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By Jonathan Tsang, Ali Merati, Jonathan Beddoes

Due to economic factors, many aircraft in service today have been operating for more than 30 years even though they were initially designed with a service life of 20 years. Improved damage management models are therefore needed for use in life prediction and management of the aging fleets of aircraft. Currently, the generally accepted procedure in fatigue life prediction methodologies is to back calculate the equivalent initial flaw size (EIFS) using established long crack growth data. However, it was observed from studies carried out at the National Research Council Canada that nucleation and short crack growth constitute up to -95% of the fatigue life. As a result, it seems that the significance of the short crack regime has been underestimated and must be further investigated and fully understood before an accurate holistic life prediction methodology can be realized. Unlike long cracks, local microstructural features such as grain boundary, grain size, inter-particle spacing, and texture play dominant roles in the behavior of short cracks. An extensive study has been carried out to evaluate different crack detection and monitoring techniques in the short crack regime for AA2024-T3. The results will be presented in detail.

Jan 1, 2004

By S. Xu, A. Ramesh, F El-dabbagh, Z. Fang, A. Sobhy, J. A. Kozinski

Waste remediation is a goal that will be driven forward by economic conditions. As the cost of waste disposal increases, new methods of waste reduction will become economically attractive, and will be implemented. It is difficult to imagine, however, a time when there will be no waste generation. For the foreseeable future, despite effective reduction practices, there will still be hundreds of millions of tons of waste that must be destroyed or controlled to protect the public health and the sanctity of the environment. To remain faithful to environmental covenants, the mineral and metallurgical industries will face these new challenges. This paper discusses novel waste remediation approaches and techniques focusing on hazardous wastes and thermal remediation. Aspects concerning technological and environmental importance are examined. Solutions for neutralization of environmentally hazardous compounds are proposed.

Jan 1, 2004

By John Stubbles

Data are presented on the global warming issue to reinforce the decision by the U.S to reject the Kyoto protocol. The evidence that CO2 is a problem rather than a benefit is inconclusive and will be discussed in this paper. Nevertheless, for economic reasons alone, the US steel industry will continue to minimize CO2 emissions (and the release of real pollutants) per ton of steel through energy reduction programs. However, relative to inevitable increases in absolute CO2 emissions from the utility industry and the transportation sector, future reductions by the steel industry will be inconsequential in the "big picture."

Jan 1, 2004

By G. Avramovic-Cingara

Grain boundary characteristics and microstructural evolution are analyzed in a comparative study using orientation imaging microscopy (OIM/SEM) and transmission electron microscopy (TEM/SAD). The subgrain sizes and misorientations were determined by the OIM for aluminum deformed in torsion to equivalent strains between 0.2 and 4 over the temperature ranges of300-600°C and strain rates 0.01-1 s". The OIM gives clearer evidence of boundaries with high misorientation than does TEM, but it overestimates their frequency b y missing boundaries less than 1 0. T EM more clearly reveals low-angle arrays of widely spaced dislocations resulting in finer subgrain sizes than those indicated by OIM. The evidence supports a mechanism combining dynamic recovery (DRY), deformation band formation with permanent boundaries and geometric dynamic recrystallization (gDRX) in contrast to the hypothesis known as continuous dynamic recrystallization (cDRX).

Jan 1, 2004

By K. S. Coley, M. A. Rhamdhani, G. A. Brooks

Interfacial phenomena in high temperature reactions such as between iron alloy and slag is well documented but not fully understood. It is believed that a gradient of oxygen concentration plays an important role to the occurrence of such phenomena. This article describes the results from the continuation of the study of interfacial phenomena between Fe-Al alloy droplets and CaO-SiO2-Al2O3 slag. Materials characterization techniques involving microscopic observations, depth profiling, bulk, point analysis and were carried out. The roles of oxygen as well as other factors that contribute to the interfacial phenomena were evaluated. The results and their implications to steelmaking will be discussed.

