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By A. P. Young, F. C. Holden

IN many of the early investigations of the aging of titanium alloys, it was observed that the retained beta phase could be aged to a high hardness without an apparent change in microstructure; moreover, in some alloys it was found that even a very rapid quench produced beta having an anomalously high hardness. What appeared to be hard beta phase was designated as "beta prime," to distinguish it from the softer normal retained beta phase. Frost and co-workers'.' demonstrated that the increased hardness is caused by the formation of a metastable phase, omega, which can be identified from its X-ray diffraction pattern. This reaction also has been studied by Brotzen, et a1.,3 and the structure of the omega phase has been published by Silcock, et al.," and by Austin and Doig.3 The X-ray diffraction analysis by Austin and Doig indicated that omega is low in alloy content, approaching the composition of the stable alpha. The aging process proceeds by the path Thus, overaging results in the formation of alpha and the ultimate disappearance of omega. This is accompanied by a decrease in hardness and a recovery of ductility. The present work represents a study of the aging process in a high-purity Ti-6.4 Mn alloy, in which optical and electron microscopy, X-ray diffraction, and hardness data were correlated. The specimens, 1/8-in. sections cut from 1/4-in.-diam rod, were heated in argon to a temperature just into the beta field (810°C), held for 1 hr, and water-quenched. The aging samples were heated in air for 1 hr at 300 to 500°C. The specimens were ground and mechanically polished, finishing with alternate etching and polishing on a slow-speed wheel to remove disturbed metal from the surface. The surface finally was swab-etched, rinsed with tap water, and air-dried. The etchant used was an aqueous solution containing 1 1/2 pct HF and 3 1/2 pct HNO3. This procedure is identical with that used for preparing metallographic specimens, except that the optimum degree of final etching required for electron microscopy may vary from that used for light microscopy. Metal replicas, backed with silica, were prepared from plastic strip-pings for examination with the electron microscope. Complete details of the procedures used for preparing these replicas are available elsewhere." Fig. 1 shows a comparison between the structures revealed by the electron microscope and those obtained by conventional light microscopy. Hardness and X-ray diffraction data are listed in Table I. No evidence of a second phase is apparent in the optical micrographs for the as-quenched sample, or for the specimens aged at 300 or 400°C; fine alpha particles can be seen in the specimen aged at 500°C. In the electron micrographs, visible equiaxed pocks appear in the as-quenched specimen, and, with increasing density, in the samples aged at 300 and 400°C. After aging at 500°C, the structure becomes markedly coarser and develops an oriented appearance of a second phase, coincident with the appearance of visible alpha particles in the light micrographs. These observations are confirmed by X-ray diffraction and hardness data. In these specimens, aged for 1 hr, the intensity of the omega pattern increases to a maximum at the 400°C aging temperature, corresponding to maximum hardness and the maximum density of pocks in the electron micrographs. At this point the beta phase shows a definite enrichment in Mn. At 500°C, little or no omega re-

Jan 1, 1959

By R. D. Daniels, T. W. Wood

The tensile properties of columbium and Cb-H alloys containing up to 455 ppm H were studied as a function of temperature and strain rate. Hydrogen, introduced into columbium at elevated temperatures, using a thermal -equilibrium technique, embrittled columbium most severely at about —77°C. This elnbrittle ment occurred even at hydrogen concentrations of an order of 20 ppm. At higher temperatures, the hydrogen tolerance of columbium increased in relation to the increased solubility of hydrogen in tile metal. Below this temperature hydrogen tolerance, as determined by ductility and fracture stress, increased slightly. Strain rate had little effect on the tensile results for cross-head speeds over the range 0.002 to 2.0 in. per min. Strain aging during the tensile test appears to explain the ductility mininmum at —77°C. The apparent increase in hydrogen tolerance at lower temperatures is attributed to the low mobility of hyhogen. Experiments were performed in which samples were prestrained in tension at room temperature and tested to failure at —196°C. Results suggest that hydrogetz segregation to preformed crack nuclei can cause subsequent embrittlement even at temperatures where hydrogen mobility is too low to cause embrittlement in a normal tensile test. COLUMBIUM is an example of the class of bcc metals with ductile-brittle transition temperatures sensitive to the presence of interstitial atom contaminants. Hydrogen is one of these embrittling contaminants. The embrittling effect of hydrogen is less potent, perhaps, in columbium than in some of the other bcc refractory metals, but it is still a problem of both theoretical and practical interest. Unlike hydrogen in iron and steels, hydrogen in columbium is exothermically rather than endo-thermically occluded. The embrittlement process in exothermic systems has not been studied as extensively as that in endothermic systems, especially at hydrogen concentrations below the limit of solubility. The purpose of this investigation was to evaluate the embrittlement process in initially pure columbium as a function of hydrogen content, temperature, and strain rate. The Cb-H phase diagram, according to Albrecht et al.,1 is shown in Fig. 1. Columbium reacts exothermically with hydrogen producing a solid solution at concentrations of less than about 250 ppm (parts per million by weight) H at room temperature. At concentrations above the highly temperature-dependent solvus a second phase is formed. Like many similar hydrogen-metal systems,2 his system exhibits a miscibility gap with respect to hydrogen solution. Albrecht found the critical temperature of the miscibility gap to be about 140°C, the critical concentration to be 0.23 atom fraction hydrogen, and the critical pressure to be 0.01 mm Hg. Above 140°C there is a solid solution of increasing lattice constant extending across the phase diagram. Hydrogen concentrations of particular interest in this investigation were those below the limit of solubility in columbium. At hydrogen concentrations above the limit of solubility, columbium will contain the hydrogen-rich second phase and will be brittle under most testing conditions because the hydride generally precipitates as platelets with coincident matrix lattice strains.1'3 At hydrogen concentrations below the limit of solubility, the tensile behavior of columbium is expected to be more sensitive to the interrelationships between hydrogen concentration and mobility and the testing variables such as temperature and strain rate. Literature references to the hydrogen embrittlement of metals, especially ferrous alloys and titanium alloys, are too voluminous to mention. It is only recently, however, that detailed studies of the hydrogen embrittlement of columbium have been undertaken. Wilcox et a1.4 studied the strain rate and temperature dependences of the low-temperature deformation behavior of fine-grained are-melted columbium (1 ppm H) and the effect of hydrogen content (1,9, and 30 ppm H) on the mechanical behavior of columbium at a series of temperatures for a single strain rate. A strain-aging peak was ob-served at about -50°C which was attributed to the presence of hydrogen in the metal. Eustice and carlson5 studied the effect of hydrogen on the ductility of V-Cb alloys at a series of temperatures over the range -196° to 25°C. Pure columbium was embrittled by 20 ppm H which produced a ductility transition at approximately -70°C. Ingram et al.6 studied the effect of oxygen and hydrogen on the tensile properties of columbium and tantalum. A minimum in the notched-to-unnotched tensile ratio of hydrogenated columbium was obtained at about -75°C, but because of the relatively large hydrogen content employed (200 and 390 ppm) the ductility

