithcompositematerials,forautomotiveindustry(pistonsforheavy-loadeddieselandracingcarmotors,supports,etc.),electronics,defenseindustry,etc.;•Technologiesandequipmentforcastingofkeyalumi-numalloypartsinpermanentmouldsandunderpres-sure;

•Industrialapplicationoftechnologiesforproductionofkeypartsandconstructionsofalloyedsteelsforauto-motive,woodworking,paper-andchemicalindustries,operatinginextremeconditionsofcorrosivemedium,intensivewearingandcavitations;•Technologicalprocessforcentrifugalcastingwithverticalaxisofbimetalcastingsforthemetallurgicalindustry.


•Specializedmachinesforcastingundergascounter-pressure;•Pressesfordirectandindirectsqueezecasting;•Machinesforcastingunderhighpressure;•Machinesfordie-casting;•Furnacesforpreciseheattreatmentofaluminumalloycastings;•Apparatusesandequipmentfortechnologicalpro-cessescontrol.

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In the Field of Technologies and Equipment for Non-metal Materials


•Developmentofcompositionsofceramics,glass,petrurgical,compositeandfixingmaterials,coatingsandproductsmadeofthem,technologiesandequipmentforproductionofsuchmaterials;•Developmentsinthefieldofhigh-temperatureprocessesandsystemsduringsynthesizingoftheabovematerials,investigationsoftheirphysical-chemicalandmechanicalproperties.


•Newclassesofglassesandfireproofmaterialsforcastingindus-try,petrurgicalproductswithhighwear-andchemicalresistance,superconductiveceramics,highwear-resistantcoatings;•Ballisticcorundumceramicsandmacro-disperseprotectionmod-ulesagainsthigh-energykineticinfluencesandothermaterialsforprotectionplateswithvariousapplications.

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Legend:

• lightfilters[1];• lightfilters[2]withhighperviousnessinthe

visible and infra-red region;• uninterruptedtapeoffoam-glass[3];• materialwithphlogopitestructure[4];• pipesofcastbasalt[5];• melted-castedwhitestoneonpyroxenebase[6];

• [8],quartzglass-ceramics-nozzles[9],productsofsiliconcarbide[10];

• galvanizationofsteelparts[11];• diamondnano-particles[12];• ballisticcorundumceramics[13],[14],[15],[16]andboroncarbideceramics[17];

• dispersedmodules[18]basedonballisticcorundum elements.



•Newclassofseleniumglasses,investigationsanddeterminationofglass-formationintervalsofnumerousdouble,tripleandquadruplesystems.Studyoftheirstructureanddrawingupofphasediagrams,synthesiz-ingoflightfilterswithhighperviousnessinthevisibleandinfra-redregion;•Technologyforproducingofmachineworkablegas-proofmaterialwithphlogopitestructureusedformanu-facturingofhigh-temperatureinsulatorsandgaskets;•Pipeswithdiameter80-20mmandwallthickness10-5mm,turncocksandmixersforcorrosivefluidsbygascounter-pressurecastingofpetrurgicalmelts;composi-tionsofpetrurgicalmaterialsfromwater-dispersecolloidsystemsforcastingofhollowpartsandotherpartswithcomplexconfiguration;•Compositionsandtechnologiesformanufacturingoffireproofmaterialsandproductsformeltingandconvey-anceofmeltsofferrousandnon-ferrousmetals;•Ballisticcorundumceramicsandmacro-dispersepro-tectionmodulesbasedonelementswithvariousshapesforprotectionagainsthigh-energykineticinfluences.


•Furnaces-electric-resistancefurnacesanddrierswithmetalheaters,electricalfurnaceswithnon-metalheat-ers;arcandinductionelectricalfurnaces;•Equipmentforgrinding(mills);•Pressesforformingandmeasuringofphysical-me-chanicalparameters;•Microscopesoperatingwithpolarizedandreflectedlightandelectronicmicroscopes;•X-rayapparatusesforphaseandstructuralanalysis;•Microsondes;•Dilatometers;•Derivategraphs;•Spectrographs;•Devicesformeasuringandcontroloftemperature,includingthermo-elements,opticalpyrometersandceramicpyroscopes;•Technicalandanalyticalbalances;•Supersoundapparatusesformeasuringofsoundtransitionvelocity;•Devicesformeasuringofwearresistance;•Devicesformeasuringofhardness;•Devicesformeasuringofgaspressure;•Specificdevicesforchemicalandsilicateanalysis.

