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By T. R. Bieler

"Hot forming and superplasticity in powder metallurgy aluminum alloys and composites is reviewed. The effects of alloy composition, particulate composition, size, and size distribution is summarized. The role of climb distance for recovery is described in connection with the size of strengthening phases. In materials with fine strengthening phases on the order of one micron or less, high strain rate superplastic deformation processes are likely. However, the quality of superplastic deformation depends on the prior processing history, and these effects are reviewed. Very few data describing the effects of hot forming history on post-forming properties exist, but some results emerging in the literature are compared.IntroductionHot deformation in aluminum based materials is done for several technological purposes, such as thermomechanical processing to alter mechanical properties of simple forms, and/or final shaping operations to produce a complex shaped part by means of extrusion, forging, or superplastic forming. In the interest of improving the mechanical properties of aluminum based materials, two microstructural design strategies are commonly used, dispersion strengthening, and composite strengthening. The introduction of fine, stable dispersions is commonly done for high temperature strength, and the dispersions are typically ceramic particles in the range of 10 nm to 1000 nm in volume fractions around 5 vol.% (Higashi et al., 1990; 1991a; 1991b; 1992; Bieler and Mukherjee, 1990; Otsuka et al., 1987; Bieler et al., 1991; Oliver and Nix, 1982). Alternatively, composite strengthening strategies using 10-40 v% of 3 µm to 40 µm ceramic particles provide high modulus and high strength aluminum based materials (Midling and Grong, 1995; Lloyd, 1994; Subramanian et al., 1995)."

Jan 1, 1997

By Leonard A. Wolff

"The 1980sfor the mining industry can be characterized as the survival of the fittest. High interest rates, low commodity prices, foreign subsidized competition and decreasing ore grades have contributed to a streamlining of the domestic mining industry in the United States, leading to the shutdown of operations or large cutback of work forces. The purpose of this paper is to look at the impact of a layoff on the employees of what was once a major uranium producer in south central Wyoming, twenty months after the final layoff and mine shutdown. INTRODUCTIONDecember 19, 1985, was the date of the final of three successive layoffs over a two-month period, leading to the complete shutdown of Petrotomics Company, a subsidiary of Getty Minerals Company. The final shutdown was due to a combination of depressed U3O8 prices and the takeover of Getty Oil Company by Texaco in January 1984.The layoffs affected 104 employees and included mine personnel, mill personnel and staff. Both hourly and salary workers were involved. The operation was considered non-union, however, a few mill hourly employees were unionized. At the completion of the layoffs. only a handful of employees remained for administrative and miscellaneous functions.For Getty employees, the terms of the merger agreement provided a generous level of separation benefits. The terms that were insisted upon by Mr. Petersen, Chairman of the Board for Getty Oil, stipulated that employees receive one month of severance pay, for each full calendar year of employment up to a maximum of two year's pay. This was the forerunner of what is now commonly known as the ""tin parachute”. All but the union employees of Petrotomics received these separation benefits. Union employees were covered by their separate, less generous, contract.Much of the literature that has been published in recent months has centred around the effects of layoffs on remaining employees, or the psychological effects on the severed employee. This study will emphasize the economic impact and ramifications due to a layoff, using the Petrotomics employees as a case example."

Jan 1, 1989

By Joseph H. Harris

Shebandowan Mine presents a unique opportunity for the mining industry to demonstrate its willingness and ability to use electrical energy effectively. The mine is a typical 250D-ton/day operation supplied by a i5-MVA power transformer. it is a recent, up-to-date design and operates on a four-day/week, two-shift/day basis. The paper outlines an energy profile based on historical data. It accurately describes the individual and total energy input For: (1) production and non-productive junctions; (2) production and down-time periods; (3) peak and average activity levels; and (4) principal energy utilization equipment. A comparison is then made of production data to electrical data, and production and electrical data to design data. The paper concludes that energy management has an important benefit for the mining industry by assisting in maintaining a competitive operation through reduced costs and fewer production slow-downs in the event of energy shortages.

