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By M. Jacobs

Keywords: Smelting, converting, sulphide, sulphide smelting, platinum, platinum group metals, PGM, base metals, nickel, copper, matte, slag, furnace, electric furnace, Söderberg, electrode, granulation, converter, flash drier, sulphuric acid, acid plant, Ausmelt, Sirosmelt, pyrometallurgy, metallurgy, Anglo Platinum, South Africa Waterval Smelter complex is situated in Rustenburg, in South Africa?s North West Province. The smelter objective is to process wet concentrate to produce crushed, slow-cooled, sulphur-deficient nickel-copper matte rich in platinum group metals (PGMs), gold, and base metals for despatch to the Magnetic Concentration Plant at the Base Metals Refinery. Throughout its history, the smelter complex has been continuously upgraded in line with increasing production demand, changing feeds, environmental initiatives, and advances in available technology. The smelter receives filter cake and slurry from Anglo Platinum concentrators and joint ventures. Wet concentrate is fed through a flash drying process utilising coal-fired, fluidised bed hot-gas generators, to produce dry feed material for the electric furnaces and slag-cleaning furnace. For primary smelting, two electric furnaces are used, each with a rated capacity of 34MW. Furnace matte, containing the bulk of the base metal sulphides and PGMs, is tapped periodically into refractory-lined ladles and granulated using high-pressure water jets, then dried through electrically powered pneumo-driers to become the main feed to the Anglo platinum Converting Process (ACP). Slag is tapped semi-continuously, granulated, and treated through the slag mill. The ACP treats the combined matte output of Waterval, Polokwane, and Mortimer smelters. It is a top-blown furnace, with furnace matte, air, and oxygen being injected into the converter via a lance submerged in the slag. Converter matte is tapped and bottom cast into moulds, slow-cooled, crushed, and despatched to the refineries. Slag is granulated and dried for recycling to the slag-cleaning furnace. ACP slag is fed to the slag-cleaning furnace along with a reductant and a sulphur source. Slag-cleaning-furnace matte is granulated for processing by the ACP, while slag is granulated and processed in the slag mill. The slag mill and flotation circuit treats granulated slag from the electric furnaces and slag-cleaning furnace to recover entrained matte containing valuable PGMs and base metal sulphides.

Jan 1, 2006

By T. L. McCall

AUTHENTIC records show that coal mining in Cape Breton dates from the year 1720, when the French military authorities obtained coal from what is now known as the Blockhouse seam, in the Morien district, for use at Louisburg, where the fortress, now of such historic interest, was being built. Thereafter, coal was mined more or less continuously, and although, for many years, in a very haphazard way, there was, on the whole, a steady growth towards a better regulation of the industry, culminating in the year 1825 with the arrival of the General Mining Association in Nova Scotia. This Company, more generally known as the G.M.A., had acquired extensive tracts in Brazil and Colombia and had also purchased the mining rights for the whole of Nova Scotia-excepting such areas as had been previously leased-the attraction being the rich veins of copper currently reported as occurring in the Province. These fabulous copper veins, upon examination, failed to materialize, but the engineer sent out to report on them returned with such good accounts of the coalfields he had seen that steps were taken immediately to investigate them. From that rime onward, the history of coal mining in Nova Scotia is one of progress and achievement. One of the first acts of the G.M.A. was to acquire the areas already leased to other concerns and develop these in a masterly fashion, employing the best machinery and talent available at that time. Such dominant control over the minerals of the Province, although it led to orderly development in the several coalfields, also, later on, resulted in restricting operations in the various coal centres to such an extent that a determined effort was put forward by the people of Nova Scotia to end such a state of affairs. Consequently, in 1857, the original lease of the G.M.A. was abrogated, the Company, however, being allowed to retain certain areas in the districts it had already developed. This opened the way for the formation of other coal-mining companies, and numbers of these immediately sprang into existence in the various coal-mining centres. In 1893, the Dominion Coal Company, Limited, was formed by the amalgamation of seven companies operating in the neighbourhood of Glace Bay, in Cape Breton. Later, in 1910, the Dominion Iron & Steel Company, Limited, obtained control of the Cumberland Railway & Coal Company, which had been formed in 1884 to acquire the rights of the two companies working in the Cumberland County coalfield.

