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By Harold B. Goldman, Don Reining

The sand and gravel industry is the largest nonfuel mineral industry in the nation. In 1981, the production of sand and gravel totaled 755 million tons valued at $2.3 billion. California, which leads the nation with more than 110 million tons, together with Alaska, Texas, Michigan, and Ohio, account for 36% of the total production in the nation (Table 1). In commercial usage, sand applies to rock or mineral fragments ranging in size from particles retained on a No. 200 sieve (0.074 mm openings) to those passing a No. 4 sieve (4.76 mm openings). Gravel consists of rock or mineral fragments larger than 4.76 mm, ranging up to 88.9 mm (3 ½ -in.) maximum size. The construction industry consumes 97% of the sand and gravel produced; the remainder is sand used for specialized products such as glass (see the chapter on "Silica and Silicon"). Utilization The building industry uses sand and gravel chiefly as aggregate in portland cement concrete, mortar, and plaster; the paving industry uses sand and gravel in both asphaltic mixtures and portland cement concrete. Aggregate is commonly designated as the inert fragmental material which is bound into a conglomerate mass by a cementing material such as portland cement, asphalt, or gypsum plaster. Portland Cement Concrete Aggregates Portland cement concrete consists of sand and gravel surrounded and held together by hardened portland cement paste. Concrete mixes commonly contain 15-20% water, 7-14% cement, and 66-78% aggregate. Sand and gravel used as concrete aggregate have to meet many requirements (Goldman, 1956). Premature deterioration of concrete has been traced in many instances to the use of unsuitable aggregates. Asphaltic Aggregate Asphaltic mixtures used predominantly for paving consist of combinations of sand, gravel, and mineral filler (material finer than 0.003 in.), uniformly coated and mixed with asphalt produced in the refining of petroleum. Except for the addition of mineral filler, sand and gravel used as asphaltic aggregate must meet the same general physical requirements as materials used for portland cement concrete aggregate. General Requirements of Aggregates Construction aggregate has many requirements that are difficult to meet if only unprocessed material from natural deposits is used. Suitable material is composed of clean, uncoated, properly shaped particles which are sound and durable. Soundness and durability are terms used to denote the ability of aggre- [ ]

Jan 1, 1983

By K. A. Svanstrom, W. R. Opie

Problems associated with deposition of titanium infused chloride baths using TiCl4 as a feed material are reviewed. A potentially workable cell design using Alumdum diaphragms is discussed. Problems inherent to diaphragm-type cells are emphasized and experiments described which led to the development of a cell without a diaphragm. INVESTIGATORS assigned the problem of developing a commercial electrolytic process for making titanium metal have found that they are faced with the difficulty of overtaking rapidly improving magnesium and -sodium reduction processes. The ultimate goal must be a simple process that can be conducted with low-cost raw materials in equipment that is inexpensive to build and operate. This paper deals with some work of a preliminary nature conducted by personnel of the Research Laboratories, National Lead Co., Titanium Division. Many others have reported on the general subject of depositing titanium from fused salt electrolytes. A partial bibliography is attached. PRIMARY CONCEPTS Anyone attempting to deposit titanium metal from fused chloride electrolytes using TiC14 as a source material is faced with at least the following problems: 1) Getting the titanium into solution in the bath. 2) Controlling oxidation and reduction reactions associated with multiple valency of titanium, which result in low electrical efficiency. a) Prevention of dichloride oxidizing to trichloride and trichloride to tetrachloride at the anode. b) Prevention of trichloride from being reduced only to dichloride at the cathode. 3) Prevention of metal formation away from the cathode thru disproportionation of titanium dichloride to satisfy the equilibrium. 3 TiCl2 == 2 TiCl3 Ti [I] 4) Protection of reduced chlorides in the bath from reaction with oxygen from the bath container or air. 5) Removing from the bath the deposited metal formed without allowing it to become contaminated with oxygen or nitrogen. 6) Selecting cell materials of construction which will not contaminate the metal product or cause cell inefficiencies. EARLY EXPERIMENTS The initial attempts made to electrodeposit titanium from fused chloride baths using TiCl4 as a source material indicated that TiCl4 was essentially insoluble in molten chlorides of alkali and alkaline earth metals. If, however, the TiCl4 was introduced close to a nickel cathode some metal could be formed and appreciable quantities of reduced chlorides would be present. These reduced chlorides reacted with any oxygen present in the atmosphere above the bath and would also diffuse quickly to the anode (graphite) where they would react with chlorine and be evolved as TiCl4. The net electrolytic efficiency of such a cell is essentially nil. The TiCl4 evolves from the anode at almost the same rate that it is introduced in the vicinity of the cathode although a small amount of titanium metal can be formed on the walls of the cathodic pipe. It becomes apparent from the operation of such a cell that: metal can be deposited on the cathode, although of small particle size and a nonadherent nature, and when reduced chlorides are present in the electrolyte, TiCl4 can be absorbed, probably by the following reactions: TiCl4 + TiC12 - 2 TiCl3 [21 2 TiCl3 + 2 faradays - 2 TiC12 + C12 [31 DIAPHRAGM CELLS These facts encouraged the development of cells containing diaphragms to prevent migration of reduced chlorides from the cathode area to the anode. Small-scale cells for process development are described by Alpert, Schultz, and Sullivan.20 A larger brick-lined cell incorporating internal heating by passing ac through the bath is shown in

