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By R. N. Zitter

PRESENT work was done in connection with a program for obtaining a low energy gap semiconductor suitable for photodetection. The inter-metallic compound InSb, which is now being in-

Jan 1, 1959

By J. R. Long, R. S. Dean, F. S. Wartman, E. T. Hayes

The production of titanium in I5-lb. lots and with a purity sufficient to be consolidated into ductile metal, as described in a previous paper,' has provided adequate material for a study of the physical properties of titanium and a more thorough examination of its working qualities. Data on the physical properties reported in that paper were obtained on metal fabricated by a fixed procedure, standardized for the purpose of control of the reduction, and are representative only of material fabricated under those conditions. There are many possible variables in the working schedule, which will have significant effects on the properties of the finished material; and since the previous working methods were not necessarily the best, an investigation of the fabrication of titanium by other methods was undertaken. In this work the consolidation of the powder by pressing and sintering was conducted essentially as outlined in the report cited' and all efforts were centered on fabrication methods for those powders and the proper- ties produced by them. Hardness, density, microstructure, and tensile properties were determined at various stages in the working and annealing; and resistivity measurements were made on a few bars and drawn wire. Consolidation of the PowdeR The screen analysis of the available titanium powder is given in Table I. No attempt was made to alter the size distribution from that noted because this powder, although coarse by normal powder-metallurgy standards, produced acceptable compacts suitable for the present work. Because of their large specific surface, finer powders are more contaminated by oxygen and produce harder compacts, which are difficult to work. The powder as produced is soft, compresses in a normal fashion, and exhibits very little tendency to adhere to the die surfaces. Unlike aluminum and magnesium powders, it can be readily pressed without the use of die lubricants. When compacted at 50 tons per

Jan 1, 1946

By J. R. Long, E. T. Hayes, R. S. Dean, F. S. Wartman

The production of titanium in I5-lb. lots and with a purity sufficient to be consolidated into ductile metal, as described in a previous paper,' has provided adequate material for a study of the physical properties of titanium and a more thorough examination of its working qualities. Data on the physical properties reported in that paper were obtained on metal fabricated by a fixed procedure, standardized for the purpose of control of the reduction, and are representative only of material fabricated under those conditions. There are many possible variables in the working schedule, which will have significant effects on the properties of the finished material; and since the previous working methods were not necessarily the best, an investigation of the fabrication of titanium by other methods was undertaken. In this work the consolidation of the powder by pressing and sintering was conducted essentially as outlined in the report cited' and all efforts were centered on fabrication methods for those powders and the proper- ties produced by them. Hardness, density, microstructure, and tensile properties were determined at various stages in the working and annealing; and resistivity measurements were made on a few bars and drawn wire. Consolidation of the PowdeR The screen analysis of the available titanium powder is given in Table I. No attempt was made to alter the size distribution from that noted because this powder, although coarse by normal powder-metallurgy standards, produced acceptable compacts suitable for the present work. Because of their large specific surface, finer powders are more contaminated by oxygen and produce harder compacts, which are difficult to work. The powder as produced is soft, compresses in a normal fashion, and exhibits very little tendency to adhere to the die surfaces. Unlike aluminum and magnesium powders, it can be readily pressed without the use of die lubricants. When compacted at 50 tons per

Jan 1, 1946

By R. J. Stokes

S. Floreen (international Nickel Co.)— One fairly simple way to differentiate between em brittle me nt due to surface microcracks or due to a dislocation barrier effect might be to load a brittle rock salt crystal in tension to some stress just below the fracture stress and then immerse the loaded crystal in water. If a surface film is retarding plastic flow then one should observe some plastic deformation of the rock salt as