Jan 1, 1936

By M. Maleki

Variogram analysis and kriging lack robustness in the presence of outliers and data with long-tailed distributions, which often arises when estimating grades in precious metal deposits. The capping technique, consisting of truncating the data to some top-cut grade, is widely used in order to mitigate the influence of the values in the upper tail of the distribution. However, this procedure omits part of the grade variability and is likely to provoke a bias in the estimates. To avoid these issues, a recently proposed approach is to decompose the grade of interest into three components (the truncated grade, a weighted indicator above the top-cut grade, and a zero-mean residual) and jointly estimate the truncated grade and the indicator by cokriging. This approach is attractive as it provides unbiased grade estimates, allows choosing the ?optimal? top-cut value, and essentially works with truncated and indicator data, thus avoiding the use of outlying values for calculating sample variograms and performing spatial interpolation. This work presents an application of this approach to a disseminated gold deposit that has been identified through exploration drilling. The effect of using an indicator covariate is assessed through leave-one-out cross-validation, by comparing the grade estimates with the true grades and with the grade estimates obtained with the conventional capping approach, which considers only the truncated grade as the variable of interest. As a result, cokriging the truncated grade and the indicator above top-cut grade outperforms the conventional capping approach, yielding significantly more accurate estimates. A few complementary guidelines are provided for validating the model hypotheses and for the implementation of cokriging.

Jan 1, 2014

By Joseph D. Davis, GEORGE S. POPE

This bulletin is the fourth of a series a showing the results of the purchase of coal by the Government under specifications. The work of inspecting and analyzing coal delivered on Government contracts was transferred to the Bureau of Mines by an act of Congress effective July 1, 1910. It had been carried on for several years before that date by the technologic branch of the United States Geological Survey. The purchase of coal on the dealer's statement as to quality or on the reputation of the mine or district producing the coal is gradually being discontinued. At present most coal-purchasing contracts make definite provision regarding the desired heating value of a coal and the composition as shown by analysis. The heating value is usually expressed in British thermal units" and the composition specified is that shown by proximate" analysis. The price to be paid for delivered coal is made to depend on whether the analyses and heating-value tests of samples representing the delivery show the quality to be above or below the quality set forth in the contract. Large coal consumers are beginning to appreciate more and more the importance of the cost of power as a factor in the cost of producing a finished article. The endeavor to increase the efficiency and the economical operation of a power plant calls for an intimate knowledge of the quality of the coal being used. The purchase of coal under specifications insures the purchaser getting what he pays for and the coal being of the quality guaranteed. In addition, the analyses and tests of the delivered coal furnish data whereby the power-plant results can be comprehensively studied and a continuous check maintained on the conditions of operation.

Jan 1, 1912

By Hamid-Reza Manouchehri

"The triboelectric charge attributes of some silicate minerals (i.e., feldspar, quartz and wollastonite) after contacting different triboecharging medium made of different materials were studied. The charge acquisitions by different size fractions of minerals were monitored and accordingly the energetic work function values, i.e., the main parameter determining the entity of triboelectric charges acquired by mineral grains, of the examined minerals were estimated. Moreover the separation behavior of different size fractions of these minerals through the electric field of a laboratory free-falling separator when the mineral grains are charged by different tribochargers were observed and considered as the electrical separation potential of the examined minerals.Furthermore, the role of adsorption of different chemical species on triboelectric charge characteristics and charge acquisition of mineral samples were described from theoretical point of view and the effects of some chemical reagents on triboelectric charge acquisition of the examined minerals were studied. In addition the separation behavior of chemically conditioned quartz, feldspar and wollastonite minerals, using different anionic and cationic reagents, through the electric field of a free-fall electrostatic separator before and after chemical conditioning were monitored.Finally an attempt was made to translate the findings from single mineral systems to a complex silicate ore, containing mainly of feldspars, quartz, and wollastonite. Different separation tests under various conditions were conducted to this complex silicate ore. Before passing through the separation device, the ore sample was conditioned by different cationic and anionic reagents and then was triboelectricaly charged by different tribocharging medium in order to find the effective reagent and tribocharging medium for separating silicates. Besides the role of temperature and humidity of the surrounding ambient in separation behavior were considered."