Jan 1, 1960

SPEAKING generally, it may be said that leaching is the simplest method of recovering copper from its ores. Likewise it is perhaps the oldest method of treatment used by copper metallurgists of the modern era. Reliable records indicate that as early as 1752 cupriferous pyrite was leached in the famous Rio Tinto region in Spain. Though the manipulation was quite different from that in use today at Chuquicamata, New Cornelia, Inspiration, and Andes, it resembled that employed by Phelps Dodge at Bisbee, as described in Chapter XIV. Leaching consists of subjecting ore to the action of a liquid solvent or menstruum (usually an aqueous solution) which dissolves the major part of the soluble copper minerals. The resulting pregnant solution is drained off or otherwise separated from the residual ore; and the copper in the solution is then recovered by some appropriate means of precipitation. When sulphuric acid is the lixiviant, as is usual, the simplest procedure is to pass the copper-bearing solution through large troughs containing scrap iron. The iron displaces the copper in the solution, precipitating it as a slime coating the iron and varying in color -from bright copper to a dull black. This may be washed off at intervals, collected as a sludge, dried, and melted with a little fluxing material to produce reasonably pure copper. Usually, of course, the mud is sent to a smelter where most often its destination is the converter or reverberatory furnace. Modern practice uses precipitation on iron only as a complemental process to electrolytic precipitation or deposition, wherein the pregnant copper-bearing solution, acting as the electrolyte in a cell having insoluble anodes and copper cathodes, is depleted of the copper it contains. Cathode copper, 99.5 per cent pure, is produced ready for the market as refined copper, or for a simple process of melting, fire-refining, and casting in

Jan 1, 1933

By Robert S. Archer, L. W. Kempf

It is now well known that the structure of aluminum-silicon alloys can be refined in a rather remarkable manner, with consequent improvement of physical properties, by certain treatments applied to the molten metal shortly before casting. The differences between the treated and the untreated alloys are so marked that special terms are used to distinguish them, the untreated alloys being referred to as "normal" and the treated alloys as "modified." The first practical method of accomplishing this result was that of A. Pacz,1 which consists in treating the molten metal with a salt flux of which the active ingredient is sodium fluoride. The result can also be brought about, and in a more economical manner, by the addition of small quantities of metallic sodium (or potassium) to the molten alloy shortly before casting.2 The action of the Pacz flux evidently consists essentially in the production of free sodium by the reaction of sodium fluoride with aluminum. The changing of a normal alloy to a modified alloy is referred to as "modification" and any process for accomplishing this result is a "modifying" process. Modified aluminum-silicon alloys were introduced several years ago, and it has been demonstrated both in the laboratory and in commercial practice that it is no simple matter to produce castings having the maximum or nearly the maximum properties which under favorable circumstances can be obtained. The alloys are rather sensitive to small changes in chemical composition, and the modifying process must be carried out in a very particular manner to obtain the best results. Extensive experimental work has been carried out in the laboratories of the Aluminum Co. of America with the object of determining the conditions that must be observed to make these alloys of the greatest possible value. It was necessary to learn how to control the modifying process