Jan 1, 1965

By Stanley J. LeFond, Langtry E. Lynd

Elemental titanium has become famous as a space age metal, because of its high strength/ weight ratio and resistance to corrosion. However, the major use is in the form of titanium dioxide pigment, which because of its whiteness, high refractive index, and resulting light-scattering ability, is unequaled for whitening paints, paper, rubber, plastics, and other materials. A relatively minor use is in welding rod coatings, in the form of the mineral rutile. United States consumption of titanium dioxide in concentrates for these applications in 1982 was as follows: pigments, 630,000 st; titanium metal, 31,000 st; and welding rod coatings, 5,000 st. The only commercially important titanium ore minerals at the present time are ilmenite and its alteration products, and rutile. Titanium was discovered by Gregor in 1790, as a white oxide which he recovered from menaccanite, a variety of ilmenite occurring as a black sand near Falmouth, Cornwall. Barksdale (1966) stated that the fundamental chemical reactions on which the present day titanium industry is based were known before 1800, although it was not until 1918 that these pigments were available commercially on the American market. Pings (1972) outlined the early history of the titanium industry in the United States, referring to the work of Guise (1964) and others: Mining of titanium minerals in the United States began sometime between 1880 and 1900, in Chester County, Pennsylvania. Small quantities of rutile were also produced during that time in North Carolina and Georgia. In 1901 rutile was mined from a deposit near Roseland, VA, and was used in making titanium chemicals and for coloring ceramics. Ilmenite in the deposit was produced as a separate item in 1913, and rutile and ilmenite were obtained from this deposit through 1921. The mining of titanium bearing beach sands began in 1916 near Mineral City and Pablo Beach, FL, for the purpose of making titanium tetrachloride to be used in tracer bullets, flares, and smokescreens. The titanium pigment industry was founded in 1918. By 1928 a large part of the domestic production of rutile, ilmenite, and zircon came from Florida. However production ceased in 1929 in Florida with the mining of newly discovered deposits in Virginia which were mined until 1968. The discovery of new deposits in Florida, and the development of better mining and concentrating methods for low-grade sands, led to a return of activities in this area. The large deposits near Tahawus, NY. were brought into production in 1942 by National Lead Co. (now NL Industries, Inc.), and by 1949 this company was the leading producer of ilmenite in the world. In 1948 the extensive deposits of ilmenite and ilmenite-bearing iron ores were discovered in eastern Quebec. The large Trail Ridge sand deposit in Florida was discovered by E. I. du Pont de Nemours & Co., Inc. geologists in cooperation with the US

Jan 1, 1983

Edward Keller, Baltimore, Md. (communication to the Secretary): When, at the New Pork meeting, February, 1899, Mr. Douglas gave an abstract of his highly interesting paper on the Copper Queen mine, he invited the members of the Institute, in his usual progressive spirit, to make a full scientific investigation of the region of that mine during the prospective excursion to Bisbee, Arizona. I volunteered to examine some of the metallurgical processes and products of the works, and obtained from Mr. Douglas a valuable series of samples. Upon the issue of his paper, however, I found that he had already a considerable volume of analyses of those products, and that little was left for me to do in that respect, except to duplicate his results, the importance of which work would not have been commensurate to the time and labor involved. I selected, therefore, only some points which he had not made entirely clear, or concerning which I was skeptical. The details of most of my work will appear in a future paper. From Mr. Douglas's figures I have calculated the values for the elimination of impurities in the so-called Leghorn converter, introduced by him at the Copper Queen works, and have found them to be as follows: Percentage of Elimination of Impurities in Pour Blows of a Converter. No of ' Selenium Sulph'r Iron. Zinc. I Nickel. Lead. Antimony Arsenic. and Blow- ! Tellurium .. 1.......... 99.4 99.6 88.0 92.6 94.4 81.6 83.8 40.3 2.......... 99.0 99.6 98.1 92.5 96.8 71.9 76.6 38.1 3.......... 98.8 99.5 93.5 91.4 96.3 63.8 80.6 25.3 4.......... 99.8 99.5 95.8 95.8 97.5 65.3 76.9 36.3 Average 99.2 99.6 93.8 93.1 . 96.2 70.6 ! 79.5 35.0