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Delivered security and defence products and systems Harbour Protection System


In the Field of National Security - Technologies and Systems for Protection


In the Field of Critical Infrastructure:•Determinationofstructuralcharacteristicsofthemetalofreactorpressurevesselof“Kozloduy”NuclearPowerPlant(NPP)andimportantequipmentofNPPandotherinstallationsinvariousindustrialbranches;•Determinationontherest-lifetimeofimportantequip-mentofNPPandotherpowerplantsanddevelopmentofprogramsandrecommendationsforextensionoftheirservicelife.

In the Field of Defense:•Creatingandimprovementoffusesystemsincorporat-ingsensorsbasedonvariousphysicalprincipleswhoseoperationmodes(activation,self-neutralization,self-destruction)arepreprogrammedorremotelycontrolled;•Developmentoffusesystemshardwareandsoftwareforprovidingmaximumprobabilityoftargetdetectionandidentification,maximumsafetyandreliabilityofoperation;•Improvementoftheexplosivechargeefficiencyusingtheeffectofexplosiveformedprojectileswhichprovidemaximumpiercingabilityandinflictheavydamagesonthetarget;•Improvementofcommunicationbetweencontrolunitsandexecutivedevicesforminimizingprobabilityofwrongactivation;•Developmentofcamouflagecoatingsandjammingdevicesprovidingindetectabilityofminesbytheenemy;


•Complexinvestigationsofthestructuralpropertiesofthemetalofnuclearreactorspressurevesselsandoth-erimportantequipmentofnuclearandthermalpowerplantsandequipmentinotherindustrialbranches;•Investigationsanddevelopmentofmethodsforas-sessmentoftherest-lifetimeofindustrialequipmentandconstructions;•Investigationsanddevelopmentofhigh-techproductsandsystemsforprotectionagainstinvasionbysea,landandair;•Investigationsanddevelopmentofhigh-techproductsandsystemsforprotectionandcounter-actionagainstterroristactions;•Investigationsanddevelopmentofhigh-techproductsandsystemsforprovidingsecurityofstateborderandcriticalinfrastructures.

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System for automatic control of the stressed state of reinforced-concrete protective shell of Units 5 and 6 of the NPP “Kozloduy”

Highway Gas pipeline “Russia - Bulgaria - South”, built by Low-alloyed nitrogen containing construction steels

of the family SAF of the Institute


•Developmentofnewcompositionsofarmormaterialsandneworiginalconstructionsforprotectionofvehicles•lightandheavyarmoredmachines,helicopters,etc.,againstvariousammunitions;•Developmentofanti-diversionandanti-terroristde-vices,includingdevicesforpersonalprotection.


InthefieldofsecurityofCriticalInfrastructure:•Methods,programs,expertreports,technicalre-quirements,etc.,forsurveillancethesafetyofnuclearreactorstype“WWER”.ParticipationinjointresearchprojectsoftheInternationalAtomicEnergyAgency,EuropeanAtomicEnergyCommunity,5thEUFrameworkProgramandseveralbilateralprojectsontheWWERreactorssafety;•Devicesformeasurementofstructuralcharacteristicsofthemetalelementsof“Kozloduy”NPPequipment;establishingofLaboratoryformechanicaltestsandmetallographicexaminationsofirradiatedsurveillancespecimensontheterritoryof“Kozloduy”NPP;•Technologiesandequipmentfordeactivation,trans-portationandstorageofirradiatedmaterials;•DesignandmanufacturingofelementsofNPPequip-ment.InthefieldofDefense:•Familiesofanti-invasionmines;•Familiesofseamines;•Familyofbottommines;