Jan 1, 1926

By Frederick Jr. Prime

THE first catalogue of Geological Reports of the United States was prepared by Prof. O. C. Marsh, and published in the American Journal of Science and Arts for 1867, vol. xliii, second series. Since then the list has more than doubled, and it was thought that the publication of a new catalogue, brought down to date, would be useful to many of the members of the Institute of Mining Engineers. The compiler will be most thankful to have any omissions or inaccuracies in the list sent to him, to be published as a supplement in the next volume of the Transactions. Especially to have the correct title, number of pages, plates, and maps of any volume on the list to which an * is prefixed, as he has been unable to personally consult such works. A preliminary list was issued last February, which has been almost doubled by the kindness of many friends. The writer desires more especially to express the obligations he is under to the following gentlemen The Chief of Engineers, U. S. A.; Principal Dawson, Mr. G. M. Dawson, Drs. B. J. Harrington and T. Sterry Hunt, of Montreal; Mr. H. Engelmann, of La Salle, Ill.; Dr. F. V. Hayden and Prof. J. W. Powell, U. S. Department of the Interior ; Prof. E. W. Hilgard, University of California; Prof. Henry Y. Hind, Windsor, N. S.; Prof. C. H. Hitchcock, of Dartmouth College; Mr. Henry A. Holmes, State Librarian, Albany; Maj. Jed. Hotchkiss, Staunton, Va. ; Prof. W. C. Kerr, Raleigh, N. C.; Dr. J. S. Newberry, of Columbia College ; Prof. W. H. Pettee, of the University of Michigan ; Dr. Samuel H. Scudder, Prof. N. S. Shaler, and Prof. J. D. Whitney, of Harvard College ; Mr. Sanderson Smith and Prof. J. J. Stevenson, of New York ; Mr. Addison Van Name, of Yale College, and Lieut. Geo. M. Wheeler, U. S. Engineers. PHILADELPHIA, 907 Walnut Street, October 1st, 1879.

Jan 1, 1879

By N. V. Hansell

The preparation of low-grade iron-ores by concentration, whether or not followed by an agglomeration of the concentrate, has in the United States only recently been recognized as a metallurgical process of vast economical importance for its iron indust.ry. This importance of the process lies not only in the fact that it makes possible the use of ores heretofore discarded on account of their low iron-content or their too high percentage of elements deleterious in the iron industry, but also in its produetion of a raw material for the blast-furnace that is more uniform in its physical character and chemically purer, with a higher iron-content, than the general run of natural ores. When mixed in the burden of the furnace, it lowers the amount of coke and fluxing-stone required per ton of pig-iron produced. The furnace-operations become more regular and more easily controlled. The pig-iron is of higher quality and more uniform in character. In brief, it is becoming recognized that the beneficiating of the natural iron-ore, even if it makes the furnace-ore higher in cost per unit of iron entering into the burden, may mean a lowering of the production-cost of the pig-iron and an improved product. At the present time, the Lake Superior district furnishes about 80 per cent. of all the iron-ore yearly produced in the United States. If the Southern States arc exempted the percentage runs as high as 93 per cent. These ores are showing a steady decrease in grade from year to year. For the past 10 or 15 years this falling off in the average grade has been about 0.5 per cent. a year. The lowered grade of ore means an in-

Jan 1, 1913

By G. F. Comstock

In the literature of metallography there is a large amount of material describing the various non-metallic inclusions found in iron and steel, and the appearance of sulfides, silicates, oxides, or alumina in steel under the microscope is fairly well known. The inclusions found in non-ferrous metals are, however, not so well known, at least judging from published writings, and the author has been interested in examining small castings of copper, brass, or bronze with certain inclusions purposely mixed with the metal, to see what was the characteristic appearance of each kind of inclusion, and if they could be readily distinguished from one another. The method employed in most cases consisted in overheating and oxidizing a small charge of copper, then cooling it somewhat, and adding a suitable amount of the element whose oxide it was desired to observe. This element was stirred in well and given time to react with the oxygen in the copper, then the melt was poured in a sand mold in the form of a cylinder about 21/2 in. (63 mm.) in each dimension, with a sprue about 11/2 in. (38 mm.) in diameter and 3 in. (76 mm.) high on top of the cylinder, the sprue forming the only riser. Samples for examination were cut sometimes from the center of the casting, and sometimes from the sprue or riser. A few of these samples were cast in chill molds. The appearance of sulfides was studied in an alloy containing 10 per cent, each of tin and lead, with which a flux of plaster of Paris was used. The appearance of foundry sand was studied in several alloys, one of them having sand stirred into the metal intentionally, and others having cut into the molds badly when poured, so that the castings were spoiled by included sand. As all this work was done on alloys having copper as the chief ingredient, the natural starting point was copper oxide, the appearance of which in a micro-section is well known. Cuprous oxide is soluble in molten copper, but separates out in freezing and forms a eutectic containing 3.5 per cent. Cu20, or 0.39 per cent. oxygen. If there is less