Jan 1, 2004

By K. S. Coley, G. A. Irons, T. Kaneyasu

"It is very important to reveal the lime dissolution mechanism in steelmaking slag, to promote its dissolution without calcium fluoride, which is now almost forbidden for use in most industrialized countries. In this research, the purpose was focused on the development of an experimental method to measure the mutual diffusivity of Ca2+ under the condition of lime dissolution into slag. By forming diffusion couples using a ""vacuum slag aspirating technique"", the method was established. The following mutual diffusivities of Ca2+, in CaO-SiO2-FeO slag systems, imitating oxygen steelmaking slag, were determined using this method:4.1*10-10 m2/s at 1400°C for 27wt.%CaO-53wt.%SiO2-20wt.%FeO slag,4.3* 10-10 m2/s and at 1400°C for 20wt.%CaO-40wt.%SiO2-40wt.%FeO slag, and 1.3*10-10 m2/s at 1250°C for 20wt.%CaO-40wt.%SiO2-40wt.%FeO slag.It was also verified that, if the basicity and ferrite content of the bulk slag are low, then a calcium silicate film forms on the lime surface, and drastically deters the lime dissolution."

Jan 1, 2004

By K. N. Bolatbaev, S. S. Naboichenko

The initial rates of dissolution of pyrite, chalcosine, sphalerite and galena in acidic sulphate solutions under oxygen pressure were measured in the range of Poe = 0.2-1 MPa, 130-180 °C, [H2SO4]0 = 0.2-0.7 M, and in the presence of surface-active agents and agitation producing Re = 4-16 x 103. Reaction orders, activation energies, and values of reaction constants for these oxidation reactions were established. The reactions also were shown to be diffusion-controlled; and the rates demonstrate a linear dependence on the surface area of the sulphides. A surface reaction model, in which oxygen is transported through a solid layer of surface products, has been advanced. The initial stage of high-temperature interaction at pH <7 is suggested to involve a chemical activation of the sulphide surface and is described by the following general reaction: MenSm + H3O+ Men-1 Sm-1 (HS-)s + H2O The subsequent oxidation of surface complex HS- to S0 or SO2-4 occurs with the assistance of Fe(III), Cu(II) ions depending on temperature and the redox potential of the medium, which are defined by oxygen pressure and composition of the reaction mixture, especially concentrations of H2SO4 and metals with variable valence. General process kinetics are complicated due to the formation of by-products on the basis of Fe3+ Pb2+, Cup ions, which displace the kinetics into the diffusion region.

Jan 1, 2004

By Jin-Hwa Song

Rolling temperatures and cross rolling ratios were varied to investigate the effect of crystallographic texture of alpha-phase on the anisotropy of mechanical properties in modified Ti-6A1-4V alloy. Hot rolling method was unidirectional and cross rolling, during which the rolling temperature was in the range of 830°C and 920°C. Cross rolling ratios were varied from 0.3 to 1.0 at 875°C. For unidirectional rolling, as the rolling temperature increased texture changed from the mixed basal and transverse texture to the simple transverse texture. Contrary to other work, it was observed that the maximum intensity of transverse components increased with the increase in rolling temperature. For cross rolling, on the other hand, the transverse texture component was almost suppressed at 830°C, giving rise to a symmetrical basal texture. With increasing cross rolling temperature, the transverse texture components developed again. A simple transverse texture, which showed two maxima appearing circularly 90° apart, was observed at 920°C. It was found that unidirectional rolling could not eliminate the transverse texture, which resulted in the anisotropy of mechanical properties. The anisotropy of mechanical properties obtained from tensile and V-notch Charpy test was closely related to the crystallographic texture and its intensity at each rolling condition. To obtain the isotropy of mechanical properties by cross rolling, it is suggested that cross-rolling ratios should be controlled above 0.5. The variation of rolling temperatures and directions has great influence on the anisotropy of impact value rather than tensile strength.