•Familiesofmarineexplosivedevices;•Familyofmagnetic(“Limpet”)mines;•Familyofunderwatergrenades;•Familyofsonars;•Familiesofanti-tankandanti-transportvehiclemines;•Familiesoffusesforexistinglandmines;•Familyofanti-helicoptermines;•Familyofhandgrenades;•Systemsforprovidingsecurityofstatebordersandothersites;•Armorsforprotectionoftransportvehicles;•Meansforpersonalprotectionofarmyandpoliceof-ficers.Thedepartmentisinvolvedinseveralinternationalde-fenseprojects:•NATOProgramforprotectionofhelicoptersagainstRPGs(theInstituteisleadingorganization);•NATOProgramforharbourprotectionagainstterroristactions;•NATOProgramfordevelopmentofanti-personnelminesalternative(theInstituteistheleadingorganiza-tionforBulgaria);•Severalbilateralprojectsonimprovingprotectionofarmoredvehiclesagainstkineticprojectilesandshapecharges.Mostofproductsandsystemsfordefenseandsecurityhavenoanalogueintheworld.Theirefficiencyhasbeenprovenbynumerousofcontractsforcommercialrealiza-tioninmorethan26countries,includingleadingNATOmembercountries.

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Facilities for preparation of prototypes

Metal processing center


In the Field of Deformation Technologies for Metals and Alloys


•Materialsunderintensiveplasticdeformations(equi-channelangularextrusion);•Improvementoftheelasto-extrusionmethodforreal-izationofsuperhighdegreesofdeformation;•Mathematicalmodelsoftheplasticformingprocess-es;•Methodsforusingsimilarityparametersforsolvingproblemsatplasticformingofmetalsandalloys;•Newcriterionforplasticflowwhichisapplicableformaterialswithconventionalandsuperfine-grainedstructure;•Physicalmodelsoftheplasticflowprocessformetalmaterialswithmicro-andnano-crystallinestructure;•Mathematicalcriteriafordeterminationthedependencyofplasticpropertiesofmicrocrystallinematerialsontheirgrainsizestructure.


•Investigationsoftheinfluenceofdeformationprocessonthephaseformationandcharacteristicsofmetalmaterials;•Investigationsofmaterials’behaviorundervariousdeformationconditions;•Studiesofthedeformationcompactingofalloyswithmicro-andnano-structurewiththepurposeofobtainingproductswithrealdimensionsatmaximumpreservationoftheinitialfine-grainedstructure;•Developmentofnewtechnologiesforplasticformingofmetalsandalloysandforobtainingofproductsfromnon-compactinitialmaterials(powders).

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Recovered surveillance specimen for three-point impact bending

AES spectra of rapidly crystallized Al-Si strip before (а) and after (b) Ar ions atomization

AES depth profile of Al-Si rapidly crystallized strip

Nucleation of sigma-phase in Cr-Mn steel

Microstructure of rapidly crystallized Al-Si strip - TMS image



•Technologiesforcompactingofmetalmaterialswithsuperfine-grainedstructure;•Deformationtechnologyforobtainingofcompos-itematerialswithmicrocrystallinestructurebasedofhigh-strengthaluminumalloyswithadditionofdiamondcomponentandTiC;•Technologyformultistageextrusionforobtainingofproductswithoneormorelongitudinalopeningswithcontrollabledimensionsandshapes-nozzlesforgasflamewelding;•Technologyforobtainingofbimetallicmaterialsthroughdeformation.


•Plastometerenablingtestingonone-axisdeformationofsamplesatcontrollableconditionsofdeformationandheatinginsaltbath;•Standformultipurposedeformationofmetalsandalloysbyapplyingvibrationsduringthedeformationprocess;•Specializedpressforrealizationofmultistageextrusionprocesses.

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Industrial Security Systems


In the Field of Specialized Sensor Devices


•Researchanddevelopmentorientedtowardscreatingofup-to-datehigh-techsensorsforapplicationinindustry,transport,energy,ecologyandsecurity;•Solvingofimportanttechnicalproblemsandcreatingofnewequipmentforscientificinvestigations,drawingupofdesignandtechnicaldocumentation,manufacturingandtestingofmodelsandprototypesofsensors;•Designandmanufacturingofsensorsanddevicesforincorporatinginsystemsagainstinvasionsonland,seaandairfornationalsecurityofEU-andNATO-membercountries.