Jan 1, 1900

By K. Mukherjee

Instantaneous resistance change during martensitic transformation in Fe-30 at. pct Ni alloy has been studied using a low-noise electronic system. The smallest signals recorded in this investigation were of the order of 10 pv. These small signals did not show the initial increase reported by earlier investigators to support a double shear mechanism.&apos; A variety of pulse shapes and sizes was observed during "burst" transformations, and these signals were neither a linear function of the size of martensite plates nor of the volume fraction transformed. Even the smallest signals, presumably from single plates, showed complications resulting from elastic and/or plastic deformation, shock wave propagation, and so forth, which are inherent in the growth process of a martensite plate. The time of formation and interface velocity determined froni this experiment agree very well with the pioneering work of Bunshalz and Mehl.&apos; AN Fe-30 at. pct Ni (c0.005 pct C) alloy was used to study the time of formation of martensite plates. Martensitic transformations, unlike the nucleation and growth processes, are usually characterized by an extremely fast reaction rate. During the transformation, the crystal structure changes and this change is propagated through a finite volume of the parent crystal lattice within a very short time interval. The interface between the two phases probably consists of moving dislocations, and the time of formation of the plate depends on how fast this dislocation interface can move. Knapp and Dehlin~er or Cottrell and Bilby mechanisms, or similar dislocation models, can be used to calculate the time of formation of a martensite plate of a given size. In the past, conventional photographic technique475 as well as electrical resistivity techniques"~-" have been used to measure the time of formation of a martensite plate. The specific resistance of the martensitic phase in Fe-30 at. pct Ni alloy is lower than that of the austenite phase. Therefore if a current is passed through a small austenite sample in series with a large external resistance, then one would observe a voltage change across the sample as martensite is formed. Such dc measurements are shown in Fig. 1. The initial large voltage drop in Fig. 1, at the M, temperature, is due to a "burst" transformation where a large number of plates are formed in a cataclysmic manner within a very short interval of time. Even during the later stages of transformation as shown in Fig. 1, one can observe discontinuous voltage changes due to small bursts. In order to resolve the time scale of such discontinuous stages, the voltage signals are amplified and fed into a highspeed oscilloscope. In this investigation a low-noise amplifier was used for the first stage of amplification. The signal to noise ratio was further improved by the design of a pulse transformer. This transformer was capable of amplifying the signal by a factor of six. Voltage signals were studied over a wide time scale ranging from 2 sec to 0.1 psec. I) EXPERIMENTAL PROCEDURE A) Specimen Preparation. Specimens were cut from induction-melted Fe-30 at. pct Ni (<0.005C) alloy and cold-rolled to 0.2 by 1 mm cross section and an average length of 5 cm. During mechanical shaping, the specimens were strain-annealed at 950°C for 24 hr in vacuum. Finally the finished samples were vacuum-annealed at 1000°C for 6 hr and water-quenched to room temperature. The average grain diameter was 0.02 cm. B) Cooling System. The M, temperature of the alloy was -55°C. Fig. 2 shows the arrangement which was used to cool the specimen at a slow rate. The specimens were mounted inside a i -in.-diam hole in the 2-in.-long section of the copper specimen holder. This cavity was filled with silica gel. A dummy specimen was used under identical conditions for

Jan 1, 1969

By F. W. Jessen, H. Kazemi

A washing technique has been developed to form a spherical cavity in massive salt. The technique is, basically, a process of controlling the fluid motion in the cavity, the concentration distribution of brine, the rate of dissolution at the walls of the cavity, and the particular settings of the wash pipe, or pipes (inlet and outlet pipe) employed. For a particular arrangement of tubing and casing, fresh water enters from the casing annulus at a position above the bottom of the tubing, and the dissolved material leaves the cavity through the tubing near the bottom of the projected hole. The initial configuration of the cavity is cylindrical, representing the drilled hole situated at the axis of the projected cavity. As washing progresses the original hole is enlarged radially (any direction perpendicular to the axis of the hole). An inert fluid (generally a hydrocarbon, natural gas, or air) which serves as a blanket is injected through the annular space between the original hole and the casing. The controlled downward motion of this blanket maintains the upper edge of the brine region that is expanding on the surface of the projected sphere. A large spherical glass container and a radial model were used to investigate the flow patterns and the concentration distribution of brine occurring during the progress of solution of the salt. Aluminum flakes and dye were injected and flow patterns were observed and recorded on motion picture film. Based on the results of these model studies and other work carried out in this laboratory, the controlled washing technique was formulated. INTRODUCTION Underground cavities leached in salt beds and salt domes have been used extensively for storing hydrocarbons. Little attention has been focused on the shape of the cavities as long as large volumes were obtained and the cavities were structurally stable. The general process involves circulating fresh water and removing brine. Two distinctly different circulating systems can be employed, each of which yields characteristically different shapes. By far the most generally accepted method of washing storage caverns in salt domes is the direct circulation system. Water is introduced through the innermost pipe of a concentric pipe system, and brine is withdrawn through the annulus. In the reverse-circulation method, water enters through the annulus and is discharged through the smallesc tubing string. The size of the operation, and hence the size of tubing and casing used, depends on such factors as cavity volume, length of hole, availability of water, disposal of brine and power requirements. Underground caverns are from 100 to 1,000 ft or more in length, and when completed vary from 40 to 100 ft in diameter, providing storage of 100,000 bbl or more. The volumes of water required per volume of salt removed vary from 6 to 7 for the reverse circulation method to 10 to 11 for the direct circulation method. Up to 80,000 BWPD are often circulated. In the direct circulation method, because water enters near the bottom of the projected cavity, solution of salt is greatest at this point, particularly in view of the fact that when the washing is begun turbulent flow undoubtedly exists in the immediate vicinity of the discharge of the inlet water. As the diameter of the hole increases, flow rates also are increased, so perhaps the condition of fluid turbulence is maintained for some time. During the later stages of leaching, when capacity of equipment may be the limiting factor in maintaining flow rates, there may still exist some turbulence adjacent to the point of influx; however, for the most part laminar flow conditions prevail. There appears, therefore, rather good evidence to indicate that the state of fluid motion is responsible for the typically shaped cavity which results from such washing — namely a cylindrical form, generally somewhat larger at the bottom than at the top. Depending on the number of so-called stages which might be employed, the walls or surfaces of the salt diminish rather uniformly from bottom to