Jan 1, 2004

By N. Ntakaburimvo, C. Allaire

This paper presents an innovative experimental set-up which simulates refractory degradation by separate and simultaneous action of abrasion, erosion and partially or totally immersion corrosion whether dynamic or static. It also presents abrasion testing results obtained from five commercial aluminosilicate refractories used in aluminium melting and holding furnaces. Abrasion wear was quantified by measuring the weight loss and the depth of wear, as well as by determining materials properties degradation, such as the residual rupture force and the residual modulus of rupture. Results were correlated to as- fired materials properties, such as rupture force, flexural strength, elastic modulus, toughness, and apparent porosity; in order to establish which property could be used for refractory abrasion wear prediction. They were also related to the critical length of pre-existing defects and to those generated by the abrasion process. Positive correlation was established between abrasion resistance and mechanical properties, particularly for refractory castables. For similar mechanical strength, the castables tested offered less abrasion resistance than the brick sample.

Jan 1, 2004

By J. F. Archibald

A research effort has been undertaken, under Workplace Safety and Insurance Board of Ontario (WSIB) sponsorship, to characterize the support capabilities of conventional and innovative spray-on lining materials for mitigating dynamic failure effects created by simulated rockbursts. Conventional spray support media, such as shotcrete and fibrecrete linings, and a variety of new spray-on lining materials [thin, spray-on liners (TSLs)], typically polymer-type thin coatings, were subjected to simulated rockburst influence. For baseline comparison, conventional rockbolt and bolt-and-mesh support products were also evaluated. Observation of lining performance was undertaken through completion of field-scale support and rock detonation trials. Controlled blasting tests were conducted at the Queen’s University Explosives Laboratory to examine the effectiveness of the variety of surface coating agents for modifying dynamic rock spalling processes. All tests were performed upon largely undisturbed and homogeneous rock materials in highly repeatable fashion. All blasts were observed seismically and photographically to provide detailed information concerning rock motion, surface fracturing, ejected fragment motion and support liner survivability characteristics. These material comparison trials were performed to assess the relative effectiveness of a wide range of currently available area support techniques for suppressing hazards associated with dynamic rock ejection. The results of this study validate that thin, spray-on linings may be equally as effective, and often better, than conventional support materials at mitigating rockburst or like damage in highly stressed mine environments.

Jan 1, 2004

By Y. Kocaefe, S. Afshar, D. Kocaefe, Z. Kunt, C. Allaire

Interaction of aluminum with silica based ceramics Jose M. Soto, Jeffrey D. Smith, William G. Fahrenholtz. Department of Ceramic Engineering University of Missouri-Rolla Rolla, MO 65409-0330 USA ABSTRACT Interactions between A356 aluminum (Al-Si alloy) and dense fused silica (FS) riser tubes used for low-pressure casting of aluminum alloys were evaluated using a sessile drop approach. The tubes have a short service life, but cost and thermal shock resistance make them an effective solution. The main problem encountered during use is the reaction of aluminum with silica to form alumina and silicon, which causes failure. Tests have been conducted on as-fired (uncoated) and modified (coated) tubes. Experiments were carried out in a horizontal furnace at 1225°C under argon to minimize the effect of the aluminum oxide on the interactions at the alloy-silica interface. Images of the drop were acquired and contact angle values were estimated for uncoated and coated samples, but no significant differences in the contact angles were observed. Scanning electron microscopy revealed the presence of cracks at the interface between the reaction zone and the unreacted silica. The presence of reaction products (silicon in the reacting alloy and aluminum in a reaction zone between the alloy and the unaffected silica) has been confirmed using energy dispersive spectroscopy. A two layer coating system was found to be effective in reducing penetration of the aluminum alloy. The interactions between bed media and aluminum have been studied under static and dynamic flow conditions. An experimental system was set up simulating a small filter. Desired flow field can be created around alumina particles and velocities can be adjusted. A mathematical model was developed to predict the velocities, and this was validated using data from a visualization study. The interaction zone on the surface of the particles was analyzed with optical microscopy and SEM. This paper presents the study and compares the results under static and dynamic flow conditions.