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Protection system against terrorist attacks Remote-controlled devices



•Sensorsbasedonvariousphysicalprinciples:microwavesensorsformovements,inductionsensors,acousticsensors,hydro-acousticsensors,Doplerradars,one-andthree-componentmagneticsensors;•Devicesforcollectingandprocessingofdata;•Devicesforcommunication;•Cameraswithdevicesforidentificationofmovingobjects;•Non-lethaldevicesforneutralizationofterrorists.


•Industrialsecuritysystems;•Systemsforrestrictedentrance;•Systemsfordefenseagainstterrorism;•Systemsforprotectionofmilitarysites.


•Methodsforcollectingandprocessingofdata;•Methodsforidentificationofobjects;•Methodsformathematicalmodeling.

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X-ray micro-analyzer - scanning electron microscope JEOL SUPERPROBE 733

Transmission electron microscope JEOL JEM 1011

Machine for tested surveillance specimens recovery


In the Field of Materials Testing and Analyses


•Investigationoftheinfluenceoftheproductionandprocessingmethodsonthematerialstructureformationandproperties;•Investigationoftheeffectofmaterialscharacteristicsontheirbehaviourunderstatic,dynamicandalternatingloading;•Developmentofnewmethodsanddevicesformaterialstesting;•Investigationofmaterialstress-strainstate;•Investigationoftheprocessesofmaterialsfractureundervariousconditionsandloadingtypes;•Investigationofmicro-andnano-structuresandmechanismsofsurfaceoxidelayerformationinmicrocrystallinealuminmalloystrips;•Studyofthehightemperaturedeformationmechanismsofmicrocrystallinealloys,strengtheningmechanismsinalloyingandpre-recrystallizationthermoplastictreatment;•Studyofdeformationparameterseffectsonthestructureformationandimprovementofmaterialsproperties;•Investigationsoftherelationshipstructure-properties-technologicalparametersintheprocessofsqueezecastingofmaterialsbasedonaluminumalloysandreinforcedbyceramicfibers,metalorceramicstructures.

Certified"Laboratoryformaterialanalysisandtesting,calibrationofmeasurementinstrumentation",holdingcertificateofaccreditationincompliancewiththerequirementsofBDSENISO/IEC17025.Thelaboratoryincludes:

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Quantitative analysis of LM, SEM and TEM images

Modernized assemblies with surveillance specimens for monitoring of WWER -1000 reactor pressure vessel metal

Versatile testing machine MTS for tension-pressure in the range from -120 оС to +500 оС



•Studyofthestructureformationprocessesincomplexconfigurationcastingproducedbythegascounter-pressurecastingmethod,creatingofinputdata-basefordevelopmentofmodelsfornumericalsimulationandoptimizationofthecastingprocessparameters;•Studyoftheprocessesofdeformationlocalizationinthestructureofhigh-strengthsteelssubjectedtodynamicalloading;•Detailedexaminationoftheeffectofaccidentalloadingonthestructure,fatiguecharacteristicsanddestructionmechanismsinsteelssubjectedtocyclicloading;•Investigationsofthemicro-andnano-structuresandmechanismsofsurfaceoxidelayerformationinmicrocrystallinealuminumalloysstrips;Thedepartmentisapermanentexecutantofcomplexinvestigationsonthemetalconditionofengineeringinstallationsinindustryandpowerengineering.

Laboratories

•Laboratory“Mechanicaltesting”;•Laboratory“Analyticalchemistry”;•Laboratory“Spectrometricanalysis”;•Laboratory“Non-metallicinclusionsandgasesinmetals”;•Laboratory“Metallography”;•Laboratory“Scanningelectronmicroscopyandmicroanalysis”;•Laboratory“Transmissionelectronmicroscopy”;•Laboratory“Auger-electronmicroscopy”;•Laboratory“X-raydiffractionanalysis”;•Laboratory“Non-destructivetesting”;•Laboratory“Corrosion”.

