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By J. W. Halley, G. L. Plimpton

BECAUSE of the two distinct stages in the solidification of rimmed steel, segregation in the rimmed ingot is more complex than that in the killed or semikilled ingot. In the earlier stage, chemical reactions, resulting in evolution of gas and vigorous stirring of the metal, effect a degree of negative segregation unique to rimmed steel. The composition of this zone constitutes the principal quality advantage of this type of steel. In the later stage of solidification, after the evolution of gas has ceased, the segregation follows the general pattern of a more completely deoxidized steel. However, the composition of the liquid remaining after the first solidification stage varies markedly from that of the original melt, some constituents having been partially removed as reaction products while the concentration of others has been intensified by rejection from the metal solidifying in the first zone. The aim, from the standpoint of segregation, in rimmed steel of high quality is to effect a maximum negative segregation in the rim zone without excessive concentration of undesirable elements at the center of the ingot. To achieve this aim, the composition of the melt may be varied and the furnace and pouring practice may be adjusted within certain limits. It is the purpose of this study to discuss segregation in rimmed steel from the standpoint of the mechanisms that produce it and to survey the phases of open-hearth practice that influence those mechanisms. MECHANISMS PRODUCING SEGREGATION The mechanisms that determine the degree of segregation in the rimmed ingot are closely interrelated, making it difficult to select the primary factors and to determine a satisfactory order for presenting them. For instance, the question of sulphur segregation is relatively simple, since sulphur is not directly involved in chemical reactions in the ingot; but its concentration in the rim zone is dependent not only on its original analysis in the melt, its segregation coefficient, and the freezing rate, but also on the rate of its removal from the impure film on the solidifying surface. This washing action involves all the factors (such as freezing rate, the carbon-oxygen product, pressure, etc.) that determine the rate of gas evolution and hence the efficiency of film removal. Sulphur distribution between the rim and core is affected by the volumetric ratio between the two zones, and its segregation in the core is a function not only of the freezing rate of the core but also of all the foregoing factors that determine its concentration in the metal when solidification of the core starts. To simplify the presentation, it is proposed to treat the mechanisms affecting segregation independently in this section, reserving a discussion of their over-all effects for the section in which actual segregation data are given. The factors affecting segregation will be treated in the following order: (I) differential solidification, (2) removal of constituents as

Jan 1, 1944

By R. A. Wagstaff

SINCE the time of the early Egyptians, the use of copper has been a boon to the life of most of the civilized world. Its use has been varied; in many connections, the art by which it attained its greatest usefulness has been lost. In this paper an endeavor will be made to take into consideration some of the many changes that have occurred during the last 40 years of copper-smelting operations. During that period the copper blast furnace has been almost forced out of existence by new methods of ore concentration-first, gravity concentration, and then flotation. These new methods of concentration introduced many new factors into the metallurgy of copper. The product was wet, it was fine and it was high grade. To overcome all these factors many changes have been necessary throughout the smelting agenda. New equipment has been necessary for transportation, unloading, sampling, bedding and moisturing in all smelting plants, especially the custom smelter. During the early days of "flotation," little was known about filtering or the use of an alkaline circuit; often the concentrate going to the smelter contained 20 to 25 per cent moisture. It is easy to imagine the difficulty arising with a product of this nature when it had to be shoveled by hand labor. To meet these conditions, mechanical unloading and sampling devices were soon developed. In many instances such good progress was made that actual costs for handling this unfavorable product were lower than those formerly incurred on the old product. Today most sampling of copper ores and concentrates is being done by mechanical sampling, pipe or augur sampling, or shovel sampling. Where concentrates are uniform in metal content, a great many of the plants now use pipe or augur sampling. For spotty ores, the old shovel sample with cone and quartering during the final stages is still in use. Where big tonnages are handled, mechanical sampling of concentrates is being done, with satisfactory results. To curtail slow and tedious cutting and mixing procedure, mechanical mixing boxes, splitters and cutters are used to cut down labor costs. MILLING As crude ores become scarcer, the use of milling operations increases. The few crude ores that are still smelted are used as fluxing types. To use these ores finer grinding has been found advantageous. This has made for better bedding and fluxing conditions, which in turn makes for faster smelting, lower fuel consumption and better metal recovery. The degree of fineness is more or less determined by the nature of the product. Most plants have set a standard of through ¾ -in. mesh screen for roaster- reverberatory smelting and through ¾ in. mesh screen for converter fluxes. For some refractory ores; even finer grinding has been found to be advantageous for good reverberatory smelting.