Jan 1, 1919

By John R. Low

A number of cases of low-temperature, intergranu2ar brittle fracture of metals containing small amounts of certain impurities, have now been identified. Some degree of understanding of this phenomenon exists for the simpler binary systems of a metal and a single impurity, but the profound effects of other impurities and alloying elements in modifying this type of behavior remain unexplained. Current research in this area is reviewed and some of the newer techniques of investigation which should make possible a more quantitative study of the structure and composition of grain boundaries in impure metals are described. To indicate the subject matter of this lecture, we may begin by reviewing the experimental observations concerning low-temperature intergranular brittleness in impure metals, particularly those examples in which the embrittlement appears to result from what has been called "equilibrium grain boundary segregation."' These are the systems in which it has been impossible, at least up to now, to detect the presence of any second phase film at the brittle interfaces. When second phase films are present they are usually readily detectable by fractographic methods, often appearing as epitaxial films in geometric or dendritic patterns. An example is shown in Fig. 1 for the case grain boundary carbides in a sensitized stainless steel which failed by intergranular brittle fracture at 78?k2 In contrast to this type of embrittlement there are numerous examples of low-temperature intergranular embrittlement in which the fractographs are essentially featureless, for example, that of an oxygen-embrittled iron shown in Fig. 2. The only second phase particles visible are the small, widely separated, round oxide particles typical of the bulk material. The fracture surface is extremely smooth and the fracture path appears to follow the intergranular interface without deviation. This type of fractograph also implies that crack propagation has occurred without plastic deformation at the crack tip, since localized slip or twinning ahead of the crack would be expected to distort the interface and be readily visible in the fractograph. Such indications are occasionally seen in these fractographs, but are not characteristic. A second example of this type of fractograph is shown in Fig. 3, which is from a temper-embrittled, carbon-free, Fe-Cr-Ni alloy containing Sb, broken at 1OO?C.3 The similarity to the oxygen embrittled iron case will be apparent. In the case of the temper embrittled Cr-Ni ferrite containing antimony, it is possible to remove the embrittlement by suitable thermal treatment. The grain boundaries may then be examined by thin film transmission in the electron microscope for the material in both the nonembrittled condition and in the embrittled condition. Two boundaries are shown in dark-field transmission in Fig. 4, one in the nonembrittled

Jan 1, 1970

By Carle R. Hayward

LEAD ore smelting plants have been operating in general at reduced capacities and secondary lead has assumed relatively more importance during the last year. Present smelting practice results in a large amount of dross, often over 25 per -cent, from blast-furnace lead. This is usually treated at a fairly high temperature in a reverberatory furnace to remove part of the lead and produce a matte-speiss product which is shipped to a copper plant. Few smelters are satisfied with this 'treatment. The fume losses are high and the matte-speiss contains considerable lead. It would seem that a fruitful field for research was open here.

Jan 1, 1934

By Chas Dobbel

THE Chief Consolidated properties are situated in the Tintic mining district of Utah, being included in Juab and Utah Counties, about 70 miles south of Salt Lake City. The drilling referred to in this paper has been carried on in the Chief Consolidated No. 1 mine, the Gemini mine, and the Eureka Hill mine at Eureka, the Grand Central mine, above Mammoth, and the Apex Standard mine just south of Dividend. The occurrence of ore through the district is typically in lenses on bedding or breaks, and in connecting pipes, without accurate geometrical trend so that the ratio between the total length of development in drifts and crosscuts to the square feet of ore exposed is very high. A section of one of the western channels (Fig. 1) through the Tintic district, shows, roughly, the irregularities calling for excessive development work, so typical of the Tintic mines. This irregular trend of the ore constantly calls for excessive cutting up of the whole area for offshoots and the connecting links always present.. In the planning of prospecting and development, no regular system may be laid out without overlooking some orebodies or segments of orebodies. It was with these facts in mind that Cecil Fitch, the general manager of the Chief Consolidated Mining Co., decided that some method of drilling was the more feasible way of successfully cutting up and bringing about the discovery of ore believed to exist; yet this drilling had to compete with a great. margin of cost over crosscutting, as a crosscut in the Tintic district, even though barren, brings out geologic facts that, in many cases, are worth the price of the working itself. Diamond drills met with the success that might be expected in a district that has a reputation for the wear and loss of diamonds; after 6 or 8 months, this method was discarded on account of the high costs. Simultaneously, a small churn drill outfit was set up underground but a few shifts proved its inapplicability. At the same time, the ordinary hammer drill was usd to drive prospect holes with jointed steel.