Jan 1, 1962

By Milton E. Wadsworth, T. D. Chatwin

Bulk density variations can usually be minimized by properly mixing the material before moisture measurement. The measuring of moisture on material being with- drawn directly from storage bins requires some form of bulk density correction. In Bethlehem's pellet plants continuous automatic bulk density correction and uniform feed-rate control are obtained with Bethlehem's patented Bin Level Control System. With this sys- tem a single probe, suspended or inserted in the bin, senses whether material is at the proper level in the bin and automatically regulates filter speed to control the filter-cake discharge rate to maintain this level. The level of concentrate in the filter-cake bin can thereby be controlled to within ± 1/2 in. of the point of contact between the concentrate and the probe. Material thickness on the conveyor does not have to be controlled accurately and mix compositions can vary widely as long as they do not contain variable amounts of water-soluble electrolytes. In sinter plants, errors caused by changes in normal feed rate and bed height are minimized by counter-weights that permit the free-floating to maintain a uniform contact pressure on the mix. Large changes in mix resistance can be taken care of either by resetting the control point or by adjusting the calibration control.

Jan 9, 1968

Jan 1, 1961

By R. L. Bowron

GROWING use of basic slag in the agricultural industry is of special interest and importance to the iron and steel industry of the Birmingham district, providing an increasing outlet for this by- product. Such use of basic slag was first developed in England about fifty years ago where it soon became wide- spread. About twenty years ago the Tennessee Coal, Iron & R. R. Co. began its production in the United States after exhaustive tests had demonstrated its high value here as in Eng- land. It is particularly valuable on heavy clay and acid soils, improving their physical condition, increasing their alkalinity where that is desirable, and providing soluble phosphate and small amounts of manganese to soils deficient in these respects. Its use in agriculture is growing as its advantages are becoming more widely known.

Jan 1, 1937

Jan 1, 1962

By AIME AIME

FIVE days, extending from Monday, Feb. 18 to Friday, Feb. 22, inclusive, will be required for the annual meeting this year. The first fours days will be devoted to reading and discussion of papers, general and committee business meetings, two lectures, luncheons, dinners and all the pleasures of a big, general reunion. The fifth day will be given over to an all-day excursion for both men and women by special train to West Point, in celebration of the birthday of the first President of the United States. Washington having been an engineer and now after one hundred and thirty-one years the country having selected as President another engineer in the person of Herbert Hoover, our own past president and honorary member, it is proposed to celebrate with a good old-fashioned picnic and inspect the school. The authorities at the Military Academy have undertaken to welcome the engineers and do whatever they may to make our pilgrimage notable. Other social features planned for the week are numerous. Luncheon will be served as usual at the building each day of the meeting to all members and guests. This year a very nominal charge will be made, primarily to overcome deficits due to irregular attendance. Monday noon, the Non-metallic Minerals Committee will lunch at the Engineers' Club and in the evening the Milling Methods Committee will dine there. The Annual Smoker will be held at Hotel Astor after dinner. Professional entertainment of high order is promised, but not too much to interfere with the numerous group reunions that characterize this func- tion.

Jan 1, 1929

By H. C., Simpson

MANY metals by virtue of their place of occurrence as ore, and their uses are travelers! Iron and steel, for instance, is one of the greatest of travelers in the form of ships and the romance of iron in this respect is only just beginning to be superseded by the stories which can be told of the travels of aluminum and its alloys, used in the building of airplanes. Tin is a traveler from the Straits Settlements to this country and Europe, for use in the canning industry; afterward traveling all over the civilized world as a part of the container for preserved foods. Silver is somewhat of an aristocrat, when its uses are measured against those of the baser metals. From earliest times it has been used for adornment (first perhaps o4 the person and later for the embellishment of weapons and' buildings), for the making of fine ar¬ticles used in the household, and as money. While its uses have been widened by the discoveries in chemistry, electricity and other sciences, its early uses are still much in evidence in our modern life.