Jan 1, 1944

By Winthrop P. Haynes

The symposium on production for the year 1943 contains few papers on the foreign situation. It has always been the policy of officers in charge of the symposium to refrain from publishing information that might possibly injure national or private interests. At the close of the war we hope again to publish full and accurate records of production abroad. A noteworthy feature of the reports on Texas this year is the map on page 469, which shows the districts covered by the statistics. Excerpts from Circular to Authors In order to facilitate interpretation of the data in this chapter, we print the following excerpts from the Circular to Authors. The field is the unit in this tabulation. In cases of fields extending across State boundaries, such as Rodessa, it is suggested that each State author treat the section of the field in his State as a unit, and by a footnote indicate that the field extends into an adjacent State. Each place in the table may represent one of three possibilities; either the proper entry is determinable and can be supplied by the author, or an approximate figure can be supplied which is the author's best guess and should be entered followed by an x, or it does not apply to the particular field and the space is left blank. Contributions of great value may be made by the author in many cases where entries are not subject to precise determina-tion. In such cases the author should use his good judgment and make the best entry possible under the circumstances. The entry of a zero is a positive declaration, and it is an important declaration where it is in order. It is thought that the nearest whole numbers are suficiently accurate for our purposes except as to percentage of sulphur in oil. If an author desires to report any other figures to tenths, he may do so. The quantity of gas produced should include, where possible, gas sold or otherwise marketed, and gas blown into the air, burned as flares or otherwise wasted. Segregation of these figures would be interesting if the authors can make such segregation. In any event, the figures should represent as nearly as possible the total quantity of gas removed from the reservoir. Under the columns on ''Depth," the average depth to the top of the productive zones and to the bottom of the productive wells, when subtracted, should give the approximate thickness of the productive zone. For fields where this is not true because of unusually high dip or for some other reasons, it is suggested that the authors indicate in their text the approximate average thickness of the productive zone. The net thickness of the producing formation should be the thickness of the producing zone, less the estimated amount to cover the portions of the zone that do not yield oil, such as dense shales, etc. It is recognized that for some fields the authors can only make rough guesses; in such cases, they should enter their best estimate followed by an x. Average production per acre-foot need not be reported as it can be calculated by those interested from the figures given. In classifying wells as to producing methods, enter all wells that are not "flowing" in the column headed "Artificial Lift." If possible, add footnotes to indicate whether the lift is "pumping," "gas lift" or "air lift."

Jan 1, 1944

By F. Keller, R. H. Brown

BECAUSE of the extensive use of Alclad 24s alloy sheet in aircraft construction, there is much interest in the metallurgical changes caused by heat-treatment of this product.1,2 One of these changes is the result of the diffusion of soluble elements from the core into the coating during treatment. This paper deals with the thermal treatments that may influence diffusion and with the practical effects of diffusion on the serviceability of the product. As is well known, Alclad 24s-T sheet has a core of high-strength alloy combined with surface layers of relatively pure aluminum. The microstructure of a cross section of this product is shown by Fig. I. hot only does the relatively high-purity coating have a high resistance to corrosion, and hence serves as a mechanical barrier between the core metal and the corroding environment, but in addition this coating I exerts electrochemical protection over areas where the core may be exposed, such as cut edges. In addition, the coating affords electrochemical protection to projecting heads of *417S-T, 17S-T and 24S-T rivets, or attached members made from these alloys. Under some conditions of heat-treatment, however, diffusion of copper into the coating will alter the electrochemical relationship between the coating and the core to the extent that only partial protection will be obtained under some corrosive conditions. The reason for the electrochemical protection lies in the fact that the coating layers of pure aluminum are anodic to the alloy core. The addition of copper to aluminum produces alloys in which the potential is lower than that of the pure metal. Moreover, as the amount of copper in solid solution in z4S alloy is increased, the potential of the alloy becomes more cathodic. When heat-treated at 920°F. and quenched in cold water, 24s-T is about 0.16 volt cathodic to pure aluminum. However, copper will diffuse from the core into the coating, and if it reaches the surface the potential will be altered in a cathodic direction. Thus the potential dif-erence between the core and coating may be less than 0.16 volt, depending upon the thickness of the coating, and the time and temperature of heat-treatment. Of the methods available for determining the extent of diffusion of copper from the core into the coating of Alclad 24S-T, two are generally used; namely, the metallographic and the solution potential method.3 METALLOGRAPHIC METHODS Metallographic methods will reveal the progress of diffusion of copper into the coating. For instance, the diffusion zone in the coating intermediate between the coating surface and the core is shown in Fig. I. This photomicrograph is of a polished and etched cross section of 0.040-in. Alclad 24S-T sheet. Diffusion proceeds into the coating more rapidly along the grain boundaries than through the body of the grains. consequently, the diffusion zone is not of uniform width