Jan 1, 1965

By H. J. Engell, W. Frank, A. Seeger

SWISHER and ~urkdogan&apos; have determined the solubility of oxygen in a iron. They found it to lie between 7 and 10.5 at.-ppm at 881°C. Using earlier work on the permeability of oxygen in bcc iron,&apos; they arrived at the following expression for the diffusion coefficient of oxygen in bcc iron (k = Boltzmann&apos;s constant, T = absolute temperature): where The present authors3 have estimated the activation energy QD for the diffusion of oxygen in bcc iron in two different ways from various experimental data.2&apos;4"6 In the first method QD + QS (QS = heat of solution for oxygen in bcc iron in thermodynamic equilibrium with solid FeO) was determined either from data on the reduction of FeO with hydrogen4 or from measurements of the internal oxidation of silicon in a iron.5 Using an estimate of QS from investigations of the oxygen solubility in 6 iron2 (in thermodynamic equilibrium with molten FeO) Q = 0.97 ev or Q~ = 1.06 ev were obtained. From the magnitude of these values it was concluded that oxygen migrates interstitially in bcc iron and that consequently the activation energy QD for diffusion of oxygen has to be identified with the migration energy E~ of the oxygen atoms. Therefore, for a second estimate of QD from the diffusion coefficient of oxygen in 6 iron at 1450" ~,~ we used the theoretical expression:3 (a = length of elementary cube edge, m = mass of interstitially diffusing atom, sM = migration entropy), applicable to diffusion via the octahedral interstices in bcc lattices. Taking sM = 3.8 k (migration entropy of carbon in a iron), one gets Q = 0.90 ev. Hence, in Ref. 3 Q = (0.98 *0.1) ev was proposed as a plausible value for the diffusion energy of oxygen in bcc iron. sM + 9 (9 = solution entropy for oxygen in bcc iron) can be determined from permeability measurements.4 Using the above-mentioned estimate for QS , the following expression for the solubility c (atomic concentration) of oxygen (in thermodynamic equilibrium with solid FeO) in bcc iron was derived: From [4] the solubility of oxygen at 881°C in a iron is calculated to lie between 0.6 and 12 at.-ppm. We see that the solubility determined by Swisher and

Jan 1, 1969

By L. W. Holm, G. G. Bernard

Laboratory experiments were conducted to determine the effect of foam on gas flow in porous media. Previous studies have indicated that foam may be applicable as a restrictive agent in influencing underground gas flow. Foam was found to be exceedingly effective in reducing the permeability of porous media to gas. Consolidated and unconsolidated sands with specific permeabilities of 100 to 146,000 md had, in the presence of foam, gas permeabilities that were less than 1 per cent of the specific permeability; in many cases the gas permeability was practically zero. Foam reduced the gas permeability of loose sand to a much greater degree than that of a tight sand. For example, the permeability of a 125,000-md sand was reduced to 3 md while the permeability of a 4,000-md sand was reduced to 7 md. This effect should cause, to some degree, selective plugging of high permeability channels in various oil displacement processes. The presence of oil in a porous medium decreased the effectiveness of foam in reducing gas permeability; apparently oil acts as a foam depressant. However, it was found that certain foaming agents were very effective in reducing permeability even. in the presence of oil. Also, continuous injection of other foaming agents increased their effectiveness, when oil was present. The effect of foam on permeability of porous media to gas was studied as a function of foaming agent concentration and injection rate, absolute permeability, total pressure, pressure gadient, length of porous system, brine concentration and time. INTRODUCTION The use of surface active agents in flood water to increase the recovery of oil has been studied in the laboratory and in the field for decades, with rather limited success. In recent years a new approach to the problem was proposed. Instead of using an aqueous solution of surfactant as an oil recovery agent, Bond and Holbrook2 proposed that the oil recovery agent be a mixture of surfactant solution and gas. In their method, a water-soluble surface active agent with foam-producing characteristics is injected into an underground formation as an aqueous slug. This slug is followed by gas to produce a foam within the rock. Foams are defined as "agglomerations of gas bubbles separated from each other by thin liquid films&apos;! A foam is fundamentally an unstable system. The foam process for oil recovery has since been studied by other investigators. Fried 1 has shown that foam can displace from porous structures oil that normally is unrecoverable by conventional water or gas drives. This superior oil displacing action is believed to be the result of several factors: (1) foam introduces into the reservoir many resilient interfaces of various sizes and curvatures, which increase the probability that a proper combination of forces for oil displacement will be created; (2) foam has appreciable viscosity which improves mobility ratio and contact efficiency; (3) foam accentuates the trapped gas effect because high gas saturations are possible without producing high gas/oil ratios. Deming4 studied the effect of various foam properties on the displacement of liquid. He found that (1) high foaming ability favors high displacement efficiency; (2) high foam stability is not necessary for high displacement efficiency; (3) displacement efficiency decreases with increase in plasticity of foam and (4) displacement efficiency is unaffected by surface tension of foaming agent solution. One of the important aspects of this oil recovery process is the effect of foam on gas permeability. The simultaneous flow of gas and liquid in porous media has been studied by numerous investigators and a large amount of literature exists on the subject. In this previous work, gas and liquid have generally been considered as essentially independent phases, whose flow characteristics are related through the saturation parameter. Foam, however, is a material with properties that are considerably different from those of its components; for example, the viscosity of a foam is greater than either of its components. Gas flow in a porous medium in the presence of foam should be considerably different