Jan 1, 2004

By R. Carpenter, H. Muntanion, P. Kleespies, E. Flood, M. Tansey

Abstract - BHP Minerals discovered the Archean lode gold ULU deposit on the western margin of the High Lake Volcanic Belt in 1989. The greenschist to amphibolite facies mafic volcanic and sedimentary rocks on the property are folded into a 5 km-long anticline. There is a close spatial association of Au-As zones to the trace of this F2 ULU anticline. The largest of these auriferous zones, the Flood zone, is localized at the core of the fold. The southeast-trending Flood zone consists of several anastomosing lenses that have been traced for 435 m on surface. Overall, it dips steeply (70° to 80°) to the southwest and has been intersected to depths below 600 m. The hosting high-iron tholeitic basalt displays a lower amphibolite mineral assemblage of ferrohornblende + plagioclase + ilmenite with accessory quartz and epidote. Alteration minerals include biotite, chlorite, hornblende, actinolite-tremolite, and potassium feldspar (microcline) with minor calcite, epidote, tourmaline, and titanite. The highest gold values occur where brecciated basaltic wall-rock clasts are replaced by acicular arsenopyrite + quartz + K-feldspar. BHP Minerals completed 54,783 m of both exploration and resource development drilling before selling the ULU property to Echo Bay Mines in 1995. Development of ULU as a satellite deposit to Echo Bay’s Lupin mine began in 1996. A -15% ramp was extended to the 155-meter level, and 16,011 m of underground drilling were completed before the decline in gold prices forced a suspension of activities at ULU in August 1997. The current owners, Wolfden Resources Inc., drilled 18,569 m in 2004 to increase confidence in the resource blocks. Following this drill program, a revised resource calculated by an independent consultant determined that the ULU deposit contains an inferred/indicated mineral resource of 1,130,000 t grading 11.34 g/t gold (373,748 oz) to the 360-m level. The portal was re-opened in 2005 and a prefeasibility study is underway.

Jan 1, 2004

By B. T. Lu, J. L. Luo, J. F. Lu

The present paper investigates the chemo-mechanical effect in slurry-erosion corrosion process of carbon steel to understand the synergistic mechanism due to interaction of chemical and mechanical factors. The erosion-corrosion tests were conducted with A1045 steel in slurries comprising tap water and silica sand. Various heat treatments were adopted to achieve different hardness in the test material. The chemo-mechanical effect is evaluated in line with the correlation between the degradation of hardness in the surface layer and anodic current density. During the erosion-corrosion tests, various anodic currents were applied to find the relation between the anodic dissolution rate and erosion rate. The experimental results indicate that the hardness decreased with increasing anodic dissolution. Based on the fact that pure mechanical erosion rate increased with decreasing hardness, this result suggests that the corrosion-induced degradation of mechanical property is a mechanism of corrosion-enhanced erosion. This theoretical prediction is verified by erosion-corrosion experimental results.

Jan 1, 2004

By J. Beddoes

The various microstructural factors that influence the creep resistance of y-titanium aluminides are presented and discussed. Titanium aluminides have potential for a variety of intermediate temperature applications in both gas turbine and reciprocating engines. While it is well established that the &apos;fully lamellar&apos; titanium aluminide microstructure offers superior creep properties, the particular influence of lamellar morphology, third phase precipitation, and grain boundary structure in controlling both the primary and tertiary creep behaviour is presented. The results are primarily based on tensile creep experiments undertaken using several titanium aluminide intermetallic compositions processed via powder metallurgical techniques, investment casting and Bridgman directional solidification. The results indicate that lamellar structure and precipitate formation have a major impact on primary creep, while microstructural degradation through both lamellar and precipitate coarsening influence on the onset of tertiary creep leading to fracture. The results are used to design a creep resistant microstructure produced by directional solidification and the effectiveness of this designed microstructure is demonstrated through 10,000 hour creep tests.

Jan 1, 2004

By B. Hart, D. J. Miller, J. T. Francis, M. C. Biesinger, Smart. R. St. C.