Jan 1, 1944

By J. Brian Eby, T. I. Harkins

THIS paper outlines the geophysical investigation of the area covering the Darrow salt dome, Louisiana. Surveys with the refraction seismograph and torsion balance failed to disclose the dome, but reflection dip shooting was successful and was confirmed by later drilling.

Jan 1, 1944

By Lester L. Hirst, Henry H. Storch, A. C. Fieldner

Experimental work on liquefaction of coal was taken up by the Bureau of Mines in 1936 when it became evident that a prudent policy from the national point of view should include preparation for the time when gradual exhaustion of petroleum resources would require supplementing the growing demand for motor fuel with gasoline and diesel oil from coal. At that time (1936) certain foreign nations that had no home sources of petroleum, especially Germany, England, and Japan, were conducting active research and at least two of them were producing liquid fuel from coal on a commercial scale. Germany was reported to have an annual producing capacity of 800,000 metric tons of gasoline per year, and England had just put into operation the Billingham plant of Imperial Chemical Industries for the hydrogehation of bituminous coal and tar by the Bergius-I.G. process. The annual capacity of this plant was about 150,000 long tons of gasoline per annum (3500 bbl. per day). With these developments taking place in foreign countries, it seemed important to undertake a long-range program of fundamental research in this country to establish a sound groundwork for the evaluation of foreign work on synthetic liquid fuels and at the same time to obtain data on the oil yields and operating difficulties using various kinds of American coals and lignite to the hydrogenation process. The results of such research would be useful in determining the yields and quality of liquid products obtainable from various coals so that American industry would be in position to select the most suitable coals and make rapid progress in establishing this new industry when the commercial need should arise. It was hoped, also, that progress in a better understanding of the chemistry of coal hydrogenation would reduce the cost of the process materially. To carry out this program, a small continuous unit capable of hydrogenating 100 Ib. of coal in 24 hr. was installed at the Central Experiment Station of the Bureau of Mines at Pittsburgh, Pa. Small steel autoclaves or bombs of 0.3 gal. (1.2 liters) capacity also were used for batch-hydro-genation experiments in the study of the chemical fundamentals of the process. Much valuable assistance was obtained in planning the experimental program and designing the equipment from the Fuel Research Station of Great Britain and the Fuel Laboratories of the Mines Department of Canada, where such investigations had been in progress for several years. Equipment and General Procedure of Research The industrial liquefaction of coal by the Bergius-I.G. hydrogenation process as practiced at Billingham, England, from

Jan 1, 1944

By Lawson P. Entwistle

SUMMARY ONE of the important reserves of manganiferous iron ore is at Boston Hill, near Silver City, New Mexico. The area consists of a faulted block of gently dipping Lower Paleozoic shale, dolomite, limestone and sandstone, which have been intruded by a roughly circular mass of quartz-bearing monzonite porphyry and subordinate dikes. From a noselike protuberance of the intrusion radiate many premineral faults, which have localized much of the hypogene mineralization. Three important stages of hypogene mineralization can be recognized: (1) mesitite, a manganiferous iron magnesite, (2) quartz sulphides, and (3) barite-galena. The carbonate stage is widespread but stronger near the intrusion. The quartz may have been derived from hydrothermal alteration of the igneous rocks. Barite-galena is most important in the Chloride Flat mining district, about one mile north, where argentiferous galena provided silver for the supergene ore. The hypogene carbonate, lean in iron and manganese, has been oxidized and consequently enriched by meteoric waters containing an excess of oxygen and carbon dioxide to form ore bodies of intimately mixed hematite and pyrolusite. The ore bodies, at one place attaining a length of 1600 ft., a width of 300 ft., and a thickness of 25 ft., are largely confined to areas of brecciation and to spreads from faults in Silurian dolomite beneath soft Devonian shale.