Jan 1, 1979

By Zainelabdin Khalid Zainelabdin Elfaki

The influence of partially replacing cement with marble waste on the workability and compressive strength of concrete bricks was investigated. Three replacement percentages, 10%, 20% and 30% weight marble waste, were used with different curing times of 7, 14 and 28 days. Two specimens were prepared for each percentage and curing time. For this study, marble powder from the Mining House Company in Saudi Arabia was used. It was observed that the replacement of cement in Concrete brick with marble waste enhanced the loading strength and the workability of the prepared concrete bricks. It was also observed that 20% replacement of cement with marble waste was the best replacement percentage compared to the other replacement percentages tested. Marble waste from manufacturing companies, either in powder, sludge or slab form, has negative impacts on the environment. In contrast, reusing marble waste has both economic benefits (i.e., selling the marble waste) and lessening the need for raw resources.

Jan 1, 2014

By He Zhexiang

The settlement properties of tailings modified by flocculants were investigated at the Shizhuyuan Mine, with the aims to screen for the most effective flocculants and the optimum dosage rates for tailings sedimentation. The settlement rate was used as the indicator of effective tailings sedimentation. Calcareousness and three polyacrylamides (F1, F2 and F3) were selected for settlement property evaluation. The results proved that sole use of calcareousness or any of the polyacrylamides had no apparent effect on the tailings sedimentation, while a remarkable acceleration of sedimentation could be observed with a combined addition of calcareousness and polyacrylamides, among which the addition of polyacrylamide F2 together with calcareousness is the most effective. The optimum dosage rate of F2 and calcareousness is 50g/t and 3kg/t respectively. The density of tailings slurry has an effect on sedimentation at the early settlement stage, with lower density generating quicker initial settlement.

May 1, 2007

By J. Mizera, B. Adamczyk-Cieslak, K. J. Kurzydlowski, A. Dobkowska

"AZ31 is the one of the most popular magnesium alloy using in the modern industry. It is well known, that compared with steel, magnesium alloys posse better properties, such as light mass, high specific strength or thermal conductivity. It should be noted that their application is limited by poor corrosion resistance. In this work the corrosion behavior of AZ31 magnesium alloy as cast and after heat treatment were described with the use of testing in neutral salt spray atmosphere.To characterise corrosion resistance and describe layers built on the surface it was necessary to do the metallographic observations with the use of optical microscopy. After that influence of heat treatment for AZ31 corrosion resistance was examined. Measurements were conducted by electrochemical impedance spectroscopy (EIS) and by neutral salt spray tests in artificial atmosphere. Surface and cross section morphology after removal of corrosion products were observed with the use of scanning electron microscopy (SEM).The weight loss measurements show that there is no significant difference between alloys as cast and with following heat treatment.INTRODUCTIONMagnesium and magnesium alloys are popular in modern industry because of the low density and good formability. Magnesium alloys are described by few properties which have got significant influence for their application in transportation and electronics industries (Feliu & Liorente, 2015). Their wide application is limited by poor corrosion resistance. As it is well known Mg is one of the chemically most active metal. Corrosion resistance of Mg alloys depends on several factors, such as impurities, chemical composition or working conditions (Cheng, Qin, Wang, & Zhang, 2009). That all causes that there are many different ways to find well defined and good solution of magnesium alloys processing to improve their corrosion resistance.There are many different versions about the influence of aluminum on the corrosion resistance of magnesium alloy. It is known that intermetallic compounds such as Mg17Al12 due to ß-phase content plays the minor role for corrosion resistance. It is proved ß-phase acts as cathode and it has good ability to build passive layer in broad pH ranges. However it should be noted that mentioned behavior depend on size and distributions of ß-phase in the microstructure (Singh, Singh, & Das, 2015)."

Jan 1, 2016

By Tom Brady

A major focus of ground control research presently being conducted by the Spokane Research Laboratory of the National Institute for Occupational Safety and Health (NIOSH) is to incorporate data on weak rock masses into existing design relationships, with an emphasis on updating the span design curve for manned entries and the overbreak curve for longhole entries. Both curves were originally developed at the University of British Columbia, Vancouver, BC. The original database has been augmented by information from mines throughout the United States, Canada, Australia, and Europe. The common factor in all these mines is the presence of a weak back and/or walls. In most cases, the ore zone is the weakest rock unit and must be stabilized so that the mineral-bearing rock can be extracted safety. The current NIOSH research attempts to provide rock mechanics tools to assist a mine operator in making economic decisions that will also ensure a safe working environment. This paper documents the North American database.