Diagnosis of the surface chemical factors playing a part in flotation separation of a valuable sulfide phase requires measurement of the hydrophobic and hydrophilic species that are statistically different between the concentrate and tail streams. Time of flight secondary ion mass spectrometry (ToF-SIMS) can be used to identify sufficient particles of a specific mineral phase for reliable statistics determining a mean value for each species with 95% confidence intervals (1). Using the region of interest (ROI) facility in the Tof-SIMS software, a mass spectrum from each particle, at 1-2 monolayer sensitivity, is recorded and stored. This analysis is reported for a chalcopyrite / pyrite / sphalerite mineral mixture conditioned at pH 9 for 20 minutes in order to study transfer of copper from chalcopyrite via solution to the other two mineral surfaces since this mechanism can be responsible for their inadvertent flotation in copper recovery. Analysis from mineral selection based on specific ToF-SIMS signals (eg. Pb, Zn, Cu, Fe, Fe/Cu) indicated no statistical difference in the copper intensities on pyrite and sphalerite after this conditioning. Principal component analysis (PCA) of the ToF-SIMS imaging data identifies combinations of factors strongly correlated (positively or negatively) in images or spectra from mass spectra recorded at each of 256x256 pixels in a selected area of particles. PCA is a better method of selecting minerals due to multi-variable recognition. It has clearly separated a statistical difference in copper intensities between the sphalerite and pyrite phases. The method has been extended to samples from an operating plant again with excellent phase recognition and diagnostic surface chemistry.

Jan 1, 2004

By D. Komljenovic, J. Paraszczak

"This paper presents the use of queuing theory in truck fleet sizing in open pit mining operations. In the first part, a methodology is developed by which an optimal ratio between the size of shovels and trucks may be determined. The second part gives the fundamentals of the queuing theory and its application in analyzing shovel and trucks. The stochastic character of involved times (loading, truck cycle, etc.) is taken into consideration. Using the above theory, the optimal truck fleet size in actual conditions may be estimated. Minimal operating cost of the working system (shovelstrucks) represents the basic requirement of the analyzed process. The methodology was validated on Caterpillar front-shovel – truck combinations. IntroductionLes camions représentent probablement les équipements les plus utilisés pour le transport dans les mines. Le coût de transport peut parfois atteindre 50 % du coût d’exploitation et 25 % du coût total (Collins, 1996; Kennedy, 1990). Il est critique pour une opération minière de le minimiser. C’est un sujet qui a été traité relativement souvent dans la littérature spécialisée. Les premières applications informatiques dans l’industrie minière ont été développées pour la détermination du temps de cycle des camions.Au fil des ans, la capacité des camions a augmenté et, aujourd’hui, les plus gros manufacturiers de camions (Caterpillar, Orenstein & Koppel, Euclid, Terex, Unit Rig, Komatsu, Liebherr, Belaz) fabriquent des camions ayant une capacité de 200 t et plus dont quelques-uns d’une capacité supérieure à 320 t. Pour les plus gros camions, le coût d’opération peut même dépasser 240 $US/heure dans des conditions modérées (Caterpillar, 1999). Les mines modernes de grande taille peuvent posséder plusieurs dizaines de camions dans leur flotte."

Jan 1, 2004

By C. J. Martin, M. P. Hay

"A methodology was developed in the mid-1980’s to predict plant performance from standard laboratory flotation tests. The technique is based on a simple, empirical kinetics model, and is tailored for use by the practical metallurgist.To date the performance of more than 20 flotation plants has been predicted, including copper, lead, zinc, phosphate, pyrite, graphite, cassiterite, platinum, nickel and various slags. The method has successfully been used to predict and size four flotation plants directly from bench-scale laboratory flotation testwork. All have since been commissioned, and have performed as predicted.The technique has now received broad acceptance within the South African mining industry, for example in the last year alone it has been used to drive flowsheet development for at least seven new plants. It is also being used to assist in the optimisation of existing operating plants.The methodology is described in this paper and verification of the methodology is presented using case studies of porphyry, polymetallic and PGM operations.INTRODUCTIONThere is considerable interest these days in the use of modelling to simulate flotation circuits, for process design and plant optimisation purposes. Although these models are proving to be useful tools for plant design and optimisation, their complexity can make them cumbersome – expensive to use and difficult for metallurgists to visualise and mentally absorb, without a background in each specific technique. In “SUPASIM” no attempt is made to measure flotation fundamentals, rather to use empirical relationships between laboratory flotation kinetics and plant performance – relationships that hold up well to validation exercises as will be demonstrated later in this paper. Although not designed to be as comprehensive as other models, “SUPASIM” is easily understood by the operating metallurgist and can be quickly and easily applied."