Jan 1, 1944

By C. D. Rubert, W. J. Parton

Large quantities of fine anthracite with associated impurities are discharged with the waste water from the coal-cleaning plants in the Pennsylvania anthracite region. Furthermore, for many years this fine material has accumulated and formed silt banks. The difficulty of removing the impurities from the fine material and the lack of adequate markets are responsible for the waste of this material. In view of a larger demand for fine coal, mainly for pulverized fuel, the Lehigh Navigation Coal Co. Inc. decided to investigate the froth flotation process for recovery of fine coal from these waste solids. A test plant was constructed and operated for six months during 1942 in order to determine the practicability of recover ing coal from the waste water of a a plant (breaker) by froth cleaning and to obtain operating data for designing a commercial plant if the results were favorable. Preliminary Investigation Before the pilot plant was constructed information was obtained by field and small-scale laboratory tests to serve as a guide in the design and operation of the pilot plant. Size and ash analyses of a representative sample of the material discharged in the wash water from a cleaning plant are given in Table. The refuse content increases progressively as the size of the particles decreases The larger particles (+35 m.) are low in ash content and could be marketed without cleaning. Since these solids are discharged from the breakers with 90 to 95 per cent water by weight, the first step in the recovery of the coal was that of reducing the quantity of water so that water in excess will not have to be handled. Furthermore, it was found that the removal of most of the minus 200 mesh high-ash material was desirable to permit the most efficient flotation of the cod. Classification tests were run and showed that a hydroseparator overflow rate of 12 ft. per hour* was sufficient to elimi-,late much of the minus 200-mesh material while allowing the coarser material to settle and be thickened,

Jan 1, 1944

By M. R. Geer, Franklin T. Davis, H. F. Yancey

COKE with low phosphorus content is required by some of the electrometallurgical and chemical plants recently attracted to the Pacific Northwest by the hydroelectric power available from Bonneville and Grand Coulee dams. Shipping such coke into the area from eastern points involves a high freight charge, and during wartime consumes precious rail and ship-bottom space, so it is highly desirable to produce coke from the coking coals of Washington to meet the requirements of these industries. Although coke has been made from Washington coals since 1884, little has been known about their phosphorus contents or about the extent to which phosphorus could be reduced by cleaning. An investigation was undertaken, therefore, to determine the manner in which phosphorus occurs in the coking coals of Washington and its amenability to removal by ordinary coal-washing methods. PREVIOUS WORK Phosphorus is a deleterious element in coke used for numerous metallurgical processes, including the production of pig iron, yet comparatively little published information is available on the occurrence and elimination of phosphorus in any of the coals of this country. A variation from 0.009 to 0.062 per cent phosphorus in various horizons of the Pittsburgh bed in the Connellsville region of Pennsylania has been reported,1 and a reduction in phosphorus content from 0.020 per cent in the raw coal to 0.018 per cent in the washed coal was obtained in washing coal from the same bed in the Pittsburgh area;2 the latter figures represent average analyses for a year's operation of the washery on about 800,000 tons of coal. A reduction in phosphorus content from 0.018 to 0.011 per cent in washing coal from the Pittsburgh bed at another washery was observed, and the same report provides data on the phosphorus reduction obtained by separating 10 other coals on a bath of 1.35 specific gravity.3 European investigators have been especially active in correlating phosphorus content with petrographic analysis; fusain and durain generally contain the highest percentage of phosphorus, but this relationship is not universal.4 Some of these investigators have found that phosphorus is removed in the coal-washing process,5 but others have observed that the clean coal contained as much or even more phosphorus than the raw coal.6