May 1, 2006

By Jucheng Wang

Unplanned open stope dilution is a major cost factor for many mining operations, even though significant advances in empirical and analytical approaches for estimating stope dilution have been made. Many factors that influence hanging wall dilution are still either ignored or assessed in purely subjective terms. Undercutting the stope hanging wall on both the overcut and undercut development are well recognized factors which contribute to hanging wall instability and dilution. In many mines, undercutting the hanging wall breaks the integrity of the rock mass that may form along continuous foliation or bedding planes parallel to the stope hanging wall contact, reducing stability. This undercutting also increases the zone of destressed or relaxed rock that may potentially fall into the open stope as dilution. An approach is introduced for quantifying the effect of undercutting on potential stope dilution. An extensive database of stope case histories has been collected to look at dilution from Hudson Bay Mining and Smelting operations (HBMS) in Flin Flon.

May 1, 2002

By K. B. Chaudhuri, I. D. Webb, F. E. Rachor, F. A. Sauert

"A characteristic of all methods of copper concentrate smelting is that slags with a high copper content are produced at some phase of the operation. Recirculation to the smelting unit, electric furnace reduction or flotation are at present used on an industrial scale to recover the copper from these slags. This paper describes the application of the top-blowing technique, originally developed by KHD Humboldt- Wedag AG for refining of metallic copper, for the treatment of copper-containing slags. By this method, a mixture of a reducing gas and commercial oxygen is blown onto the melt at velocities which can be supersonic from the tip of a water cooled lance. The impingement of the reaction gas mixture on the surface of the slag forms a depression in the molten phase and a deflection of the jet which brings the slag into a rotating motion. This causes high rates of heat and mass transfer. Results of pilot-plant tests for batch and continuous treatment of slags are presented, and the potential applications of top blowing for industrial-scale operation are indicated. In combination with the cyclone as a smelting unit, this process appears to be economic for smelters of very low capacity."

Jan 1, 1980

By Mike D. Riley, Alan V. Bell, Ernest K. Yanful

Acid mine drainage (AMD) research under the MEND program has been ongoing since 1988 at the Heath Steele Mines waste rock piles including sulphide material, outside Newcastle, NB. In 1989 approximately 10,000 mt of waste rock was placed on a prepared sand base with an underlying impermeable membrane. The waste rock pile was heavily instrumented for measuring oxygen concentrations and temperatures. In September 1991, a composite soil cover designed for the Heath Steele climatic conditions, using local soils, was placed over the pile, creating a totally enclosed system. Moisture content and oxygen probes were installed within the composite soil cover to monitor changes within the soils over time, while two large-size lysimeters were installed below the cover to monitor the hydraulic conductivity of the cover. The waste rock site has been monitored on a monthly basis since installation of the cover, for performance of both cover and waste rock. The monitoring shows very clearly that the placement of the composite soil cover has had a major impact on the generation of AMD. Major reductions in temperature and oxygen concentrations within the waste rock pile indicate that the cover has significantly inhibited the oxidation reaction that generates the AMD. Performance data have shown that the cover has maintained its integrity under the climatic conditions of the area.