Certified"Laboratoryformaterialanalysisandtesting,calibrationofmeasurementinstrumentation",holdingcertificateofaccreditationincompliancewiththerequirementsofBDSENISO/IEC17025.Thelaboratoryincludes:

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Propullsion investigations of high speed catamaranequippedwithwaterjetpropulsors for Office of Naval Research, USA

Propeller cavitation tests for DELTA MARINE, Turkey

Model investigations of floating platforms for Keppel FELS, Singapore

Disaster investigation study for the National Investigating Agency, financed by the BG Government

Sailing ship “ROYAL HELENA” model investigations for MTG “Dolphin”, Bulgaria

Hydro- and Aerodynamics Centre


•Developednovelexpressmulti-variantshipsoptimizationschemes;•Performedtheoreticalpredictionsandimprovementsofshipperformanceinrealoperationalconditions;•Performedinvestigationsofwave/windenergyutilizationfacilities;•UnderdevelopmentisinlandandshortseashippingsimulationfacilityforDanubeRiverandBlackSeanavigation;•Complexinvestigationsonhighspeedcatamaranmanoeuvrabilityatstillwater,wavesandshallowwaterareinaprocessofrealization;•Performedinvestigationsofresistanceandpropulsivefactorsofdisplacementhulls,high-speedmarinevehicles,bargesandbargetrainsindeepandshallowwater;•Performedopenwaterinvestigationsofpropellers,propellersinnozzles,poddedpropellersaswellascavitationinvestigationsfordeterminingtheirhydrodynamiccavitation,unsteadypressurecharacteristics;•Investigatedmodelaerodynamicparametersofdifferentobjects,shipparts,subseaapparatuses,transportmeans,aircrafts;•Investigatedairflowsintheshipdecksregions,citymicroregions,industrialbuildings,etc.;•Carriedoutlaboratorymodelinvestigationsoflay-outofportandcoastalengineeringstructureswith

TheHydro-andAerodynamicsCentre-Varna(internationallyknownasBulgarianShipHydrodynamicsCentre(BSHC))isperformingfundamentalandappliedresearchaswellaseducationandtraininginthefieldofshiphydrodynamics,aerodynamics,watertransport,oceanandcoastalengineering,seaandrivercrisesanddisasters,environmentalprotection,renewableenergysources,nationalsecurityanddefenceetc.infavourofthesociety.

Research and Development in the Fields of:

•Shiphydrodynamics;•Hydro-andaerodynamicsoptimizationofships,platforms,engineeringstructures;•Shippowering;•Shipdynamicsandoceanengineering;•Coastalengineeringandmarineecology;•Aerodynamics;•Seaandrivercrisesanddisasters;•Watertransportefficiency;•Marineengineeringsoftware;•Fishingandaquaculturefacilities;•Renewablemarinesources;•Nationalsecurityanddefense;•Measuringequipmentmanufacturing;•Simulationandtraining;•CAD/CAMofmodelsforexperimentalinvestigations.

Aerodynamic resistance investigation of undersea Remotely Operated Vehicle (ROV) for ABRITUS SOFT Ltd, Bulgaria/France

Model investigation on a WAVECAT device for near beach wave energy utilization for VICUS DESARROLLOS TECNOLOGICOS S.L., Spain