Jan 1, 1944

By Walter Renton Ingalls

Metallurgical literature has no record of any ore beneficiated for cadmium alone, and the cadmium of commerce is derived from zinc ore, with which cadmium is generally associated. Zinc ores free from cadmium—e.g., the ores of the Franklin and Stirling mines, New Jersey, and of Broken Hill in Rhodesia—are rare. Blende concentrates of 50 to 60 per cent grade have contained (in production of important tonnage) as much as I per cent Cd, which is unusually high. The concentrates from the Tri-State district average from 0.3 to 0.4 per cent Cd, which is high. The concentrates from mines west of the Rocky Mountains seldom are higher than 0.2 per cent. In the periodic system of the elements, cadmium is in the same group with zinc. Its properties and compounds are similar. Its metallurgy is also similar. Cadmium has a melting point of 320°C. and a boiling point of 778"C., while the melting point of zinc is 415'C. and the boiling point gos°C. These conditions, together with the lower reduction temperature of cadmium oxide, indicate means for. separating cadmium from zinc. Cadmium in spelter is viewed, if not as an impurity, at least as an alloying element that may be objectionable, its special effect being hardening. However, for some purposes, a little cadmium in spelter is desired, and 0.4 per cent may be permissible, even in spelter for rolling. Cadmium in spelter for brassmaking is completely volatilized at the temperature of that process, and in bygone days an immense quantity of cadmium must have been lost in the fumes from these furnaces. Pyrometalltjrgy—Early Cadmium compounds, sulphide and oxide, being more volatile than the corresponding compounds of zinc, loss of cadmium begins to occur from the first furnace operation. In normal roasting, even with Tri-State ore, this loss may not be very high. Raw ore, assaying 0.4 per cent Cd, may be expected to give a roasted product of the same assay, which would imply a cadmium loss of about 15 per cent. Roasted ore, assaying 0.4 per cent Cd when distilled at ordinary furnace temperature, yielded spelter containing about half of that in the ore charged. The first draw of spelter under these conditions may assay 0.8 per cent Cd (accounting for 22 per cent of the cadmium recovery) and after the several draws of spelter have been equalized the cadmium content may average 0.35 per cent. If, therefore, 2000 lb. of blende averaging 0.35 to 0.4 per cent Cd is roasted and distilled, there may be obtained 1000 lb. of spelter, assaying 0.35 per cent Cd or 3.5 lb. content, which entering into Prime Western spelter will be sold at the spelter price. It will be observed from the outline hereinbefore (summarizing conditions prior to the introduction of sintering) that the main loss of cadmium occurred in the distillation process and by failure to condense, which could be ameliorated by attaching a prolong to the condenser, thus collecting

Jan 1, 1944

By G. L. Hassler, E. Brunner, T. J. Deahl

The capillary effects in reservoir rock are discussed in terms of the pressures they cause in sandstones and dolomites. Data for the two-phase case (oil-gas or water-gas) and for the three-phase case (oil, water and gas in rock) are used to demonstrate that in one sense the wetting preference of a rock depends on its saturation. The nature of capillary hysteresis is described for partially stable conditions, and the concept is enlarged. Reproducibly measurable pressures include the "capillary pressure," which is the pressure difference between any two phases that are each interconnected; the "threshold pressure," necessary to force a nonwetting phase through partially saturated rock; the "displacement pressure," which is that special case of the threshold pressure in which both phases fully saturate separate portions of the rock. Displacement pressure is equal to the minimum value of the "capillary pressure." The theory of flow including capillary forces is developed at the producing surface of a well to reveal the presence there of a pressure discontinuity in the gas (or other nonwetting) phase that can be controlled to the end that more oil may be poduced from an oil field. Experiments with packed sand-flow tubes having artificial producing surfaces support the theory. Introduction The basic surface quantities acting in an oil field are two: namely, surface tensions and contact angles. These are the quantities, variously expressed, and particularized as spreading forces, adhesion tensions, heats of wetting, etc., which are measured in the laboratory by techniques mostly confined to flat or circularly cylindrical surfaces. Such measurements have not had the extensive engineering application they seem to deserve because in most practical cases they are unavoidably compounded with the complex and unapproached subject of the internal shape of the interstices of rock. In this paper it is intended that the pressure differences developed in rock by capillarity be examined, defined, and given some engineering use in terms of some new measurements that have been made. Such pressure differences—namely, the capillary pressure, the displacement pressure and the threshold pressure—seem to provide a proper contact between the basic molecular quantities and the oil field. While certain modifications of usage will be undertaken, the present effort rests upon the background of work by the U. S. Geological Survey,l by Versluys, and especially by W. 0. Smith, 3,4,5 which has been reviewed recently in papers by Leverett.=s7 The most important concept of pressure difference is the capillary pressure, a function of saturation that expresses the pressure difference between the interconnected phases in a rock. It is often measured when water and air are the fluids present, but it can be measured with other fluids. A number of curves of capillary pressure have recently been measured by a method which it is intended shall be published in a later paper. Since heretofore capillary-pressure measurements upon rock have not been