Jan 1, 2003

By C. Strachan

This paper presents an evaluation of tailings dam incidents from the 1994 USCOLD Tailings Dam Committee report. Comparisons are also made with water storage dam incidents from USCOLD reports and recent tailings dam incidents. The evaluation results show that tailings dam incidents are due to a number of factors including overtopping, static and seismic instability, seepage and internal erosion, and foundation conditions, and that no particular type of tailings dam or operational condition is more susceptible to incidents. In addition, the results confirm that tailings dams should be located, designed, operated, and reclaimed with a thorough knowledge of site conditions, mill operation, site monitoring, and tailings characteristics.

Jan 1, 1999

By Donald R. Williamson

Statistical studies at Cyprus Pima Mine indicate that samples from 22 blastholes are necessary for determining average copper grades, within a desired range of precision, for mine-model blocks by arithmetic averaging. The average number of holes in such blocks is 14. Many considerations show that more holes will not be drilled for sampling. A way to determine block grades more reliably than by" arithmetic averaging was sought. Thus far arithmetic averaging has proven to be the best procedure for the particular operation characteristics despite the small number of samples. It naturally follows that expenditure of great effort in sampling blasthole cuttings is unwise.

Jan 1, 1977

By A E. Annels, I P. Hodkinson an, S P. Barr

Narrow vein systems represent an important source of gold, which have generally been exploited by small to medium sized companies. Their evaluation poses particular problems because of their grade and geological complexities. The determination of grade is arguably the most important activity in resource estimation, as it is generally grade and not tonnage that makes an orebody. This is particularly true of narrow vein-gold deposits whose resources are generally relatively small, though medium to high-grade (6 - 40+ g/t). They often display extreme grade anisotropy in all directions. Two grade populations are generally observed; 1) low, often subeconomic, background grades and 2) high-grades associated with discrete ore shoots. It is possible for gold to be distributed within the wallrocks as well as within the vein. Extremely high-grade values typify this style of mineralisation and require special consideration during grade estimation to determine if top cutting is valid or not. Estimation of both width and accumulation in 2D on vertical longitudinal projections or inclined planes have historically been used to evaluate narrow veins. Resource estimates based on traditional 2D methods is still widespread, but has in some cases been replaced by computer-based 3D modelling. Grade estimation methods are well-known, ranging from classical to geostatistical. Historically, classical methods such as inverse distance weighting have been used, though geostatistical indicator kriging methods are sometimes applicable. Geostatistical studies are driven by the production of reliable variograms, which in narrow gold veins is often problematic. It is generally difficult to define resources from drillhole intersections beyond the inferred and indicated categories with any confidence. In the majority of cases underground development is required to define measured resources and ore reserves. Trial mining/bulk sampling is often used to test estimated grades and also provides important data on ground conditions and the parameters relating to the proposed mining method required for ore reserve definition. Regular reconciliation should be undertaken between the estimated stope grades, grades indicated from stope/truck sampling and grades realised in the mill in order to determine whether correct evaluation strategies are being applied. The important feature of narrow vein-gold deposits is their strong geological controls; in response to this, geologists must understand the geology as best as possible.