Jan 1, 1965

By R. W. Jordan, J. Winter, A. J. Goldman

Kirkendall diffusion of copper and nickel atoms across the bond interfaces, as well as oxygen diffusion in the core to the interfaces, are the mechanisms which control the variation in bond strength with annealing time at 1600°to 1800°F in the cupro-nickel clad copper Mint composite. The unequal mass transfer resulting from the high diffusion rate of copper in cupro-nickel compared with that of nickel in copper caused void formation in the core. Small voids also formed in the cladding after short annealing times. These may have been nucleated by nickel oxide particles which are formed by the dissociation of the cuprous oxide in the core and the movement of oxygen to the cupro-nickel interfaces. The bond strength drops to very low values for annealing time up to 3 hr when the void density is greatest. The increase in bond strength after 16 to 72 hr at 1600°F is a result of the decrease in the void density in the cupro-nickel cladding and the growth of grains across the interface. The void density decrease is attributable to grain boundary diffusion of vacancies to the surface. The abnormally large grains in the copper preclude a similar process from taking place in the core. THE solution to many engineering materials problems that cannot be satisfied by using a single metal or alloy is often attained by combining two or more metals in such a way that each component performs a different function, while the composite meets the overall requirements. The Coinage Act of 1965 authorized a changeover from the traditional 90 Ag-10 Cu dimes and quarters to a bimetallic laminate of 75 Cu-25 Ni clad on a copper core. Economic considerations as well as physical, chemical, and mechanical properties provided a basis for the selection of this composite as a substitute for the silver-bearing alloy. An extensive survey of alloys suitable for use as coinage was prepared by Battelle Memorial Institute for the U.S. Mint.1 It was found that the cupro-nickel/cop-per/cupro-nickel composite satisfied the required color, density, mechanical properties, corrosion resistance, electrical properties, and magnetic properties to make it completely acceptable to the general public and the vending machine industry. This investigation is part of a program to determine the feasibility of reclaiming composite scrap by thermally degrading the bond strength of the cupro-nickel clad copper laminate. The composite exhibits bond degradation and subsequent bond improvement during annealing in the temperature range 1600" to 1800°F. A study of the operative diffusion processes and the resultant structural changes was made in order to explain the observed variations in bond strength with annealing time. EXPERIMENTAL PROCEDURES AND RESULTS Bond Degradation. A measurement of the forces required to peel the cupro-nickel cladding from the

Jan 1, 1969

By R. W. Smith

A study has been made of the crushing and grinding circuits by the Portland Cement Association in nine cement plants. Five of the plants used the wet process and four, the dry method. Both raw and clinker grinding were studied in the four dry processing plants. The raw materials used varied considerably from plant to plant. Actual power consumption data were obtained for the majority of the grinding mills in these plants. Previously representative raw and clinker samples had been obtained from the nine plants, and Bond1 and Hardgrove2 grindability tests were run on these samples. All pertinent data concerning the grinding mills, such as mill size and speed, ball charge size and weight, size distribution of feed, and discharge materials were also obtained. Thus it became possible to calculate the actual horsepower used by the various mills, and to compare this figure to the theoretical horsepower as calculated by several different methods.