MODELS MANUFACTURE

21 simulationofregularandirregularwavesandlittoralcurrents;•Developedanewdesignandengineeringconceptsforshipsinoperationandenergysavingofseagoingandrivervessels;•Developedtelematiclinksbetweenharbors,vesselsandadministrationandinvestigatedenvironmentalimpactanalysisofnavigation;•Ensureddataacquisitionandstatisticalprocessingduringandaftermodelinvestigationscarriedoutbycustomscientificinterfacesoftware;•Developedandappliedcomputationalfluiddynamics(CFD)packagesallowingacostefficientanalysisofthehydrodynamicperformanceofshipsandmarinestructures;•Performedmeasurementsofforcesonafishnetconstructionsanddeformationofthefishnetundercurrentandwaveaction;•Performedmomentsandforcesmeasurementsbetweentheelementsofthefloatingfishfarmcagesystemundercurrentandwaveaction;•Manufacturedmorethan500shipmodels(madeofwood,plastics)upto12meterslongandmoldsforracingvessels,floatingdrillingplatforms,pleasurefacilities,complex-formbodies,etc.ofdimensionsuptoL=12.0m,B=2.40m,H=1.20m,aswellaslargercompositestructures,alsoover700propellers,nozzles,poddedpropellers,waterjetspropellersmodels;•Developedexperimentalequipment-automatedinstallationsforshipmodelforcedoscillations,gauge

calibrationunits,steeringgears,etc;•Developedcomputersimulationsystems;•Performedmorethan100scientificappliedinvestigationsundercontractsfor14countriesfromEurope,Asia,North/SouthAmerica.

Since02November2009anewaerodynamicsresearchandtraininglaboratoryisfunctioningforthefollowingpurposes:airpressureloadingofconstructionsofindustrialandcivilbuildings,airresistanceoftransportobjects,metrologicalsecurityofairflowscharacteristicsmeasuringinstruments,ecologyanddefense,aswellasfortrainingandpresentationpurposes.ThemainlinesofmodernHigh-Techdevelopmentsare:•submarinehandlingsimulator“Valna”;•underwaterapparatusesformilitarypurposeshydro/aerodynamicallyinvestigated.

TheCentreisinvolvedinseveralinternationalprojects:•“Promotionofhigh-techinhydrodynamicsresearch”•“Coordinatedactionsonoceanenergy,ultilization,CA-OE”;•NATOprojectNIREUS”Virtualship”.

HYDRO- AND AERODYNAMICS CENTRETel:+35952370500Fax:+35952370514E-mail:[email protected]:www.bshc.bg

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Welding process Welding of tubes


Centre of Welding

• Investigation and measurement of temporary and residual stresses in welded and other constructions:Non-destructivemethodsareappliedfor

measurementofthestressesinweldedandotherconstructionsbyusingportablecomputerizedapparatusesthatpermitcarryingoutthemeasurementsinconditionsofproductionandassembly.• Reduction and redistribution of the residual welding stresses:UnderaNATOproject,anewmethodisdeveloped

forreductionandredistributionoftheresidualweldingstressesbylocalexplosivetreatment.Themethodisparticularlysuitableforlargeweldedconstructionsorforconstructionsofheterogeneousmetalswhentheheattreatmentisinapplicable.Appliedtechnologiesforreductionandredistributionofresidualweldingstressesintanksandreservoirsareelaborated;Investigationsarecarriedoutforoptimizationofthe

parametersoftherelaxationprocesswiththepurposetoincreaseitsefficiency.• Development and approval of welding technologies and procedures:Weldingproceduresaredeveloped,testedand

approvedincompliancewithBDSЕNISO15607,BDSЕNISO15609,BDSЕNISO15614.

The main activities of the Centre of Welding are in the field of:

• Examination and testing of the weldability of different materials (steels, plastics, etc.):Mechanicalcharacteristicsarestudiedandtested

atnormal,highandlowtemperatures.Besidesthetraditionaltestmethods,anewnon-destructivemethodisalsoappliedfordeterminationofthestrengthofsteelsbymeasuringthehardness.Themeasurementsareperformedbyportablecomputerizedapparatusandcouldbecarriedoutinconditionsofproductionorassembly.Inthatwaycuttingofsamplesfromtheconstructionsisavoided;Anoriginalmethodfordeterminationofthe

weldabilityofsteelsbyquantitativeassessmentoftheirresistancetoformationofcoldweldingcracksisdevelopedandapplied.• Examination and testing, welding materials and welded joints:Mechanicalcharacteristicsofweldupmetal,seam

metalandweldedjointarestudiedandtestedatnormal,highandlowtemperatures.Thermo-physicalcharacteristicsofweldupmetalarealsodetermined(heatconductivityfactor,thermalexpansioncoefficient,etc.).