Jan 1, 1999

By Haijian Shi, Drew Pizzo

This article focuses on the appropriate application of subsurface investigation methods for transmission structures, which are typically designed to resist lateral rather than vertical loads. Currently, the three methods used most often for the subsurface investigation of transmission structures in the field are the Standard Penetration Test (SPT), the Cone Penetration Test (CPT), and the Flat Dilatometer Test (DMT). Each of these methods has advantages and disadvantages, and each is more applicable to some scenarios than to others. To gain a better understanding of these test methods and the implications of using them for various kinds of applications, a comparison study was conducted in the field in Maryland, for three boring locations. Each boring location was explored using each of the three tests as stated. The results of the tests and lessons learned are presented and compared, and these comparisons show that the three test methods agree on the majority of the findings. The results from each test method were also used to derive key parameters such as the soil friction angle for given foundation designs considered in order to establish a clear basis for comparison. Recommendations for performing transmission structure subsurface investigations are made in order to optimize the use of each method and thereby optimizing subsequent foundation designs. INTRODUCTION For overhead transmission structures, the most important structural requirement for determining the foundation design differs from the requirement for other structures such as buildings and bridges in accord with the conditions the transmission structures will need to withstand. In addition to the ability to bear a given vertical load consistent with its use, the foundation must bear lateral loads arising from wind and other weather conditions. The foundation types used most often for overhead transmission monopole structures include concrete drilled pier, vibratory caisson, and direct embedment. In order to determine an appropriate and even an optimum foundation design for any given set of conditions, an appropriate subsurface investigation method or approach is needed. Currently, the standard penetration test (SPT), the cone penetration test (CPT), and the flat dilatometer test (DMT) are the three most commonly used subsurface investigation methods.

Jan 1, 2018

By Ira L. Wright

This paper describing the milling practice of the Black Hawk Consolidated Mines Co., is one of a series being prepared by the United States Bureau of Mines. ACKNOWLEDGMENTS Part of the information contained in this paper was furnished by I. H. Stanley, mill superintendent, Black Hawk Consolidated Mines Co., Hanover, M. M., and a part by the South-western Engineering Corporation, Los Angeles, Calif. The assistance of T. G. Chapman in arranging the paper for publication is also acknowledged.

Jan 1, 1930

By Hillary W. St. Clair

Mining activity began in colonial times with ironmaking operations scattered along the eastern seaboard. Iron furnaces and forges manufactured iron implements from bog iron ores using charcoal from the extensive forests as a fuel. Lead ores were mined in the Mississippi Valley and copper ores in the Lake Superior region. However, the real beginning of the American mining industry did not occur until the 19th century. The history of American mining is organized around three epochal events. The first was the discovery of gold in California in 1848, which marked the beginning of a period of apprenticeship in mining and metallurgical techniques. The second was the discovery of the fabulous Comstock Lode in western Nevada in 1859, which expanded mining throughout the Far West and led to large-scale underground mining and the development of smelting techniques for lead, silver, and copper ores. The third event was the building of a transcontinental rail-road system after the Civil War, which brought about the consolidation of the industry from a large number of independent mines, mills, and smelters into integrated operations run by large corporations. Thus developed the mining industry that today supplies the energy and critical materials for the great-est industrial complex the world has known.

Jan 1, 1977

By James J. Cahill

Contractor's working in an urban environment face a multitude of working conditions. There is no typical "Downtown" job site. From afar we just see the skyline, or up close a specific building. This, of course, does not give us a clue as to the site conditions the foundation contractor faced in doing his work. The open, downtown building site is still available on some projects, but they are becoming rare as our cities are becoming more developed. A typical site today might include any one or several of the following problems: A. Deep pit with no ramp access B. Multi-type known or unknown obstructions C. Height limitations D. Load restrictions E. Existing adjacent building founded on shallow foundation F. Existing foundations G. Existing tunnels, utilities or subways