Jan 1, 1944

By Carl F. Floe, Michael B. Bever

The solubility of hydrogen in molten copper-tin alloys is of both practical and theoretical interest. From a practical standpoint, data on the equilibrium solubility as a function of temperature, pressure and alloy composition are valuable for a better understanding of porosity problems in bronze castings. From the theoretical point of view the determination of the hydrogen-copper-tin equilibrium is of interest since it extends the laws governing the solution of gases in metals. This paper presents the results of an investigation of the solubility of hydrogen in representative compositions of the copper-tin system at temperatures ranging from above the liquidus to I300°C. and at pressures from less than 50 mm. of mercury to about atmospheric. Review of Previous Work The solubility of hydrogen in copper was determined by Sieverts and Krumbhaarl in 1910 and by Roentgen and Moeller2 in 1934. Their values are in fair agreement. In 1926 Iwasé3 reported results that were very much higher. The published data on the solubility of hydrogen in tin do not agree. Smithells4 states that no reliable data are available According to Sieverts and Krumbhaar,5 hydrogen is insoluble in tin. Bircumshaw,6 on the other hand, found a definite solubility at 800°C. The latter's experimental procedure did not provide for stirring of the metal and in his opinion he failed to reach equilibrium. Iwasé3 again reported large solubility values. For copper alloys, Sieverts and Krumbhaar5 distinguished between alloying elements that do not markedly affect the solubility of hydrogen, elements that increase the solubility, and elements that reduce it. They named gold, tin, and aluminum as examples of this last group and reported hydrogen solubility data at 1225°C. for the copper-rich side of these alloy systems at atmospheric pressure. Without giving experimental results, they stated that the amount of hydrogen dissolved by liquid copper alloys is proportional to the square root of the pressure as in pure metals. These authors suggested that in a limited way the effect of an alloying element on the solubility of a gas is related to the constitution diagram for the alloy system. Sieverts7 also called attention to the fact that the curve of hydrogen solubility versus composition of copper-tin alloys shows a sharp change of direction at the composition of Cu3Sn and suggested that this compound persists at least to some extent in the molten state. Iwasé3 reported large hydrogen solubility values for several compositions of copper-tin alloys, which appear to be in error.

Jan 1, 1944

THERE is probably no phase of basic open-hearth steelmaking that is more of an art and less of a science than mold and pouring practice. It varies widely from plant to plant; consequently it is obviously impossible to set down in detail in this chapter the many ramifications of practice that are now used. The discussion that follows therefore attempts only to give an outline of the more common methods, with examples sufficient to indicate some of the variations in procedure, and to emphasize a few of the many underlying problems that face the open-hearth operator at the pouring platform. MOLD DESIGN Ingot molds are hollow castings of considerable wall thickness. Despite this, non-uniformity in wall thickness should be strictly avoided to prevent the setting up of unnecessary stresses. Molds are cast in various forms, sizes, and shapes depending on the type of steel, and on whether the ingot is to be withdrawn from the mold or the mold from the ingot. The selection of ingot-mold material, which is usually cupola or blast-furnace iron containing approximately 3.5 per cent carbon, 1 per cent silicon, 0.9 per cent manganese, 0.2 per cent phosphorus, and 0.07 per cent sulphur, is governed by numerous considerations that affect mold life. (1) Factors in addition to wall thickness that should be given primary consideration at the foundry are casting skin, shrinkage stresses, and casting temperature. Factors in Mold Design. In use, mold thickness is of greatest importance, for it must be heavy enough to freeze the molten metal rising in the mold and to reduce the temperature of the steel below that of the melting point of cast iron to prevent the inner surface of the mold from melting, which would result in the welding of the ingot to the mold. The skin of an ingot, which solidities immediately upon contact with the relatively cold walls of the mold, must soon become thick enough to contract on the fluid mass and pull away slightly from the sides of the mold. The separation of the ingot from the mold depends entirely on the heat taken up by the mold from the steel.

Jan 1, 1944

Jan 1, 1944

By H. P. Greenwald

THIs paper brings forward a discussion that was prepared for the meeting of the Coal Division in Chicago in 1938.1 War in Europe less than a year after that meeting, followed by our defense preparations and entry into the conflict, caused general cessation of large-scale experimentation on the subject, and it is best to confine this paper to events in the United States during the five-year period since the preceding paper was written. The views of members of the Coal Division's Committee2 on Rock-dust-ing for 1943 were obtained before this paper was written and the manuscript was reviewed by them. Extent of Rock-dusting Statistics on the use of rock dust in the United States during the years 1930-1933, appearing on page 97 of Volume 139 of the Transactions are extended in Table I herein through the year 1941. The results through 1933 did not appear encouraging, but there has been improve-ment since that date. It has always been true that the larger operations were the ones that used rock dust. In 1941 only 10 per cent of the mines in the country used rock dust, but they produced 57 per cent of the coal, employed just under 50 per cent of the miners, and accounted for 52 per cent of the man-hours. Unfortunately, collection and compilation of these statistics are slow procedures, and figures dealing with the tremendous war expansion of the industry are not likely to be available for a year or more. In 1941 the five leading states in regard to percentage of man-hours worked in mines using rock dust were: Utah, 92.1; Wyoming, 79.3; Alabama, 77.4; New Mexico, 72.5; West Virginia, 65.3. The first four states were the same as in 1933, but West Virginia displaced Washington in fifth place. On the basis of pounds of rock dust used per ton of coal, the five leading states in