Jan 1, 1928

By J. R. Stone, J. T. Roy

ASARC09s continuous tapper for lead blast furnace is described. Its use throughout the company's plants has resulted in higher production rates, lower labor costs, and better working conditions. It has also permitted wide latitude in blast pressures, as well as in charge and slag compositions. The practice of tapping a lead blast furnace has remained essentially unchanged for many years. In principle, it is a batch operation discharging the products from the continuous smelting of lead-bearing materials. As such, it imposes certain restrictions on the proper functioning of the smelting operation. First, it calls for a highly developed sense of timing, and a considerable amount of physical effort on the part of the operator. Dirty and hot working conditions, as well as the hazards of flying metal and slag, usually prevail. These conditions have resulted in higher labor costs, both in rate and in amount. Labor turnover has also been high. Secondly, rigid control of mechanical and metallurgical factors must be maintained. Frequent oxygen lancing of the tap hole is needed to permit tapping, thereby increasing operating costs. Rapid increases in smelting rate, plugged tap holes, or forgetfulness on the part of the operator may permit the molten material to rise above the tuyeies and freeze the furnace. Also, the operator will often blow out the tap hole after draining, filling the area with fume. Composition of charge also vitally affects the tapping. The type of lead-bearing material being smelted will naturally affect the smelting rate, and thus the frequency of tapping. The amounts and types of fluxing materials, which determine the ultimate fluidity of the slag, must be regidly controlled. Finally, the batch tapping of a continuous smelting operation of this type appears to be wrong in principle. The molten material drains into the crucible at the bottom of the furnace where it starts cooling immediately and continues to cool until tapped out. While keeping the lead molten is no particular problem, maintaining a fluid slag at all times is often difficult, and sometimes impossible. These factors all point to the desirability of a method for the continuous tapping of a lead blast furnace. The expected advantages would be more desirable working conditions, lower labor costs, increased production, and a much wider latitude in both blast pressure and charge composition. CONTINUOUS TAPPING Historical. A number of devices, e.g., mechanical tappers, siphons, and lead wells, have been tried in the past in attempting to effect continuous tapping. None proved to be entirely satisfactory for tapping lead and slag simultaneously. It was not until 1955, however, that ASARCO designed and put into operation a successful tapping unit at its East Helena, Mont. lead smelter. This unit is described in detail in U.S. Patent NO. 2,890,951. Continuous Tapping Unit—See Figs. 1 and 2. Fig. 1 is a schematic drawing of the unit in place, showing front and side views. The component parts are identified in the caption. Fig. 2 is an actual photograph, front view, of the tapping unit attached to the base of the blast furnace. Operation. The operation of the tapping unit is quite simple. Essentially it consists of a narrow tapping bay surrounding the furnace tap hole, with a deep notch in the front wall. When the blast furnace is started this notch is open down to the level of the tap hole. Starting the furnace may be accomplished in several ways but the most satisfactory method is to plug the tap hole with clay, permitting metal and slag to build up inside the furnace. Before the liquid reaches the tuyeres, the plug is removed and the furnace is drained to the settler. The blast is then stopped momentarily while the notch in the front wall of the tapping bay is dammed with chrome brick and plastic chrome ore. The blast is again started, and the height of the dam is adjusted so that the liquid in the bay will counterbalance the internal pressure of the furnace. When the desired level is reached the slag and metal will overflow to the settler. It should be noted that the molten material ,is not siphoned from the furnace and that the metal 'acts as a liquid valve controlling the flow of slag through the tap hole. During normal operations the tapping bay is filled primarily with lead, covered with a thin layer of slag. Thus, the heavier lead plays the major role in compensating for variations in furnace pressures. Due to the high specific gravity of lead, changes in the liquid level in the tapping bay will never exceed a few inches. For this reason it is seldom necessary to change the height of the dam due to minor variations in operating conditions. Some turbulence of the liquid in the bay is essential at all times. This indicates that the level of the

Jan 1, 1963

By J. Fred Johnson

MORE ORE is mined in the Bingham District than in any other mining district in Utah. In addition to the open-pit operations of the Utah Copper Co., there have been, many large underground mines. Until recent years the principal production was from the Jordan and Commercial limestones, but in the last eight years valuable ore deposits have been developed in the so-called alphabetical or "A," "B," "C," and "D" limestones, mainly by the U. S. Smelting, Refining & Mining Co. The value of these developments has led the company just mentioned to acquire large holdings in the district and within the last year to install at the Niagara shaft a hoist capable of going to a vertical depth of 4000 ft., or 1800 ft. deeper than the present lowest level. Ore from Bingham has been the chief factor in enabling the