Jan 1, 1991

By E. A. Rychkun

"For the last 700years of recorded economic history, man has been subjected to alternating inflationary and deflationary patterns. Through this period of time, a severe deflationary pattern has developed approximately every 55 years, creating 12recordable occurrences. Through the last two centuries, this severe deflationary phenomenon has come to be known as a depression. As these depressions have repeated themselves regularly, they are cyclic. This in turn leads to the question of whether the 13th cycle will also repeat itself in the form of a depression. As this cycle is now 51 years old, we must consider the possibility at about 1984.In analyzing a 700-year record of consumer prices in Southern England, the 55-year cycle appears to vary in shape and intensity. This varying phenomenon is due to the effect of longer cycles upon which each one ""rides "". Because each cycle effectively rides on the next largest, which in turn rides on the next largest and so on, the combined measured effect of all cycles together at any point in time is always unique. This means that anyone cycle can never repeat itself in an exact identical manner. The combined effect therefore is what we observe in the form of prices and, as cycles interact, variations in deflation are produced . The ""science"" of economics attempts to quantify and develop theory on situations which are never identical and hence can be conservatively classified as a useless predictive tool.This means that more unconventional approaches may be required to predict our economic future. In looking at previous depression cycles, it is possible to recognize similarities in human behaviour patterns and hence the resulting economic movements. These behaviour patterns create major events or influencing factors which set the scene for a major deflationary condition. The way in which these factors occur, however, is not predictable. As more and more of these similar events are identified in each cycle, we can increase our confidence on the probability of the last event occurring (a depression). By also unravelling the set of larger cycles, we can determine the potential combined effect at any point in the future.This paper presents a system of cycles ranging from 800 years to 3 years which appear to operate in our economic system. By so doing, a long-term projection into the next century can be made. Finally, the paper deals with the main controlling similarities within the depression cycle, to show that a comparison with our current cycle implies that a major deflationary collapse in the mid 1980's is virtualy inevitable."

Jan 1, 1980

By Thomas J. Peters

The U.S. Bureau of Mines and the U.S. Geological Survey are responsible for the evaluation of the mineral resources and potential of further planning areas included in the U.S. Forest Service Roadless Area Review and Evaluation (RARE II) program. The Bureau of Mines primarily evaluates mineral deposits and prospects within the areas. The Geological Survey naps the area's geology and conducts geochemical sampling. Evaluations are in conformance with the Forest and Rangeland Renewable Resources Planning Act of 1974 as amended by the National Forest Management Act of 1976. The Hauser RARE II area, which consists of 7,600 acres (3,100 ha) within the Cleveland National Forest, is in southern San Diego County, California. The area, which forms the north slope of Hauser Canyon, ranges between 1,600 and 3,919 ft (490 m) in elevation. It is sparsely to densely covered with desert shrubs. The area is underlain by granitic rocks of the Peninsular Ranges batholith.

Jan 1, 1983

By D. Govender

In recent years, economies of scale have continued to drive copper projects to larger throughputs to offset depleting lower grade resources. A decade ago there were only a small number of projects that stretched beyond 100,000 Mtpd throughput rates. Nowadays and moving forward virtually all the major copper projects are sized beyond this, with throughput rates up to 250,000 Mtpd now under evaluation for a number of key projects in Chile and Peru. This paper explores the development from the 160 m3 flotation cells, through to the 257 m3 cells and nowadays to the 660 m3 machines. The contributions of specific copper concentrators to this growth phase are reviewed herein. The historical basis of flotation machine scale-up is also briefly discussed. Metallurgical results as well as layout, maintenance and operational aspects are highlighted.