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Preparation of oil-pipeline for welding using technologies developed by the Institute


• Development of technologies and equipment for special welding methods:Diffusionweldinginvacuumofhomogeneousand

none-homogeneousmaterials;Weldinginnarrowgapofthickjoints.

• Simulation and numerical modeling of welding processes:Adatabaseforcarryingoutsimulationexaminations

andverificationofnumericalmodelsiscompiled.Newmodelsarefoundanddevelopedforthethermalanddeformationprocesses,fortheprocessesofstructureandphasetransformationsduringwelding.• Training and qualification - Center for Professional Training in Welding at the IMS-BAS:TheCenterorganizesandconductscoursesfor

trainingofweldersonnationalandinternationallevel.Commonusedweldingprocesseslike:MMA,MAG/MIG,TIG,Oxy-acetylenegasweldingandcutting,submergedarcwelding,areincludedinthetrainingprograms.Thequalificationtestsareonthreequalification

levels:FilletWelder;PlateWelder;Tube(Pipe)Welder.

AttheCenterforProfessionalTrainingarealsoorganizedcoursesforweldingcoordinationandinspectionpersonnelwiththefollowinglevelsofcompetency:•InternationalWeldingSpecialist(IWS)-acc.Doc.

IAB-252-07•InternationalWeldingPractitioner(IWP)-acc.Doc.

IAB-252-07•InternationalWeldingInspector(IWI)-acc.Doc.

IAB-041-06

The Center for Professional Training in Welding is licensed by the National Agency for professional education and training and by the Bulgarian center for qualification in welding through the International Institute of Welding (IIW).

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24 TheInstituteisoneoftheleadingorganizationsinBulgariainthefieldofnationalsecurityanddefense.ConsiderableshareoftheInstitute’sactivitiesisrelatedtoinvestigation,designandproductionofhigh-techdefenseequipmentandsystems,includingdevelopmentofhigh-techanti-terroristssystemsaccordingtotheNATO’sconceptionsfordefenseagainstterrorism.ThemaindefenseproductsoftheIMSETHCare:

Products and systems against invasion by • water:Familyofseamines(anti-invasionmines,bottom•mines,diversion(“Limpet”)mines);High-techunderwaterfusesforexistingexplosive•devicesandmines;Underwateranti-diversiondevices;•Underwatergrenades;•Hydro-acousticmanagementsystems;•Mine-layingequipment.• Products and systems against invasion by • land and air:Familyofanti-tankmines;•Familyofanti-helicoptermines;•High-techfusesforexistinganti-tankmines;•Remotecontrolledignitionsystems;•Armorsforlightandheavyarmoredvehicles;•Meansforpersonnelindividualprotection.•Products and systems against terrorist action:• Systemsforprotectionofharborsagainst•underwaterandsurfaceterroristattacks;

Guardsystemsforprotectionofimportant•targetsandborderareas;Meansforprotectionofhelicoptersagainst•RPGs;Familyofhandgrenadesagainstterroristthreats•andforhostagesavingoperations;Equipmentforexplosivedevicesdetection;•Meansforindividualarmorprotectionofanti-•terrorismunitsofficers.

TheIMSETHCisinvolvedinseveralinternationalR&Ddefenseprojects:

NATOProgramforprotectionofhelicopters•againstRPGs;NATOProgramforharborprotectionagainst•terroristactions;NATOProgramfordevelopmentofanti-•personnelminesalternative-theInstituteistheleadingorganizationonBulgariansite;Bilateralprojectonimprovedprotectionof•armoredvehiclesagainstkineticprojectilesandshapecharges;Bilateralprojectonmethodsandsystemsfor•detectionofimprovisedexplosivedevices.

AnumberoftheIMSETHCsecurityanddefenseproductsandsystemshavebeenacceptedforusewiththeBulgarianArmedForcesandhavebeendeliveredtoabout20countries,mostofthemEUand/orNATOmembers.