Jan 1, 1944

THE purpose of this chapter is to present a general outline of the basic open-hearth process for the benefit of students, practicing open-hearth operators, and metallurgists who wish to review the subject. The discussion is limited to a description of the sequence and purpose of the operations, illustrated by data and examples. Subsequent chapters deal with more detailed and fundamental studies of the subject. The function of the basic open-hearth furnace is to convert various types of ferrous material into finished steel of given composition and quality. In comparison with other steel-making methods, the basic open-hearth process is one of the most versatile, both from the stand- point of the raw materials that can be used and the types of steel that can be produced. The process can be considered as a sequence involving melting, refining, and deoxidation. In the case of some types of liquid-metal charges the melting stage is not present, but refining and deoxidation in varying degrees are fundamental features of the process. GENERAL DISCUSSION OF THE BASIC OPEN-HEARTH PROCESS The first consideration in open-hearth practice is the type of charge on which the operation is based. This consists of three components-fluxing, oxidizing, and metallic materials. Fluxes. In the basic process the fluxing material is primarily lime, added in the form of either limestone (CaC03) or burnt lime (CaO). This is supplemented by magnesia (MgO) and lime from the furnace bottom and banks. The function of these fluxes is to form a slag with the silica (SO2), manganese oxide (MnO), iron oxides (FeO and Fe203), and phosphorus oxide (P205) that are produced by the oxidation of varying amounts of the silicon, manganese, iron, and phosphorus in the charge during melting and refining. The slag, composed of the basic fluxes and the neutral and acid oxides, floats on top of the steel bath when the charge is melted. The composition of this slag depends on the amount of each slag-forming element present in the charge and on the extent of oxidation of these elements during the course of the

Jan 1, 1944

By Rollin Farmin

"SWELLING GROUND" delivers pressure on mine timbers that originates in expansion of the wall rock, whereas "heavy ground" delivers only gravitative pressure. Of the several possible causes considered, the swelling is attributed to the physical surface action of water on gouge and flaky rocks at the periphery of the mine opening.

Jan 1, 1944

By E. P. Klier, Taylor Lyman

THE structures formed when austenite is quenched to subcritical temperatures and allowed to transform isothermally have been the subject of intensive study since the work of Davenport and Bain.1 Isothermal transformation diagrams summarizing the results of many of these studies have become widely familiar to metallurgists. Of particular interest to metallographers are the dark-etching, acicular products of transformation formed by isothermal reaction below the temperature of maximum velocity of the austenite to pearlite reaction. These products, the bainite structures, can be formed in a wide variety of steels. However, the constitution of bainite is not well understood and divergent views have been expressed as to its mode of formation. In this investigation a combination of dilatometric, microscopic and X-ray methods has been brought to bear upon the problem in the hope of some elucidation of the bainite reaction as it occurs in hypoeutectoid steels. MECHANISM OF BAINITE FORMATION Davenport and Bain1 considered the mechanism of bainite formation to consist of two steps-an allotropic transformation followed by precipitation of carbide. The separation in time of the two processes was considered to be very slight in the upper temperature range and very marked at temperatures just above the martensite range. This concept has been restated by Vilella, Guellich and Bain2 in the form of a definition of the acicular mode of transformation as: The successive, abrupt formation of flat plates of supersaturated ferrite along certain crystallographic planes of the austenite grains; this supersaturated ferrite begins at once to reject carbide particles, (not lamellae), at a rate depending upon temperature. In effect, this is the acicular mode of transformation, even though the temperature be such as to limit the actual life of the quasi-martensite to millionths of a second. The investigation of isothermal decomposition of austenite in certain alloy steels (notably those containing chromium or molybdenum) has revealed that there may be a range of temperatures between the pearlite and bainite reactions in which the austenite decomposes at a relatively low rate.3-6 Further, it is characteristic that in the second region of fast reaction the decomposition of the austenite is incomplete by one reaction but goes to completion by a second reaction. These observations led Wever7 to a description of the bainite reaction as follows: I. The reaction takes place by initial precipitation of a martensitic intermediate structure. 2. In the upper temperature range this structure readily decomposes into ferrite and cementite. In the lower range carbon separates in an unknown form. 3. In the upper temperature range the precipitated carbide nucleates the precipitation