Jan 9, 1925

By William Campbell

The structure of iron and steel, though the object of so much study and research for the past 25 years, is by no means thoroughly understood. In the first place, we have three or more distinct iron-carbon thermal diagrams, each with its own supporters, and each representing a theory of the structure and constitution of cast-iron. In the second place, by reason of the fact that austenite, the solid solution of carbon in iron, decomposes in the solid state into ferrite, or pure iron, and cementite (Fe3C), and that quenching from above this transition-range, no matter how rapid, cannot entirely prevent the change and thus preserve the austenite by itself at ordinary temperatures, it happens that under the microscope we find, in addition to the ferrite, Fe3C, and austenite, which the thermal diagram of steel requires, a series of transition-products with distinctive structures, to which have been given the names martensite, troostite, sorbite, etc. Now these transition-products, in addition to the solid solution, austenite, have been the source of much controversy, at times very bitter. One side would insist that, say, troostite was an entity, which the other side would deny, pointing out that it must be a transition-mixture, with a particular structure. That austenite was a solid solution of carbon in iron has been denied by one school; we have been told that Fe24C dissolved both Fe3C and Fe, and thus gave rise to a whole series of quenching-pro-ducts—all this in spite of the fact that no matter how the thermal diagrams differ in regard to cast-iron, they all agree in regard to the solid solution, austenite, for Fe24C finds no place on the diagram. Thus it happens that while the authorities fight both in regard to the iron carbon diagram and the structures met with in hard-

Jan 1, 1913

By John M. Lovejoy

NATURAL resources become a source of wealth as they are exploited and made available to the people in usable form. Experience has taught us that Nature does not readily give up her treasures, but the ingenuity of man in the field of techologic progress is required to find and efficiently exploit these resources. History has also demonstrated that with advancing technologic knowledge the. world has become progressively richer in its resources. Those that could not be commercially exploited are now being turned to beneficial use. Through expanding technology and the use of substitutes and synthetics, availability of the world's sources of natural wealth is today many times that of a hundred or a thousand years ago. And so it is with petroleum. Technology is also the great multiplier of our petroleum resources. Through improvements in the art of finding, drilling, and producing, our ability to meet rapidly increasing demands over the last quarter century has been maintained. On the other hand, had our

Jan 1, 1944

By Jack A. Simon, M. E. Hopkins

Coal is defined as a combustible rock that originated in the accumulation and physical and chemical alteration of vegetation. Coal can be ignited and burned like the wood that was man's earliest fuel, but coal gives more heat than the same amount of wood and has many industrial uses. Unlike wood, coal is not generally found on the surface of the ground but is mined from the solid rock of the earth. Before taking up the occurrence, formation, and the unique character of coal in the rock sequence, let us briefly consider the general character of all rocks in the crust of the earth. Relatively little is known about the very earliest history of the earth, although a number of logical theories have been developed. Manned exploration of the moon and the rocks returned to earth continue to provide some answers to questions concerning the earth's origin and history. The period of earth history with which we concern ourselves here begins after great areas of water had evolved on earth and substantial land areas of once molten (igneous) rock existed. Weathering and other processes that attacked the surface of the rocks reduced them to small particles. Water provided by rainfall transported this material, ultimately, to large bodies of water where it was deposited. Thus was initiated the geologic sequence of sedimentary rocks that lie above the once molten igneous rocks. The crust and upper mantle of the earth are made up of several large plates along which differential movement (primarily horizontal) takes place. Such movements, although small, are occurring today. These horizontal movements are accompanied by vertical movements causing important changes in the relative position of the continents and oceans. Low-lying coastal swamps with favorable climates are ideal locations for coal accumulation and burial by river-borne sediments, and large areas

Jan 1, 1981

By Alfred W. Gauger, George A. Burrell

The senior author of this paper, while in Colorado on other official business, made a trip to the Cripple Creek gold-mining district to get more data than are at present available regarding the composition of the gas that issues from the rock into the mines of the district. This was done at the suggestion of George S. Rice, Chief Mining Engineer of the Bureau of Mines. There are -many questions of interest and importance in connection with the ventilation of the mines in the Cripple Creek district, such as the menace to life and mining of a suffocating gas entering the mines from the rock, the danger due to powder smoke (from blasting operations), and danger of continued inhalation of rock dust by the miners. This report confines itself to the first problem, the gas from the rock, and principally to one phase of this question, the composition of the gas and its effects on men and lights. A more thorough study of this and other ventilation problems is planned. That the rock gas is a real menace is shown by the fact that miners (variously estimated from 25 to 50 by different persons interviewed) have been killed by it in the 25 years that mining has been vigorously carried on at Cripple Creek. Many men have had narrow escapes from death, some of them having been incapacitated for days. In addition, much loss of time results because at certain periods of the year or on certain days it is impossible to enter some workings. At a few mines, fans force air into the workings, thus supplementing the natural ventilation and much improving conditions, but the improvement is not entirely adequate at all times. Origin of the Gas Lindgren and Ransome1 think that the gas found in the rocks of the Cripple Creek mining district represents the last exhalations of the ex-