Jan 1, 2004

By Z. -E. Nakagawa, O. Yamamoto

After the formation of a concentration gradient of SiC within C-C composite, either zircon or mullite thin films were coated on the surface by sol-gel process. Oxidation resistance tests of as-prepared composites with a couple consisting of a ceramic thin film and a SiC-gradient were then carried out in air at the temperature range from 600 to 1600°C. By the coating of zircon with a thickness of 1.5 µm, a pronounced oxidation resistance was observed; the mass loss by oxidation was almost negligible at 1000°C and one hundredth of original composite at 1400°C. In the case of the coating of mullite with a thickness of 1.0 pm, the marked improvement in oxidation resistance over the whole temperature range examined, from 600 to 1600°C, was found with the combination of a SiC-gradient and a mullite thin film

Jan 1, 2004

By John Emery, George Wang

Research and applied utilization activities for the increased use of ferrous and nonferrous slags in construction are presented. The overall use of blast furnace slag is relatively well known for a range of construction applications from aggregates to slag cements. In contrast to blast furnace slag, which is volumetrically stable and straightforward in its construction uses, steel slag contains hydratable oxides that can result in volumetric instability that must be dealt with through appropriate steel slag aging, testing and quality control to ensure its appropriate use. Particular care must be taken to prevent potential steel slag expansive behaviour in confined applications. Quality requirements and guidelines on steel slag expansivity to further the use of steel slags, with demonstrated acceptable performance, are outlined. There is a full range of proven construction uses - from aggregate to cementitious materials - for copper, nickel and phosphorus nonferrous slag. The use of air-cooled nickel slag is presented, based mainly on practical highway construction experience. It has been shown that air-cooled, crushed nickel slag can be an excellent aggregate in granular base, engineered fill and hot-mix asphalt. There is a good potential for increased ground, granulated copper and nickel slags use as supplementary cementitious materials that is being developed, which takes advantage of the &apos;latent energy&apos; content. The scope of a new technical text in preparation on the technology of slag utilization is reflected throughout to provide a practical context for the engineer.

Jan 1, 2004

By A. R. Naji Meidani, A. Cameron, A. Richardson, M. Isac, R. I. L. Guthrie

The supersonic core of shrouded jets remain coherent over longer distances vs conventional supersonic jets. This phenomenon should allow for greater penetration of oxygen into slag/steel reactor systems. As such, they hold the promise for faster slag/metal mixing in BOF type metallurgical reactor systems, possibly creating greater surface area/volume ratios of reacting phases, and thereby faster kinetics, as compared to conventional supersonic jet systems. In order to assess the potential of shrouded supersonic jets versus their conventional counterparts, an experimental investigation of impinging shrouded supersonic jets into a water model of a simplified BOF system was carried out in the MMPC&apos;s water modelling laboratory. The experimental results for three different designs of a shrouded supersonic jet nozzle have been compared in terms of greater penetration depths and reduced mixing times. Based on a novel dimensional analysis, the depth of penetration of a gas jet into a liquid bath is shown to depend on the nozzle-bath distance, the liquid&apos;s Froude, Reynolds and Weber numbers, reflecting the ratios of gravity, viscous and surface tension forces to the jet&apos;s inertial, or momentum, forces. Good agreement between the mathematical model and experiment was obtained in terms of predicted and observed depths of penetration. Further efforts have been made to study jet penetration into liquid metals. The effects of mean liquid density of slag/metal mixtures and a wide range of gas flow rates on the penetration depth were investigated theoretically. The results show that the penetration depth can be increased with increasing gas flow rate and decreased bath density.

Jan 1, 2004