Feb 27, 2013

By Mark P. Juzli

During the 1980s, a revolution has been taking place in industrial minerals marketing. Transportation deregulation and a handful of creative marketing and distribution managers have completely changed the rules for marketing many industrial minerals. Minerals are being transported much farther than in prior decades and at much less cost. Bulk and package terminals are becoming increasingly common as a means to take advantage of freight rate savings and to provide enhanced service to faraway customers. Water and rail transportation are being used increasingly to penetrate markets considered unreachable just a few years ago. No longer do the textbook rules of thumb for industrial minerals marketing apply. This author recalls three of those rules he was taught in mineral economics graduate school in the 1970s. As recorded in class notes: • construction aggregates are seldom shipped more than 32 km (20 miles) from the quarry; • cement is sold within 240 km (150 miles) of the mill; and • industrial sand is sold regionally - it is freight constrained to a market radius of no more than 320 to 400 km (200 to 250 miles) from the plant. And yet, the author looks up in 1989 and observes overland movements of aggregates of many hundred miles, overland movements of cement and industrial sand of 1600 km (1000 miles) or more, and water movements of both aggregates and cement into the United States from sources halfway around the world. Truly, industrial minerals are in the midst of a marketing revolution. The companies that have led this revolution have enjoyed considerable financial success in the 1980s. They have enhanced their profitability by increasing market share, capacity utilization, and average selling prices by taking product to remote markets where premium prices are available. They have consistently outperformed their competition, many of whom remain unaware that the marketing revolution going on around them is actually a transportation/distribution revolution. The successful industrial minerals company of the next 10 to 15 years must participate in the transportation revolution as it continues to evolve. Additional human and capital resources must be committed to maximize the effectiveness of a company's transportation and

Jan 1, 1989

By V. F. Parry

[Approximately 7-1/2 million tons of subbituminous coals are mined annually in Colorado, Wyoming, and Montana, of which 50 percent probably reaches domestic consumers. The moisture of these subbituminous coals is high, averaging about 25 percent when they are mined. The coals are non-caking end stack to a variable degree when exposed to normal atmospheric conditions. They are good domestic fuels, are considered to be smokeless in most furnaces, and have been used for many years in hand-fired domestic furnaces in which the practice is to employ large lutes for efficient combustion.]

Jan 1, 1941

By A. Opara

The weathering of coal mine waste rock releases iron, calcium, sulfate and associated trace elements like selenium [Se], which are introduced to seepage waters. Nitrogen species, such as nitrate and ammonia, are also found in association with coal-mining drainages mainly due to leaching of residual blasting compounds. Elevated concentrations of Se are a ubiquitous occurrence in coal mining environments in British Columbia, with values ranging from below 50 to over 500 µg/L in site waters. Selenate is the most common form of selenium found in waste rock seepages, and is exceedingly mobile in aerobic freshwaters. A major concern with waterborne Se in British Columbia is the potential for its bioaccumulation in aquatic food chains. Treatment to remove Se from coal-mining wastewaters has proven to be challenging for conventional water treatment technologies. Compounding this challenge, many streams are characterized by high flows and low selenium concentrations. Conventional membrane and ion exchange treatments produce concentrated brine streams that are difficult to treat or require disposal. Conventional biotreatment systems use excess nutrients to provide the required electrons to compensate for inefficient and variable electron availability, as well as to adjust reactor chemistry. The Electro-Biochemical Reactor (EBR) technology provides electrons to the microbes directly at a low voltage potential (1-3 V), supplying a controllable and consistent supply of useable electrons to the system and microbes at low current. In this manner, the EBR technology overcomes the shortcomings found in conventional systems, as it reduces the required nutrient addition and provides a more controllable, efficient, economical, and robust biotreatment system than found in past generations of biological treatment systems. Additionally, the EBR process does not produce excess solids or biomass; therefore, solids management post-treatment is not required. Laboratory EBR bench-scale and on-site pilot-scale systems were used to treat five British Columbia coal mine wastewaters; influent Se concentrations ranged from 35 µg/L to 531 µg/L. Se treatment targets for the tested waters ranged from 5 to 10 µg/L. Mean Se concentrations in EBR effluents ranged from 0.5 µg/L to 1.4 µg/L, while reducing sulfate concentrations. The test data demonstrate that the EBR technology is an effective Se removal option for British Columbia?s coal-mining wastewaters.