Jan 1, 1917

By F. J. Plecity, J. T. Michalak, W. C. Leslie

Isothermal recrystallization and grain growth in zone- and vacuum-melted irons and Fe-Mn alloys, up to 0.60 pct Mn, were studied in the range 480° to 650° C, after 60 pct cold reduction. In initial stages, rate of grain growth and rate of recrystallization of iron decrease with time. The recrystallization is typical of a growth-controlled process, and rate of growth is determined by the extent of recovery. Mn decreases rates of growth and of recrystallizatzon. The recrystallization process changes at about 0.30 pct Mn and nucleation may become time-depetzdet~t. In recent years, considerable effort has been expended in determining the effects of solute elements on recrystallization and boundary migration in fcc metals. The results have indicated that the effects produced by single solute additions are dependent upon both the element added and its concentration.'-' In contrast, there have been very few attempts to determine the characteristics of recrystallization and boundary migration in high-purity bcc metals, especially after heavy deformation, and the effects thereon of single solute elements.9-11 This study was undertaken to determine the recrystallization characteristics of various "high-purity" irons and the effects of manganese additions at two levels of base purity. It was hoped that the information obtained would improve our understanding of the recrystallization of pure metals and aid in formulating a theory for the effect of solute elements. The interest was not entirely academic, for the annealing of low-carbon steels, which is of very great commercial importance, is but poorly understood. MATERIALS The compositions of the irons and iron-manganese alloys used are listed in Table I. The zone-melted iron and Fe-Mn alloys were made by Battelle Memorial Institute. Iron S-1 was arc-melted in a water-cooled steel mold in an argon atmosphere. The ingot was forged into a bar, then given two horizontal zone-refining passes in an alumina boat. Iron V-4 was treated in a similar manner, but was not zone-refined. The iron for the zone-melted Fe-Mn alloys was induction melted in vacuum in MgO crucibles and cast into alumina molds. The ingots were forged into bars, machined to shape, and a groove milled down one side of each. The best available electrolytic Mn was placed in the grooves, and the bars were zone melted. The vacuum-melted Fe-Mn alloys were induction melted in this Laboratory in MgO crucibles and poured into cast-iron molds. Iron V-5 was purchased from National Research Corp. in the form of a small vacuum-cast ingot. The low-carbon steel was made by induction melting in air at the U.S. Steel Corp. Applied Research Laboratory. The history of the materials prior to the final cold reduction differed; these details are given in the Appendix. The penultimate grain size of the principal materials was kept in the range ASTM 2 to 4, except for the low-carbon steel. PROCEDURES The cold work prior to the final recrystallization anneal was kept constant at 60 pct. It is known that rolling procedure can influence the kinetics of recrystallization of ironI2; therefore, all specimens were rolled in one direction only, between clean,

Jan 1, 1962

By V. Jares

DESPITE the fact that a combination of metals-aluminum-zinc-tin, and sometimes aluminium-zinc-cadmium-is extensively used for aluminum solders, as well as for die-castings, the constitution of these alloys has not yet been made clear. I. BINARY SYSTEMS The system aluminium-zinc is the basis of the ternary alloys under consideration. Their composition was made sufficiently clear by the investigations of Roscnhein and Archbutt,1 Bauer and Vogel,2 Sander .and Meissner,3 Hanson and Gayler4 and Isihara.5 Only the temperature of decomposition of the crystals s seems still to be doubtful, whether it is considered as a compound of Al2Zn3 (according to Bauer and Vogel) or as an intermediate phase of variant composition (according to Hanson and Gayler). This temperature is given by most of the authors, as in the neighborhood of 256° C., only Isihara giving 280° C. As its accurate determination is of special importance in the study of the ternary alloys under consideration it was experimentally controlled in the following manner: An alloy corresponding in composition to the formula Al2Zn3 was made, in which the temperature effect was found to be the greatest. This was drilled and a silver-constantan thermoelement inserted into the cavity so as to be in direct contact with the alloy. The whole was then very slowly heated and the heating and cooling curves determined. The transition temperature from the heating curve was found to be 281° C., whereas-from the cooling curve it was 252° C.