Jan 4, 1961

By A. Matsubara

Jan 1, 1922

By A. Matsubara

Jan 1, 1922

By C. G. Goetzel

Until recently porous bronzes have found many applications for self-lubricating bearings in the automotive, electrical, household appliance and general machine industries. The bulk of an annual production of several million pounds of copper powder had gone into the manufacture of these articles, of which by now more than a billion are in service. However, the war has brought severe curtailment of these bearings because of the scarcity of the two main constituents, copper and tin. The development of substitute materials of equal or superior properties has led to a large-scale replacement by products made from iron powder. In spite of the diminished interest in powdered copper-tin alloys caused by this trend, it was believed worth while to investigate some mechanical properties of these materials as a reference base for substitutes. In addition, experiments using the hot-press method were incorporated to investigate possibilities of saving vital equipment or opening new fields of applications. It must be assumed that by this time the powder metallurgy process of making porous bronzes, a development that found its first industrial applications more than 10 years ago, is well known in engineering. The patent literature and bibliography is volu- minous, most publications referring to porous, self-lubricating bronzes, containing about 10 per cent tin and I to 5 per cent graphite, with porosities in the range of 25 to 35 per cent.l-7 The excellent antifriction properties of these bearings, caused by the uniform impregnation with oil, are dependent on the interconnection of the pores and the uniform distribution of the graphite inclusions. The sintering mechanism of porous bronze, with its structural changes during the transformation of the metal powder into the sintered bearing has been shown in colored photomicrographs by Hall.* Diffusion between copper and tin was found to begin within one minute, when tin-rich transitory phases were formed. After 25 min. a homogeneous matrix of alpha was reached for an alloy containing 9.5 per cent tin and 6 per cent graphite. Price, Williams and Garrand,9 studying certain metal powder combinations in which sintering is accompanied by the cementing action of a liquid phase, including a 90-10 bronze sintered at 925°C., have found that if the treatment is carried out within the liquidus and solidus temperature range of the system, a peculiar process of alternate solution and precipitation occurs. The particles of the major solid constituent are dissolved in the minor liquid phase, but thereafter are reprecipi-tated on certain nuclei, which develop into large grains, usually rounded.

Jan 1, 1945

By L. G. Sprague

The fact that this latest and most modern of the Universal Atlas Cement Company&apos;s plants at Northampton, Pa., is the fifth to be built on these same properties, and their development has been coincidental with the development of the portland cement industry in the United States, makes it appropriate to sketch briefly the history of the successive steps. In 1889 the original Atlas Portland Cement Co. started its first plant at Coplay, Pa., which is just across the Lehigh River from the present operation. Here the first successful rotary kiln was operated. These kilns were 6 ft. in diameter and 60 ft. long; they used oil for fuel until 1895, when the company developed the first burner for pulverized coal. Shortly thereafter the Atlas company acquired property on the Northampton side of the river and built its plants Nos. 2, 3 and 4 within the following 10 years. During the same period the production of portland cement in the country was increasing rapidly; owing largely to the development of the rotary kiln and improved grinding machinery, which lowered the cost and improved the quality of cement. The general tendency has been to increase the length of the kiln and grind both raw material and finished product Liner. In 1930 the Atlas Portland Cement Co. and the Universal Portland Cement Co. united to form the Universal Atlas Cement Co., and the same policy of improving the product has been continued. Because of the large amount of research carried on by manufacturers and consumers, including government agencies, there is a demand for cement of different chemical and physical characteristics for different kinds of structures. Hence many engineers in recent years have been asking for cements of certain definite chemical analyses, which they think are best for their particular jobs. This has compelled the manufacturer to make several different types of cement by variations of chemical composition. These are generally made by adding silica, iron and lime to the standard mixture, which necessarily increases the cost of the product. Therefore the Universal Atlas Cement Co., in planning the modernization of its Northampton plant, gave this particular phase of the problem considerable study. Research and experimentation have developed the practicability of making a wide variety of differently proportioned raw materials for cement by a process of subtraction rather than by addition. With such process, it is possible to discard the undesirable aluminates and silicates from the ample supply of impure limestone available from the company&apos;s property rather than by adding high-grade limestone obtained from distant sources. This procedure requires mineral separation by centrifugal sedimentation and froth flotation. Since the chemical and mineral constituents of Lehigh Valley "cement rock," together with the methods of separating them, have been thoroughly described in published

Jan 1, 1948

By L. G. Sprague

The fact that this latest and most modern of the Universal Atlas Cement Company&apos;s plants at Northampton, Pa., is the fifth to be built on these same properties, and their development has been coincidental with the development of the portland cement industry in the United States, makes it appropriate to sketch briefly the history of the successive steps. In 1889 the original Atlas Portland Cement Co. started its first plant at Coplay, Pa., which is just across the Lehigh River from the present operation. Here the first successful rotary kiln was operated. These kilns were 6 ft. in diameter and 60 ft. long; they used oil for fuel until 1895, when the company developed the first burner for pulverized coal. Shortly thereafter the Atlas company acquired property on the Northampton side of the river and built its plants Nos. 2, 3 and 4 within the following 10 years. During the same period the production of portland cement in the country was increasing rapidly; owing largely to the development of the rotary kiln and improved grinding machinery, which lowered the cost and improved the quality of cement. The general tendency has been to increase the length of the kiln and grind both raw material and finished product Liner. In 1930 the Atlas Portland Cement Co. and the Universal Portland Cement Co. united to form the Universal Atlas Cement Co., and the same policy of improving the product has been continued. Because of the large amount of research carried on by manufacturers and consumers, including government agencies, there is a demand for cement of different chemical and physical characteristics for different kinds of structures. Hence many engineers in recent years have been asking for cements of certain definite chemical analyses, which they think are best for their particular jobs. This has compelled the manufacturer to make several different types of cement by variations of chemical composition. These are generally made by adding silica, iron and lime to the standard mixture, which necessarily increases the cost of the product. Therefore the Universal Atlas Cement Co., in planning the modernization of its Northampton plant, gave this particular phase of the problem considerable study. Research and experimentation have developed the practicability of making a wide variety of differently proportioned raw materials for cement by a process of subtraction rather than by addition. With such process, it is possible to discard the undesirable aluminates and silicates from the ample supply of impure limestone available from the company&apos;s property rather than by adding high-grade limestone obtained from distant sources. This procedure requires mineral separation by centrifugal sedimentation and froth flotation. Since the chemical and mineral constituents of Lehigh Valley "cement rock," together with the methods of separating them, have been thoroughly described in published