Feb 23, 2014

By A. Opara

The weathering of coal mine waste rock releases iron, calcium, sulfate and associated trace elements like selenium [Se], which are introduced to seepage waters. Nitrogen species, such as nitrate and ammonia, are also found in association with coal-mining drainages mainly due to leaching of residual blasting compounds. Elevated concentrations of Se are a ubiquitous occurrence in coal mining environments in British Columbia, with values ranging from below 50 to over 500 µg/L in site waters. Selenate is the most common form of selenium found in waste rock seepages, and is exceedingly mobile in aerobic freshwaters. A major concern with waterborne Se in British Columbia is the potential for its bioaccumulation in aquatic food chains. Treatment to remove Se from coal-mining wastewaters has proven to be challenging for conventional water treatment technologies. Compounding this challenge, many streams are characterized by high flows and low selenium concentrations. Conventional membrane and ion exchange treatments produce concentrated brine streams that are difficult to treat or require disposal. Conventional biotreatment systems use excess nutrients to provide the required electrons to compensate for inefficient and variable electron availability, as well as to adjust reactor chemistry. The Electro-Biochemical Reactor (EBR) technology provides electrons to the microbes directly at a low voltage potential (1-3 V), supplying a controllable and consistent supply of useable electrons to the system and microbes at low current. In this manner, the EBR technology overcomes the shortcomings found in conventional systems, as it reduces the required nutrient addition and provides a more controllable, efficient, economical, and robust biotreatment system than found in past generations of biological treatment systems. Additionally, the EBR process does not produce excess solids or biomass; therefore, solids management post-treatment is not required. Laboratory EBR bench-scale and on-site pilot-scale systems were used to treat five British Columbia coal mine wastewaters; influent Se concentrations ranged from 35 µg/L to 531 µg/L. Se treatment targets for the tested waters ranged from 5 to 10 µg/L. Mean Se concentrations in EBR effluents ranged from 0.5 µg/L to 1.4 µg/L, while reducing sulfate concentrations. The test data demonstrate that the EBR technology is an effective Se removal option for British Columbia?s coal-mining wastewaters.

Feb 23, 2014

By A. R. Farkoosh, J-P. Fortin, M. Pekguleryuz, S. Bagherpour

"Titanium aluminides are structural intermetallics which offer an attractive combination of high temperature strength and light weight. For such properties, these intermetallic alloys have become front-runners in replacing nickel-based superalloys used for several high temperature applications. These alloys are produced from metallic titanium, aluminum and master alloys involving an expensive and difficult process. A low cost alternative to current industrial production method is the new modified aluminothermic process which directly reduces titanium oxide (TiO2) to titanium aluminides. Nevertheless, this process has itself significant challenges in achieving alloys free of oxide inclusions; the close densities of the slag and the titanium aluminides makes slag/molten metal separation a challenging task. Usually, the alloy produced requires a second refining step. In this study, thermodynamic calculations based on CALPHAD method were performed to determine the solidification path and an attempt has been made to develop a criterion to increase the density deference between the slag and the alloy by alloying with appropriate elements. Furthermore, scanning electron microscopy (SEM) and x-ray diffraction (XRD) techniques were utilized to examine the microstructure and phase selection of three Ti-Al alloys produced by the aluminothermic reaction, including the as-cast, refined in a controlled atmosphere and inert-gas-refined alloys. The composition range of the alloys studied was restricted to the a2-Ti3Al + ?-TiAl phase field (Ti-30Al) in the binary Ti-Al phase diagram leading to a lamellar structure with different complex intermetallics as shown in Figure 1.INTRODUCTIONTiAl based alloys are promising structural materials for high temperature aerospace and automotive applications. This is due to some attractive properties such as low density, high specific strength, high specific stiffness and high temperature strength retention (Wen-bin, Xue-wen, Hong-fei, & Yong-feng, 2011). These alloys have become leading candidates to replace Ni-based super alloys in gas turbine engines. Replacement of Ni-based super alloy parts with titanium aluminides is expected to reduce the structural weight of high performance gas turbine engines by as much as 20–30% (Kothari, Radhakrishnan, Sudarshan, & Wereley, 2012)."

Jan 1, 2016