This paper presents the results of a study and analysis of the effect of modifying low-chromium hypoeutectic cast iron with a new boron–barium ferroalloy on its properties—wear resistance and impact resistance—in comparison with traditional boron- and barium-containing additives. The uniqueness and novelty of the work lies in the study of the nature of changes in the structure and wear-resistant properties of low-chromium cast iron as a result of its modifying treatment with a new boron–barium ferroalloy. In a laboratory electric resistance furnace, low-chromium cast iron was melted, and four batches of prototypes were cast. Samples of the first batch, for subsequent comparison, were made without modification. When casting the remaining three batches of samples, the cast iron was modified with three different additives: ferroboron FeB12, ferrosilicobarium FeSi60Ba20, and a new complex boron–barium modifier. In order to compare the degree of effectiveness of the applied modifiers, a metallographic analysis of the structure was performed, hardness measurements were performed on the surface of the samples, and they were subjected to abrasion and cyclic shock-dynamic impact tests. In all cases, when modifying cast iron, there was an increase in hardness, a noticeable grinding of the microstructure, and a redistribution of structural components towards an increase in the proportion of perlite and finely dispersed ledeburite. A comparative analysis of the results of testing samples for dry friction and shock showed a higher surface resistance of cast samples made of modified cast iron compared to unmodified low-chromium cast iron of the same composition. A comparative study of the parameters of wear tracks and craters on damaged surfaces established that the most optimal combination of wear-resistant qualities of low-chromium cast iron occurs when it is treated with a complex boron–barium modifier, which is also evidenced by obtaining a more favorable microstructure.

This study investigates the use of the complex reductant FeAlSiCa as an alternative to the conventional FeSiCr in the EAF smelting of FeCr. The smelting process using FeAlSiCa is characterized by a stable furnace operation, active discharge of metal and slag, and effective phase separation. It was found that a 20% excess of FeAlSiCa over the stoichiometric requirement leads to a sharp increase in Si content in the FeCr alloy, with approximately 85% Cr recovery into the metal. A stoichiometric amount of FeAlSiCa results in a metal with 1.5–1.6% Si content and about 80% Cr recovery. A comparable Cr recovery using FeSiCr was achieved only when applying a 20% excess of that reductant. The use of FeAlSiCa also holds promise for technological sustainability due to its low production cost and the utilization of waste materials during its synthesis. The resulting slags are solid and rock-like and show no signs of disintegration after storage for more than 45 days.

The paper presents the results of studying the effect of modifying low-chromium hypoeutectic cast iron (chromium content about 1%) with boron- and barium-containing additives on its structure and hardness. The modification was carried out with carbothermicferroboron (0.08% of weight of the liquid metal); ferrosilicobarium (0.05% of weight of liquid metal); complex boron barium ferroalloy (0.14% by weight of liquid metal). The microstructure and properties were compared with a sample of unmodified cast iron of the same composition.