Jan 1, 1948

By A. Grant Elliot, H. W. Lavendel

qualitative picture has been developed to describe the oxidation behavior of TaSi2-coated tantalum and CbSi2-coated columbium. These systems have a significantly lower inherent oxidation resistance than MoSi2-coated molybdenum does. This stems primarily from the fact that Ta2O5 and Cb2O5 are nearly as stable thermodynamically as SiO2, whereas MoO2 or Moos are not. Further, diffusion of silicon in the Ta- and Cb-Si system is considerably slower than in the Mo-Si system. These ,factors prohibit the mechanism of selective oxidation of- silicon which accounts for the oxidation resistance 01- MoSi2-coated molybdenum. The silicide can be stabilized by adding suitable Modifiers which increase the thermodynamic stability of the silicate formed during oxidation. Modifiers, such as aluminum, can be inroduced into solid solution in the coating. in controlled amounts through proper selection of the source in the pack cementation process of coating fov~rzatiorz. Addition of aluminum to TaSi2, coatings on tantalum was effective in moderately increasing the oxidation resistance. EXTENSIVE experimental work and analysis have established the nature of the oxidation behavior exhibited by MoSi2- and MoSi2 -coated molybdenum-base alloys, and defined the conditions for maximum protection against oxidation of the substrate.&apos;-* The oxidation resistance of MoSi2 in the temperature-pressure range of 1100°C-PO2 > 10-5 atm to 1900°C— PO2 > 10-1 atm is due to the formation at the surface of a continuous film of SiO2 which results from selective oxidation of silicon. Under the prevailing kinetic conditions, this film is stable toward the molybdenum silicide with which it comes in contact. Initially molybdenum oxidizes also, but it forms volatile species. SiO2, however, nucleates and grows as a condensed phase. Once a continuous film of SiO2 has formed, the oxidation rate falls to that observed for the oxidation of pure silicon indicative of diffusion through the oxide film as the rate-controlling mechanism. This oxidation behavior is of course highly dependent upon temperature and oxygen pressure. Bartlett and Gage13 and Bartlett, McCamont, and Gagelb define precisely this dependence in terms of the oxygen partial pressures and silicon diffusivities required to support a stable SiO2 film. At low temperatures (near 500°C—the "pest" region) silicon diffuses too slowly to be selectively oxidized. Hence, molybdenum and silicon oxidize readily in proportion to their stoi- chiometry. At high temperatures and low pressure, SiOz dissociates to form volatile SiO(g), and a protective film cannot be maintained. Application of the MoSiz/Mo system is limited to temperatures below 1900oC, the eutectic between MoSi, and MO5Si3.5 The oxidation behavior of MoSi2-coated molybdenum is essentially the same as that outlined above with the exception that the MoSi2 is not in equilibrium with the molybdenum substrate. At the temperatures under consideration silicon will diffuse rapidly into the molybdenum eventually converting the coating to MosSi3.4 The rate constant for subsequent decomposition of Mo5Si3 into Mo3Si plus silicon, and/or the diffusivity of silicon through Mo3Si then becomes low enough to allow active oxidation of both molybdenum and silicon with subsequent degradation of the specimen. A stable silica film can be formed but at temperatures and/or oxygen partial pressures higher than those required with MoSi2 present as a source of si1icon.l, 4 Because of the similarity between the silicides of molybdenum and those of columbium and tantalum one would expect similar oxidation behavior for coatings in the respective systems. This is not entirely the case, however, as shown by the experimental results reported herein. Regarding tantalum and columbium disilicide coatings on tantalum and columbium substrates, respectively, the oxygen arriving at the surface of the coating partitions itself nearly equally between the metal and the silicon, and a two-phase oxide layer (Me2O5 plus SiO2) is always formed. The diffusion of silicon in the tantalum and columbium silicides is relatively slow, compared to that in the molybdenum silicides, which further enhances this equipartitioning of oxygen. Thickening of the coating during service by inward diffusion of silicon into the substrate is correspondingly slow, and the effective thickness of the coating at the roots of cracks and defects is only slightly changed providing high probability for premature coating failure. Furthermore, the SiO2 glass that is generated is not thermodynamically stable with respect to the coating. The metal silicide tends to reduce the SiO2 liberating either free silicon or SiO. The situation can be improved by suitably modifying the coating such that the stability of the protective glass which is generated during service is increased. Thus, selective oxidation of silicon and the modifying agent will occur, and the silicide coating will not tend to reduce the oxide layer. Modifying agents can be introduced into the coating by the pack cementation process. Using sources containing the modifier at controlled chemical potentials allows control of the coating composition. Partially substituting aluminum for silicon in TaSi2 coatings by forming a Ta(Si,Al)2 solid solution was effective in moderately increasing the oxidation protection.