Jan 1, 1995

By Francis Breton, Lei Pan, Kun Liu

"Effects of Fe, Cu and Mg minor alloying elements on creep properties of 8xxx aluminum conductor alloys were investigated by conducting compressive creep tests at 100 ºC under a constant load of 69 MPa. The microstructural evolution was studied using an optical microscope and electron backscatter diffraction technique. The creep properties were characterized by the primary creep strain in the first stage and the minimum creep rate in the second stage of creep deformation. Results showed that additions of all three minor alloying elements (Fe, Cu and Mg) demonstrated a beneficial effect on the creep resistance but individual alloying elements exhibited different impacts on creep properties. The additions of Fe and Mg showed a strong impact on both the primary creep strain and minimum creep rate, while the Cu addition displayed a favorable effect on the primary creep strain but no impact on the minimum creep rate. Microstructure observation revealed that with increasing Fe contents, the volume fraction of fine intermetallic dispersoids gradually increased while the subgrain size and misorientation angle became smaller, providing strong barriers to the dislocation and grain boundary movements. The addition of Cu moderately reduced the subgrain size and misorientation angle and in combination of solid solution strengthening it promoted the retardation of the creep deformation during the primary stage.INTRODUCTIONThe 8xxx aluminum conductor alloys offer significant advantages such as low density, high conductivity to weight ratio and low price over copper conductors and become an attractive candidate in electrical engineering and building wiring (McQueen, Chia, & Starke, 1986; Birol, 2009; Engler, Laptyeva, & Wang, 2013). The mass resistivity of aluminum conductors is one-half of copper conductors. Thus, only one-half the weight of aluminum is required for equivalent capacities. Therefore, this unique property coupled with a relatively low price of aluminum offers significant economic advantage to develop aluminum conductor alloys for electrical applications in the electrical wire industry."

Jan 1, 2016

By H. Dundar, C. Dzomeku

An extensive testwork was performed around the HPGR plant at GoldFields Ghana Limited Tarkwa Gold Mine. The HPGR was used to prepare the feed for heap leaching. The circuit was configured in such a way that the edge material from the HPGR discharge was recycled for further crushing while the product from the centre reported to the heap leach section. The set-up of the Polysius HPGR provided an opportunity to study the effect of different design and operating variables. This paper will discuss the results from the tests performed to assess the effect of rolls’ speed and applied pressure on the capacity and the grinding efficiency of the HPGR. Applying different pressure values appeared to have an influence on the amount of edge material recycled.

Jan 1, 2012

By B. Stuckert, P. Sheehan, J. Balfour, B. (Manas) Das, D. Fawcett

"With the growth of large scale surface mining operations, waste disposal and stability of waste dumps pose a challenging problem to engineers. Vibrations due to blasting operations proximal to these dumps further complicates dump design. Many dumps which are statically stable may become unstable due to the effects of blasting vibrations.A joint project between CANMET and Smoky River Coal Ltd. has been initiated to study the dynamic stability of waste dumps. The study involves development of an analytical algorithm combined with field monitoring to assess dump performance.Another objective of the study is to provide baseline data for a vibration attentuation relationships for sedimentary rock (coal) environments: most studies to date are for base metal mines. The effect of dump thickness on vibration response is also addressed.The key objective of the study is to present a methodology for assessing the dynamic stability of waste dumps. Implicit in this methodology are a number of assumptions concerning vibration attenuation in sedimentary rock environments, and response of the dump material to induced vibration. Where possible, these assumptions have been compared with monitoring data as a check on their validity."

Jan 1, 1989

By H. Dundar

An extensive testwork was performed around the HPGR plant at GoldFields Ghana Limited Tarkwa Gold Mine. The HPGR was used to prepare the feed for heap leaching. The circuit was configured in such a way that the edge material from the HPGR discharge was recycled for further crushing while the product from the centre reported to the heap leach section. The set-up of the Polysius HPGR provided an opportunity to study the effect of different design and operating variables. This paper will discuss the results from the tests performed to assess the effect of rolls? speed and applied pressure on the capacity and the grinding efficiency of the HPGR. Applying different pressure values appeared to have an influence on the amount of edge material recycled.

