This study presents the development of an eco-efficient laboratory-scale production route for long
steel products, focusing on sustainable casting and hot deformation processes. Conventional
casting using 80x80 mm molds and gravity filling generated significant shrinkage defects, leading
to scrap generation, repeated melting, and reduced material efficiency. Alternative mold designs
with a 15° inclination and exothermic feeders were evaluated via simulation software, minimizing
defects and enabling Ø70 mm castings with 20% less raw material. A new laboratory-scale hot
rolling unit replaced hydraulic presses, achieving the target Ø29 mm round cross-section in a single
cycle with a 0.83 reduction ratio, increasing specimen yield and reducing energy consumption.
Equipment selection prioritized the reuse of idle industrial motors and gearboxes, aligning with
circular economy principles. Mechanical testing and microstructural outcomes obtained from the
new process were closer to industrial production standards, demonstrating not only enhanced
process yields but also improved product quality. Overall, the combined process modifications
reduced scrap, minimized energy use, and leveraged existing resources, demonstrating a practical,
sustainable and eco-friendly approach for laboratory-scale steel production.
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