Jan 1, 1944

By Robert Henderson

SEVERAL very interesting articles have been written on the caving system of mining, but most of these papers have dealt separately with the slusher system or the chute and grizzly system. In this paper, a comparison will be made of the two methods, both of which are being used at the Climax mine. The mine is on the Continental Divide, in central Colorado, at an altitude of approximately 11,500 ft. above sea level. The long, cold winters, characteristic of the high Rockies, create a number of operating problems not usually found in other mining areas. THE ORE BODY The Climax ore body is just east of the Mosquito fault. This structural deformation has brought the granite on the east against the sedimentary rocks on the west. The ore occurs in an intensely altered granite and schist around a silicified granite core. The ore is in a highly fractured zone of moderate silicification. The principal mineral, molybdenite, is found in these fractures. Barren dikes of granite porphyry cut through the ore body and core with no apparent regularity. The grade of the ore is fairly uniform and gradually decreases toward the footwall core and also into the hanging-wall granite. The footwall and hanging wall are determined entirely by assays. The ore body is roughly dome-shaped, with the apex truncated at the surface. It is covered to varying depths with talus. A horizontal section of the ore body on the Phillipson level appears as an annular ellipse surrounding the footwall core. The ring of ore varies in width from 300 ft. to as much as 800 ft. The north-south axis of the core is about 1200 ft. and the east-west axis is about 1800 ft. In the ore zone, the rock is sufficiently strong to maintain reasonably large openings, and openings larger than haulage drifts usually have to be supported. The ore is cut by a great many fractures and shears and breaks into rather large blocks when caved, necessitating considerable secondary blasting. The waste that overlies the ore body breaks relatively fine in comparison with the size of the blocks of the caved ore and tends to run through the broken ore in the cave, causing dilution unless the draw is carefully controlled. MINING SYSTEMS For several years the ore was mined by the chute and grizzly system, a system that differs from that used in other caving mines only in the size of openings and equipment. In the chute and grizzly system, main haulage laterals were driven along the footwall core and also along the

Jan 1, 1944

By S. E. Maddigan, B. R. Zimmerman

Most metallurgists are well acquainted with the contributions already made to the study of metals by the use of X-rays. On the one hand, the radiographic method is constantly becoming of increasing importance as a nondestructive testing procedure, while on the other hand the techniques of X-ray diffraction have made important contributions to the fundamental knowledge in studies of phase diagrams, stress conditions, and so forth. A new, and as yet insufficiently appreciated, tool exists in the application of microradiography to alloy structures. This new procedure in many respects bears the same relation to microscopic investigations as does macroradiography to the gross inspection of metal surfaces. However, where macroradiography is used ordinarily to determine the soundness of the metal structure, this new method can be used not only to investigate micro-un-soundness but also to examine the distribution of the constituent elements within the body of the alloy. When combined with the normal procedures of microscopy, this offers a technique of great potential power. It is intended in this paper to present a few examples of copper-base alloys demonstrating the additional knowledge obtained from the microradiographic method. The detection of micro-unsoundness is demonstrated in Fig. I for a sample of cartridge brass as cast. The sample ap- peared quite sound when viewed under the microscope, but in reality was thickly populated with minute voids. This application of the method conforms in every way to conventional large-scale radiography and has been used to facilitate production of metal for vacuum devices.' The true potentialities of the technique are revealed by comparison of Figs, 2a and 2b, which are respectively a photomicrograph and a microradiograph of a cast alloy of 80 per cent Cu, 10 per cent Sn, 10 per cent Pb. The remarkable difference in appearance provides some concept of the additional information this method may yield when used as an auxiliary to microscopic studies. Fig. 2a shows two phases of the copper-tin system plus segregated_ lumps of lead. Fig. 2b, on the other hand, shows with exceptional clarity the actual dendritic growth of the metal crystals during solidification. The practice of microradiography depends upon the laws of absorption of X-rays. This subject has been reviewed thoroughly in recent papers,l,2,3 but for clarity a brief resume will be given here. As is well known, when a beam of X-rays is transmitted through a, layer of homogeneous material, the intensity is reduced according to the relation: where Il is the transmitted intensity, I0 is the incident intensity, µ1 is the linear absorption coefficient of the material, t1 is the thickness of the material.

Jan 1, 1944