Jan 1, 2012

By V. Maazallahi, A. Rouleau, A. Saeidi

"The geometry of the terrain topography before and after the failure are the essential factors for analyzing a landslide and for the design of remedial works. This paper presents a method to determine these factors, considering that the determination of the slide surface profile is difficult and costly using traditional methods and the pre-slide topography data is often not available. The presented method to locate the 3-dimensional geometry of the slide surface is based upon determining the slide surface in 2- dimensional vertical sections. This method utilizes post-slide topography of the area to determine the pre-slide topography and uses equations to estimate the pre-slide situation using a statistical process applied to points located on the sliding mass. This method is tested on the Maskun landslide in Iran. The results indicate the applicability of the proposed method to obtain the key factors for the back analysis of a landslide in a cost effective manner.INTRODUCTIONProbably the most reliable method of determining the strength of soil and rock mass is to back analyze a failed or failing slope (Caia et al. 2007; Wyllie & Mah, 2004). This method is used in geotechnics for estimating geotechnical parameters of the rock and soil mass (Sakurai et al., 2003; Frayssines and Hantz, 2009; Cepuritis et al. 2010), but it requires that the failure mode is well established and that there is complete and precise information available on the slide surface and the sliding mass (Sjöberg, 1996). Measurement of the slope profile before failure provides the basic information required for a back analysis (Hock & Bray, 1981). The post-slide topography is another key factor. The back analysis process for determining the actual strength parameters of soil or a decomposed rock mass after a landslide requires knowledge of the sliding mass geometry, both before and after the sliding event. Many studies are reported in the literature about the application of back analysis for determining geotechnical and geomechanical parameters of rock and soil mass (Sakurai et al., 2003; Cepuritis et al. 2010; Frayssines and Hantz, 2009, Hussain and Stark, 2011), but they generally present little information about the geometry of the slide surface, and the weight of rock and soil mass that slid, although these factors are the most important parameters for back analysis process. Liang and Xue-song (2012) determined the slip surface having the minimum factor of safety (called critical slip surface in deterministic analysis of slopes) and the slip surface with the minimum reliability index (called critical reliability slip surface), but they have not considered the actual profile and geometry of the slide surface. Rocscience (2013) proposes the back analysis option in the Slide software for slope stability study, but it requires an imposed slide surface as input; alternatively, one can estimate by a finite element analysis the surface with the minimum factor of safety. However, this estimated surface is very likely different from the actual sliding surface, considering the uncertainties in input data of the finite element method."

Jan 1, 2015

By G. Danha, S. Wabula, D. Glasser, D. Hildebrandt, N. Hlabangana

"Impact tests on single particles or a bed of particles are used to determine the fracture characteristics of particles. Many different techniques have been adopted in comminution in order to find ways of optimizing energy consumption in the size reduction process. In this paper, we apply one such method called the Attainable Region (AR) analysis technique to optimize the impact energy on a bed of silica particles. The attainable region is a fundamental approach that is equipment-independent and can be used to analyze breakage processes. The AR is defined as a set of all possible outcomes, for the system under consideration that can be achieved using fundamental processes operating within the system.INTRODUCTIONThe energy crisis in Southern African has reached such critical levels, that most cities in countries like Zambia, Zimbabwe, Lesotho, Swaziland and even South Africa are experiencing load shedding challenges lasting sometimes up to 18 hrs a day. Southern Africa is well known for its riches in mineral resources, and the economies of most states in this region are driven by the mining & mineral processing sector. With the emergence of small scale miners due to government empowerment policies, national energy providers have had to resort to power cuts mainly to domestic users in a bid to cope up with the huge industrial electricity demands.It has been estimated that about 4% of the total energy used in the world is consumed by the mineral processing sector (Fuerstenau & Lutch, 1999). Tomanec and Milovanovic (1994) estimated that milling alone accounts for more than 50% of the total power used in mineral processing, but this can rise to as high as 70% for hard or finely dispersed and inter-grown ores. Today, the greatest challenge in mineral processing is how to optimize energy input to the size reduction process (Dey & Das, 2013; Nomura & Tanaka, 2011), where it has been observed that only a small percentage (1.5%) of the total energy input really does the breaking (Khumalo et al., 2008) while the rest is consumed by the equipment concerned and lost to contacts that do not result in breakage. The immediate benefits of focusing research on the optimization of energy in size reduction operations in the mineral processing sector lies in potential savings on industrial electricity usage that may then be directed towards domestic users."