Jan 10, 1926

By Frederick Laist

THE object of the construction and operation of the 80-ton leaching plant was to test out the leaching of sand tailings on a large scale and, if possible, determine a definite method of operation, and the best construction for the larger unit which is now being built. It was also of importance to obtain some practical data as regards cost items. The 80-ton plant was not expected to be a commercial success. A leaching process on such low-grade material necessitates the treatment of a very large tonnage.. Such a cost item as labor, for instance, is entirely out of proportion in such a small plant. The amounts of acid, salt, scrap iron, and fuel for roasting, however, are the same per ton in an 80-ton plant as in a 2,000-ton plant. These costs were definitely established. Also the percentages of extraction and grade of tailings were definitely determined for a large-sized unit. Following will be found the description of the plant, the method of operation and the results obtained. A -general view of the plant is given in Fig. 1. The bins consisted of one coal bin with a capacity of 30 tons, one salt bin with a capacity of 20 tons, and a "mill tailings" or feed bin which held 70 tons. The coal and salt bins were placed with their floor level even with the firing floor of the roasting furnace. The feed bin, to give it greater capacity, discharged about 12 ft. below this point, to a 12-in. conveyor belt, which, in turn discharged into a pug mill. This fed another conveyor belt, which discharged into the top hearth of the furnace. The furnace was an ordinary six-hearth MacDougall roaster, .20-ft. in diameter. It was equipped with two fire boxes, on opposite sides, the flames entering on the third hearth. An induced draft was obtained with a Buffalo blower, worked as an exhaust fan. Just above the top hearth was an annular flue around the whole circumference of the furnace. Slots at intervals of about 18 in. led from this flue down into the top hearth. The slots were 2 in. wide by 6 in. long. This annular flue proved rather unsatisfactory, as it tended to fill up with flue dust and choke the slots, thus cutting down the draft. The volume of gas through

Jan 8, 1914

By R. W. Raymond

THE question, what is the best proportion among weight, fall, and speed of stamps, is one which has not yet received thorough and systematic examination. In considering the economical application of stamping machinery, we meet, at the beginning, with serious difficulties in obtaining accurate data for comparison. The weight and fall of stamps vary as the shoes and dies wear out; and this may lead to a change of speed also. Moreover, defects in engines, boilers, or machinery for the transmission of power, may occasion serious losses, which cannot fairly be charged to the arrangements of the stamps proper. Again, the capacity of stamp-mills is directly dependent, in some degree, upon the nature and extent of discharge, fineness of screens, and other peculiarities of the battery. Finally, the hardness and tenacity of the rock crushed varies so much that comparisons between different localities cannot be implicitly trusted. The safest experiments are those made in the same mill, by changing first one and then another condition of working; but this is seldom possible for such conditions as weight and lift of stamps, and only within narrow limits for their speed. We may eliminate questions of friction, transmission, and generation of power, in the case of stamps, by measuring the power actually developed by their fall. Thus, the weight, multiplied into the fall in feet, and the number of drops per minute, gives us exactly the number of foot-pounds exerted by each stamp. Dividing by 33,000, the number of foot-pounds per minute in one-horse power, we have the horse-power per stamp, from which the effective power of the whole mill may be obtained. Dividing the amount of rock crushed daily by the effective horse-power, gives us the daily amount per horse-power; and this is the best measure that can be obtained for the effectiveness of the stamps. A complete discussion of the subject would require us to determine the exact influence of the discharge, etc., and the exact resistance offered by different classes of rocks, for both of which points the data are wanting. Professor J. D. Hague, in the third volume of the United States Geological Exploration of the Fortieth Parallel, gives a valuable