High-Tech Products and Systems for Defense and Security


25


25

Critical Infrastructure Protection Warning Surveillance System Warning Surveillance System Architecture


TheNationalCenterforAnti-terroristAdvancedSystemswasfoundedattheInstitutein2008.TheCentreisconductingactivitiesconnectedwithresearchanddevelopmentoftechnicalandoperationalconceptsforadvancedprojectsandtechnologiesagainstterrorism.TheCenteriscarryingoutresearch,developmentandexperimentalactivitiesinthefieldofnewdefenseandsecuritytechnologiesandproducts.ThespecificgoalsoftheCentreare:1.Toprovideadequateparticipationin:•nationalprogramsandprojectsagainstterrorism;•NATODATProgramme;•implementationofEUStrategyagainstterrorism;•activitiesoftheinternationalnetworkofCentresofExcellence intheanti-terroristarea.

2.ToprovidesynergyofexpertactivitiesandresultsonthebaseofparticipationinsomeNATODATprojects:•Reducingthevulnerabilityofhelicopterstorocket-propelledgrenades (RPGs);•Harbourprotection;•Protectionofcriticalinfrastructure;•Developingnon-lethalmeansforprotection.

3.TrainingofnationaloperationalandtechnicalpersonnelandNATOmissions-orientedpersonnel.

www.homeland-security-center.bg

National Center for Anti-terrorist Advanced Systems

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26

Engineering SciencesJournal of Materials Science and Technology


Education

Periodicals and Journals

Editorial Office Address:InstituteofMetalScience,Equipment andTechnologies“Acad.A.Balevski” withHydroAerodynamicsCentre67ShipchenskyprohodSt.,1574SofiaTel./2/4626200Fax:/2/4626300e-mail:[email protected]'ssite:http://jmst.ims.bas.bg

Editorial Office Address:InstituteofMetalScience,Equipment andTechnologies“Acad.A.Balevski” withHydroAerodynamicsCentre67ShipchenskyprohodSt.,1574SofiaTel./2/4626239Fax:/2/4626300e-mail:[email protected]'ssite:es.ims.bas.bg

TheInstitutetutorspersonsworkingforDoctorsdegreeinregular,extra-muralandfreemannerinthefollowingscientificdisciplines:01.02.05 “FluidMechanics”02.03.01 “ShipTheory”02.15.17 “RiverandSeaConstruction”02.01.02 “Materialsciencetechnologyofthemachinebuildingmaterials”02.01.08 “Methodsofcontrolandtestingmaterials,productsand

apparatuses”02.01.17 “Technologies,machines,andsystemsforplastic,deformation

treatment”02.01.18 “Technologies,machinesandsystemsforfoundryproduction”02.09.01 “Materialscienceandheattreatmentofmetals”

JOURNAL OF MATERIALS SCIENCE AND TECHNOLOGYItisthemostsignificantperiodicalinmetalscienceinBulgaria.Itssubject-mattercoversscientificandengineeringnoveltiesrelatedtoinvestigationanduseofmetals,alloys,engineeringceramics,polymers,composites,newmaterials,techniquesfornewcharacteristics.Itisissuedsince1993inEnglishlanguage,withfrequency4numbersperyear.Scientistsanduniversitylecturersfromabout40countriespublishinthejournaltheirachievementsandideas.Therelativeshareoftheforeignauthorsexceeds50percent.

ENGINEERING SCIENCESItisthemostsignificantBulgarianacademicjournalinthefieldofengineeringsciencesandispublishedinBulgarianandEnglishlanguageswithfrequency4issuesannually.Thesubject-mattercovers:materialscienceandtechnologyofmaterials,automationandtelemechanics,informationtechnologiesandcomputerengineering,waterissues,electrotechnics,urbanizationandarchitecture,otherareasoftheengineeringsciences.

27Институт по металознание 2008 година

Address:•

67ShipchenskyProhodSt,•

1574Sofia,BULGARIA•

Telephone:(+3592)4626200;•

Fax:(+3592)4626300;•

Website:http://www.ims.bas.bg•

institute of metal science, equipment and technologies ... · institute of metal science, equipment...

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