Jan 1, 1934

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Jan 1, 1938

By L. Weaver

THE Tennessee Copper Co.'s mines are in the southeast corner of the state of Tennessee, Polk Co., in the well-known Ducktown copper basin. Their new circular production shaft will eventually be the only ore hoisting shaft, and is located for handling ore from Boyd, Calloway, Mary, and Cherokee mines. A circular, rather than a rectangular, shaft was decided upon because: 1-The circular shaft section is stronger when lined with concrete. Reinforcing steel was not required, thus reducing lining cost by one- quarter. 2-Water sealing was desired; it was thought it could best be done with a concrete lining followed by pressure grouting to eliminate water seeps. 3-The shaft labor saving equipment could best be used in a large opening, so the round section was made for economy, sinking, mucking, concreting and water sealing. Less shaft steel is used than could have been possible with steel sets. There are no posts required; center beams and Tee plate assembly placed at 10 ft hold the 100 lb steel guide rails.

Jan 1, 1950

By NONE N

Jan 1, 1963

By C. D. Haynes, S. C. Gambrell

The practice of roof bolting in WORLD-WIDE mining activities is very well-known, having been used extensively for over 50 years. The theory of roof bolting, however, is extremely complicated, and only recently have investigators attempted to explain the theory. Various means of stress analysis have been utilized in rock mechanics, most of which reduce rock to an isotropic, homogeneous medium that can be easily analyzed. One of the indirect research methods is the photo-elastic technique, the theory of which is widely known and needs no elaboration. This technique has been used extensively to examine the state of stress around underground openings of various shapes in certain types of strata, and under various loading configurations.'-" In-Situ Mine Roof Trusses The photoelastic technique was employed here to evaluate the state of stress above a mine opening where support is provided by the in-situ mine roof truss. This support configuration, shown in Fig. 1, has gained popularity in recent years, particularly in mines with bad roof conditions." To the authors' knowledge, no scientific determination has been made of the advantages roof trusses may offer over conventional bolting configurations comparable to roof trusses. Ordinary mine roofs usually sag or bulge downward soon after mining. Normally, after some movement the roof begins to stabilize, but the face of this bulging mine rock is usually in tension and will almost always fail unless supported. Because rock fails easily in tension, it is desirable to "preload" the roof, that is, to impress a compressive force on the mine roof to prevent bulging and subsequent tensile failure. Ordinary rock bolting installations, particularly if the bolting is perpendicular to the mine roof plane, do not produce a preloading effect. Although bolting installations squeeze the strata together and produce a beam effect desirable for support, they do not have the advantage of actual uplift. They pull down at the anchorage point with a force equal to the bolt tension which sometimes causes a separation in the plane of the anchorage detrimental to roof strength. In-situ mine roof trusses require the installation of steel tension rods in the roof of the mine much the same as conventional roof bolts, except that the rods are arranged to produce a stress pattern above the upper surface of the opening similar to that of a prestressed beam. The roof rock acts to transmit the compression force. The simplest form of truss consists of two steel rods anchored to the back of holes drilled at an angle of approximately 45 over the mine pillars. These rods are collared near the middle of the room, and the lower ends of the rods are connected by tie rods and turn-buckles. Used in this manner, a small-diameter steel rod can provide essentially the same support as a wide-flange steel beam. By tightening the turnbuckles, an uplift on the roof can be produced. Objective of the Investigation The objective of this investigation was to determine qualitatively the state of stress that exists above a mine roof after the installation of the in-situ mine roof truss vs. that of two angle roof bolts, hereafter referred to as "roof bolts," drilled and placed in the same configuration, that is, 45" above each pillar and connected together in the middle of the room by a bearing member such as a steel beam. Each state of stress was to be identified, insofar as possible, as compression or tension above the mine opening. Model Construction A photoelastic model of a mine opening was coil-structed from -in. thick PLM-4B birefringent plastic and was machined to specification shown in Fig. 2. The dimensions of the opening were chosen to simulate a width-to-depth ratio of 3 to 1. Two % -in. holes were drilled at 45" angles, as shown, to provide for the loading devices. After construction, the model was annealed at 240°F to remove stresses produced during machining.