Jan 1, 1873

By C. R. Whitney, G. N. Maniar, D. R. Muzyka

Previous results have shown that Pyromet 860, an Fe-Ni-base heat-resistant alloy, is stable at temperatures as high as 1500°F for aging times as long as 100 hr. This Paper describes the results of long-time creep-rupture testing at 1050" to 1400°F at various stress levels. Times as long as 37,660 hr were employed. The effects of time, temperature, and stress on the precipitates and their morphologies were studied by optical and electron microscopy, X-ray and electron diffraction, and microprobe techniques. phase, containing cobalt, nickel, and molybdenum, was detected after extended exposures from 1200" to 1400°F and careful study was performed to describe the kinetics of its formation in this alloy. µ phase formation apparently has little effect on the elevated-tem-perature properties of Pyromet 860. For times as long as 500 hr at 1300°F and below, with µ phase present, m significant effects on ambient temperature properties were noted. For longer times at 1300°F and after 1400°F exposure, the effects of u phase on ambient temperature tensile strength properties are not clear due to y' effects and grain boundary reactions. Electron-vacancy, N,, numbers were calculated using different methods described in literature and correlated with the present findings. In the selection of alloys for use in gas turbine applications, structural stability ranks as a primary criterion. High-temperature strength and cost are also of major concern. With these factors in mind, Pyromet 860 alloy, an Fe-Ni-base superalloy was designed. This alloy combines the cost advantages of Fe-Ni-base alloys such as A-286, 901, and V-57 with improved strength and structural stability'1,2 and no tendency to form the embrittling cellular 77 phase. A previous study3 reported on the stability of Pyro-met 860 at temperatures from 1375" to 157 5°F and times up to 100 hr. That study showed that the y' precipitates increased in size and separation and decreased in number with an increase in time or aging temperature. No deleterious phases were found to occur. In the present work, samples from four production heats were subjected to long-time creep-rupture testing at 1050" to 1400°F at various stress levels. Various heat treatments were used on the starting samples and tests were run up to 37,660 hr. The effects of time, temperature, and stress on the precipitates and their morphologies were studied by optical and electron microscopy, X-ray and electron diffrac- tion, and microprobe techniques. Electron vacancy numbers, Nv , calculations were made by TRW.4 Experimental results are correlated with the Nv data used to predict occurrence of intermetallic phases such as a phase. EXPERIMENTAL PROCEDURE Mechanical Tests. Material for the present study came from four production size heats of Pyromet 860 alloy, weighing from about 3000 to about 10,000 lb. All of these heats were made by vacuum induction melting plus consumable electrode vacuum remelting. The nominal analysis for this alloy is compared with the actual analysis of the four heats in Table I. Sections of these heats were forged to 9/16-in. round bar,3/4-in. square bar, 3-in. round bar, 4-in. square bar, and a gas turbine blade forging about 16 in, long, about 6 in. wide, and weighing about 20 lb. In general, all forging of this alloy is done from a 2050°F furnace temperature. Longitudinal test blanks were cut from the centers of the smaller bars, from mid-radius positions for the 3- and 4-in. bars, and from the air foil of the gas turbine blade and heat-treated according to the procedures outlined in Table 11. Heat treatment A is the "standard treatment" recommended for this alloy for best all-around strength and ductility. Heat treatment B is a modification of treatment A for improved tensile strength at moderate temperatures. The treatment coded C was designed for treating large sections according to a procedure previously described.' Heat treatment D was developed to yield optimum stress relaxation characteristics at 1050°F for a steam turbine bolting application. After heat treatment, the test blanks were machined either to plain bar creep specimens with a gage diameter of 0.252 in., to combination smooth-notched stress-rupture bars with a plain bar diameter of 0.178 in. and a concentration factor of Kt 3.8' at the notched section, or to notch-only specimens. All specimens conformed to ASTM requirements. Metallography. Most of the creep-rupture tests were continued to failure. A few bars were fractured as smooth or notch tensiles after creep-rupture exposures. After fracturing, ordinary metallographic sections were made primarily in gage areas adjacent to fractures to represent a "high-stress" region and through specimen threads to represent a "low-stress" region. All metallographic sections were made in a longitudinal direction with respect to the test specimen axes. For optical microscopy, the samples were etched in glyceregia (15 ml HC1, 5 ml HNO,, 10 ml glycerol). For XRD analysis, the phases were extracted electrolytically in two media: 20 pct &Po4 in H20 for selective extraction of y' and 10 pct HC1 in methanol for carbides and other phases.

Jan 1, 1970

By C. D. Michaelson

The memory of D. C. Jackling serves chiefly to remind us how much we owe to the pioneers of our industry. Jackling was one of the giants. Orphaned at the age of two, he made his way through sheer persistence and plain hard work. His brilliance gave rise to a vision, and his tenacity made his vision a reality. Foreseeing that economies of scale would make the handling of low-grade ore profitable, he introduced the revolutionary concept of open-pit copper mining. During World War I, the defense effort of the United States was immeasurably strengthened by the tremendous supplies of copper from the western mines that Jackling had made possible. Again in World War II, the demands for copper were supplied, and the nation once more had profound reason to be grateful to this rugged, stubborn man who had long ago ventured into the mountains and unlocked their wealth. We are now embarked upon another great era of change, and we must devise new concepts to meet it. The task is not only to create new techniques of mining, but to forge better ties between men and institutions which will let us work in harmony with the techniques we have. We might recall that while Jackling was a man of towering pride and formidable will, he was also adept at getting others to share his vision and join his purpose. Today our reach for cooperative endeavor must go far beyond our own shores as we seek to develop the buried riches of distant lands. And we would do well to remember that Jackling's remarkable insight would have come to nothing had not British investors been willing to provide much of the initial capital. As was true of so many early enterprises in America, European capital was absolutely essential.

Jan 4, 1969