Jan 1, 2016

By G. C. Weatherly, D. S. Wilkinson, A. M. Limarga

In addition to the harsh environment, materials for high-temperature applications are often subjected to a significant mechanical loading. Several researchers have noted that the rate of oxidation can be affected by stress in a range of materials. We have recently studied this effect in y-TiAl, based on the preliminary work of Magnan and Weatherly which showed that nitridation rates on the tensile side of a flexural creep specimen could be 10 times higher than on the compressive side. We have since developed a four-point bending creep setup capable of controlled atmosphere testing. We present quantitative data on the effect of creep on scale growth under a range of atmospheric conditions. Finite element analysis will also be used to show how modest applied stresses can have a large effect on scale growth rates through the generation of large stresses due to the mismatch of creep rate between the metallic substrate and the scale.

Jan 1, 2004

By A. M. Hadian

The use of dolomite refractories in steel making and cement industries has advantages over other basic products particularly in countries where this type of refractories is produced. Due to existence of high-quality dolomite deposits in many regions of Iran, there is a good potential for producing dolomite refractories in the country. This study focuses on the effect of such additives as iron oxide and alumina on hydration resistance and density of Iranian dolomite. It was found that addition of Fe2O3 is more effective than Al2O3 on increasing density as well as resistance to hydration of dolomite.

Jan 1, 2004

By Kai Zhang, Aijun Huang, Jeremy H. Rao, Xinhua Wu, Paul Rometsch

"As one of the most typical additive manufacturing (AM) technologies, selective laser melting (SLM) removes many of the shape restrictions that limit materials design, thereby allowing computationally optimised and high performance structures to be directly produced and tested. Due to the high reflectivity and lower absorptivity of Al alloy A357 powder during high temperature laser melting, one of the issues SLM might bring is the surface roughness and defects present on the parts. In this regard, this study investigates the surface roughness – fatigue property relationship for a heat-treated aluminium alloy A357 after SLM. Via the adjustment of SLM parameters, an ultrafine microstructure can be obtained due to the fast solidification rate. Therefore, comparable or even better mechanical properties can be achieved with respect to traditional A357 casting counterparts. Meanwhile, the surface roughness conditions of the SLMed Al alloy are also influenced by various processing parameters, raw powder properties, and sample building methods. For selective laser melted Al alloy A357 specimens, a dense part with a smoother surface would be expected to correspond with a good fatigue performance.INTRODUCTION Additive Manufacturing (AM), also known as 3D printing, is a process in which a complex part is fabricated layer by layer from a digital design package (Martin et al., 2017). AM has the potential to conserve raw materials, reduce the energy consumption, part cost, and fabrication time. Furthermore, as a typical additive manufacturing (AM) process, selective laser melting (SLM) was originally developed from selective laser sintering (SLS) based on higher quality lasers (Rao, Zhang, Fang, Chen, Wu, & Davies, 2017b). Different from conventional casting consuming valuable time and energy, SLM is now used as a cost effective method for the manufacturing of metals, such as Al-Si alloys, to produce almost full density parts using fine metallic powder and high power laser beam (Tang & Pistorius, 2017)."

Jan 1, 2018

By Brent Robertson

Failure to meet quality objectives during the execution of any industrial project has lasting negative impacts on facility life cycle performance. Cost overruns, schedule delays, and rework are characteristics of project quality issues that arise during the project. Commissioning and start-up problems, low production, production bottlenecks, breakdowns and the necessity for operational work-arounds are characteristics of project quality issues that appear after project completion. Risks such as production facility downtime, shortened equipment life, and potential HSE violations must be clearly identified and addressed during project planning phases. Appropriate Quality Assurance (QA) and Quality Control (QC) focus must be placed on identified high-risk areas. In order to be effective, quality systems must be flexible, non-confrontational, consistent, and adaptable to projects of any size ? from capital mega-projects to small maintenance projects. All project participants must be aligned in how they are approaching quality and the difference between QA and QC must be clear to everyone on the project. Emphasis must be placed on QA activities to minimize project cost, reduce rework, manage change, and reduce the production facility operational risk. QA is focused on the work processes used to generate the design and confirming that the processes are present and being followed. Issues in the work processes guarantee that the output drawings and specifications will be less than optimal. The identification and monitoring of quality-critical processes provides a focus for QA activities. QC activities are then used to generate proof that the project was implemented correctly and become a key part of the turnover.

Nov 1, 2011