Jan 1, 1971

By Stanislaus Skowronski

OVERPOLED copper, as commonly defined, is copper which has been excessively reduced during the poling period of the refining process. Owing to its porosity, such copper is unfit for commercial purposes. The cause of this phenomenon is undoubtedly the lack of oxides in the copper, yet this does not completely explain it. Refined copper of the same "pitch" and "set" varies considerably in oxygen contents, and analyses of overpoled bars also show similar wide differences; moreover, it is possible to melt copper in crucibles so as to obtain bars that are practically free from oxygen although they show a "tough pitch" and "level set" surface. Frederick Johnson advances the following theory: The regulation of the quantity of oxygen in copper is the keynote of all copper refining. It is the presence of a Well defined proportion of oxygen in the form of cuprous oxide, forming a copper-cuprous oxide eutectic, Which enables copper to be cast free from blowholes. It seems that When oxygen is present, other gases are less soluble in molten copper; When oxygen is absent, or is present in insufficient quantity, the copper dissolves other gases, such as hydrogen and carbon monoxide, Which are insoluble in the copper when solid, and, being rejected during the process of solidification, causes internal porosity and external ridges and excrescences.1 The "level set" of Wire bars, etc., is entirely the result of a compromise between the occluded gases and cuprous oxide. With excess of the former the metal would be "overpitch" and spongy, While an excess of the latter would result in the metal being "underpitch" and brittle.2 The result of the absorption and subsequent expulsion of reducing gases, carbon monoxide and hydrogen, and the effect of this action. on the overpoling of copper are in dispute; the literature on the subject is full of contradictory statements and will continue to be so until better analytical methods have been developed. Sulphur, however, is tangible. The refiner can see it in his button sample and consequently attributes to it any trouble that may happen during the melting of the copper.

Jan 3, 1918

By Paul. D. Merica

I LIKE to look upon the award this year also as a recognition of the importance of metallic materials of construction to the engineer and of the active progress which I believe is continually being made in almost all branches of that field today. It has been said that metals are the material backbone of industry and technology. Well in that case, I suppose we metallurgists are industry's bonesetters. And it is possibly not inappropriate that we should occasionally give some atten¬tion to those bony structures of our industrial activities upon which engineers in other fields hang their manifold and striking creations. What is going on in the field of metals development? Well, in the first

Jan 1, 1938

By N. O. Taylor

THE failure, by swelling, of several cast aluminum-zinc, spiral, pump rods, used to circulate water in a constant-temperature bath, brought up the question as to whether the presence of tin in varying quantities would have any appreciable influence in controlling this action. Previous workers had found the same difficulty with aluminum-zinc alloys, due to their swelling in water or solutions of electrolyte^.^ It was known that pure aluminum was practically insoluble in concentrated sulfuric and nitric acids, presumably due to the formation of an oxidized film on the surface. Concentrated sulfuric acid had little or no effect on pure zinc and tin and concentrated hydrochloric acid would attack all three metals. These facts aroused curiosity as to the probable reaction of the ternary alloys of these metals, and tests were made to determine their resistivity to the action of common laboratory reagents. Samples, covering the entire range of the ternary series of aluminum, zinc and tin alloys, were made up from good grades of the commercial metals.2 The materials were melted, at as low temperatures as possible, in graphite crucibles in a gas-fired crucible furnace. Graphite crucibles were used in preference to clay, to prevent the absorption of silicon by the aluminum, as found by previous workers. The melted materials were stirred thoroughly with pine sticks in order to ensure complete mixing and the greatest possible freedom from oxidation, and were cast in sectional, iron molds giving bars % in. in diameter and 5 in. long.

Jan 1, 1927

By C. W. Dunham

DESIGN of the structures for the Morenci Reduction Works involved many interesting problems. Naturally, the chief purpose of these structures is to house and support the equipment and other things necessary for or incidental to the conduct of production. hence most of the features of the design were developed to suit these particular conditions; however, several are so generally applicable as to warrant description.

Jan 1, 1942