Jan 1, 1968

CARL HENRICH (communication to the Secretary*).-I have read with much interest the discussions of my paper by Messrs. A. S. Dwight, E. P. Mathewson, Win. B. Boggs, Jos. W. Richards, and W. C. Smith. Mr. Dwight&apos;s acknowledgment that he always-in lead smelting¬obtained better results by figuring A1203 as an acid in his slags, I may take as a confirmation of my views, notwithstanding his later conversion by, the late T. S. Austin to the latter&apos;s empirical view and way of neglecting the consideration of A1203 altogether in the composition of slags-letting the slags "dissolve" in Al203. I have a strong suspicion that Mr. Austin, in a large custom smelting plant at El Paso, has been able to keep the alumina percentage of his slags sufficiently low, not to give him much trouble, although I have also a suspicion that his furnace foreman may have had a somewhat differing opinion of the practical working of the "dissolving" theory,, whenever its applicability was tested to its limits. That Austin should have conceived the notion that the Ca of CaF2 would enter into a slag as CaO, seems hardly in accord with the recognized ability of that late metallurgist. It is a well-recognized fact that even small amounts of CaF2 will reduce the viscosity of a slag; but I did not think anyone ever had an idea that CaF2, in some mysterious way, parted with its F and coupled itself with 0 to satisfy a craving for CaO on the part of 802-least of all in a lead furnace. The "dissolving" theory for CaF2 was doubtless appropriate, and an improvement on figuring the Ca of CaF2 as CaO to satisfy the demand of Si02 for RO bases. However, I cannot understand the rationality of extending this "dissolving" theory to A1203 and to ZnO. It would be interesting to have more specific data from Mr. Mathewson in regard to the actual composition-analyses-of the slags made, when he had these unusually high alumina slags in Colorado. We "old" smelters all know that within certain limits, usually found out by rather tough experience, we could safely "disregard" A1203. In fact, I believe, we never really analyzed for alumina, except in slag analyses, when we

Jan 6, 1917

By G. M. Wiles

The increasing number of problems of the modem mine manager has led the author to discuss the art of management. He lists the principles concerning selection of personnel, exploitation and development, new equipment, process improvements, new processes, maintenance, operating cost data and public relations. Application of the principles to problems of mine startup, operation and rehabilitation are described. Since D. C. Jackling was famous for his adeptness at organizing and training teams of operating personnel, the subject of mine management is particularly appropriate for a Jackling Lecture. In fact, it is doubly appropriate because in very basic ways Jackling&apos;s career changed the nature of the tasks and challenges facing a mine manager. Management of mines, of course, is the art of finding and winning minerals economically from the earth&apos;s crust, and it involves the use of all the engineering sciences. But also of prime importance is a skill which is not yet a science - the area of management often referred to as human engineering. Since expenditures on staff and labor may well involve more than 50% of the direct costs of operating a mine, ability at human engineering is just as important as the ability to plan and put into effect the most efficient operating procedures. In addition to his ability to select and train operating personnel, Jackling possessed, to a degree unmatched by many of his contemporaries, broad, analytical powers covering both the economics and operating phases of large scale mineral extraction. His breadth of vision found its greatest expression at the time he analyzed the Utah copper deposit. Fortunately, Messrs. Penrose and Gemmell had enough faith in his analyses to furnish the capital needed to begin operations. The result, as is well known to all of you, was Kennecott&apos;s lucrative Utah copper mine — and the beginning of the open pit porphyry copper era. The Utah copper mine, and Jackling&apos;s subsequent similar successes in Arizona, New Mexico and Nevada, had one thing in common —all of these large porphyry deposits were worthless until open pit, large daily tonnage schemes were developed for their exploitation. The successful development of such schemes made vast new mineral resources available for economic exploitation. But at the same time, the trend away from smaller high grade operations in favor of the far more complicated operations required to handle large deposits of low grade ore have greatly altered a mine manager&apos;s problems. We are all familiar with the saying "mines make managers." There is still some truth in this statement, but far less than there used to be in the days when high grade properties were the rule rather than the exception. When high grade orebodies prevailed, many managers, superficially at least, could not make a mistake because the profits of their mines

Jan 1, 1962

By Robert W. Fullerton, Barry G. McMillan, Donald T. King, Henning E. Soderberg

INTRODUCTION Dust control in coal preparation and related transport is a multi- faceted problem which must be anticipated whenever dry, fine coal is subject to rough handling which can disperse it in the air. This problem can be minimized by careful planning and proper design, by eliminating procedures which maximize dust production, and by utilizing the most appropriate dust-collection "hardware" for a given situation. Proper maintenance after dust-collection systems are installed is also very important, and will not only enable the selected equipment to perform properly, but will also reduce component wear, recover valuable product with the highest efficiency, provide cleaner and safer working conditions, and allow local clean-air standards to be met. This chapter is designed to provide basic information about dust control in relation to material processing and handling during coal preparation. Areas discussed should provide the reader with insight into basic dust-collection theory, particle behavior, equipment types, ductwork and hood considerations, general maintenance and design planning, and the economics of dust collection. Because of the wide range of areas covered and the various specialized problems inherent in each, the text is organized to be a practical reference, and not a complete, unabridged treatise of ventilation and dust-control design. Nevertheless, the information presented should be of value in both understanding and reducing problems of dust control in coal preparation.

Jan 1, 1979

By George M. Fowler

MINING geology is a progressive study, so we must look to the future for the solution of many of its most significant problems. These problems, world-wide in scope, offer ample opportunity for the exercise of the utmost skill and intelligence by all that attempt to solve theta, as it is generally recognized that many ore deposits of the future will he found only by months or years of combined intelligent effort by the several engineering groups. Renewed appraisals are continually being made to better understand the relationship of physical-chemical processes to ore deposition and other mineralization and to interpret the findings of the geophysicists and others in terms of economic results. A study of current geologic activi¬ties clearly reflects the growing tendency for cooperation between the different branches of geology in order to appraise their united efforts. In line with these activities arrangements have been made to transfer the geophysical section of the U. S. Bureau of Mines to the Geological Survey.

Jan 1, 1936