Previous experience achieved with two of the leading systems, namely the VAIron closed-loop expert system of Siemens VAI Metals Technologies and the VAIF blast furnace expert system are described for several installations. The advantages of both systems have since been combined into an advanced, state-of-the-art system referred to as VAIron–The Next Generation. This paper outlines the structure and highlights of this new expert system.

Coke production capacity within AM FCWE is not self sufficient for the total HM production. PCI was started up in 2004 at Bremen BF2 and Eisenhüttenstadt BF5, with a ramp up to 180 kg/thm in one year. A working group defined the BF operating conditions leading to stable and efficient operation at high PCI. At Florange BF3 PCI trials at 220 kg/thm were successful. At Dunkerque BF4 and Gent BFA and B, the PCI rate exceeds regularly 210 kg/thm.

During 2006 four chilled blast furnaces were recovered using the oxyfuel lance technology. All recoveries were successful and brought the blast furnace back to full production within 200 hours. This recovery method has been under constant development since 1990 and has now been applied over 25 times. It is considered safer, faster, easier and cleaner than the traditional recovery methods for chilled hearths.

The feasibility of direct thin strip casting of various steel grades for further metallic coating has been investigated. The surface evolution is described for each processing step. Special attention to steel cleanliness and scale formation was given, since local surface heterogeneities of grain structure and chemical composition may disturb the coating process. Low alloyed cast strip can be coated with 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 year 2006. The share of welded pipes has raised up to 58% and is expected to grow further in the future. Russian tube producers are involved in a steady effort of modernization of equipment and commission of new facilities with a view to offer larger volumes of higher quality products that meet the requirements of international standards.

A new image analyzer, Thixomet®, has been developed with the ability to create “panoramic” images of material microstructure for investigations. Capabilities of the Thixomet image analyzer for material microstructural characterization are demonstrated with examples of nickel-based superalloys. Practical use of the Thixomet for controlling material properties by characterizing their microstructure is demonstrated.

The technology of mono-metals has reached maturity and further technological developments are impeded by some natural limits. Basic resources have been largely investigated and major innovative steps should not be expected in this area. Further progress in the science and technology of metallic materials will rather concern composite metals, layered composites in particular.