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By Jorge A. S. Tenorio, Chuanwei Zhuo, Joner O. Alves, Yiannis A. Levendis

"The disposal of wastes is a serious environmental problem, since available landfill space is dwindling. Their treatment by pyrolysis or combustion has merit, and the corresponding fuel or power production is of technological interest. However, such processes need a rigid control of emissions. This work addresses the gaseous light hydrocarbons (LHCs) generated during sequential pyrolysis and partial oxidation of unserviceable tires, PET bottles, com wastes (DDGS) and sugarcane bagasse in a two-stage laminar-flow horizontal furnace, kept at 1000 °C. Gas chromatography was used to identify and quantify the components of the emitted gaseous light hydrocarbons. The results showed that the biomass residues generated the highest emissions of aliphatic hydrocarbons, whereas PET generated the most aromatic hydrocarbons. When stainless steel meshes were inserted in the exhaust flow, it was found that hydrocarbon emissions were curtailed; as such meshes catalyzed partial conversion of these carbon-bearing gases to carbonaceous nanomaterials.IntroductionLight hydrocarbons (LHCs) are volatile organic compounds, consisting of hydrogen and carbon with low molecular weight; the most common species are methane, ethane, propane, butane, etc. LHCs are valuable since they are a very important energy resource. However, uncontrolled release of light hydrocarbon gases to the atmosphere should be avoided [l, 2]. In this work, a development is presented for the evaluation of LHCs generated during the controlled pyrolysis/combustion of several wastes in a two-stage laminar-flow horizontal furnace. Samples of unserviceable tires, post-consumer PET bottles and waste residues from the bioethanol industry (DDGS and sugarcane bagasse) were burned. A catalyst system, consisting of stainless steel screens, was tested for its effects on the gaseous emissions."

Jan 1, 2011

By Paul J. Axtell

This case history describes the foundation design and construction for the New Mississippi River Bridge, presently under construction in St. Louis, Missouri. The 1,500 ft (457.2 m) main span of the cable-stayed bridge is supported by two delta tower pylons in the river, with anchor piers on each bank. The final foundation design was completed as a part of an Alternate Technical Concept (ATC) proposal by the winning construction team, and utilized drilled shafts up to 11.5-ft (3.5-m) diameter that were socketed into very hard limestone. As part of the ATC foundation design, a full-scale, bi-directional static load test was performed to verify the design and allow use of higher resistance values. This paper presents the results of the site exploration, construction of the load test shaft, details of the load testing, and a comparison of the test results with various design parameters.

Jan 1, 2011

By Mark Kennedy, Allan MacRae, Cameron Hams

New technology projects, particularly those involving first-of-a-kind metallurgical facilities, have a poor track record of achieving their overall financial targets, as they incorporate technological risks in addition to normal project risks. Traditional project management tools focus on risk from concept development through implementation, but typically fail to address the additional risks associated with a new technology project including slow start-up, slow ramp-up, and failure to achieve design performance (quality or throughput). These additional risks affect future cash flows produced by the project and hence its value, typically measured as net present value (NPV) or internal rate of return (IRR). Common accounting practice is to reduce the present value of future cash flows by applying a chosen discount rate, often reflecting the corporation's cost of capital. This discount rate does not contain an allowance for technological risk, which is often underestimated or misunderstood by both the financial and engineering project managers. This paper will focus on the topic of project risk and new technology, and how these play a role in the probability of achieving the predicted future cash flows. By properly addressing technological risk in the form of risk-weighted returns, marginal projects can be prevented from proceeding, while sound projects can be given the additional time and resources required to achieve the optimal level of front-end-loading (the level which returns the maximum risk-weighted net present value). A simple set of mathematical tools should enable engineers and financial professionals to establish a common level of understanding, thereby leading to a more accurate assessment whether a new technology project is ready to pass through its next level of approvals.

Jan 1, 2011

By Rob Farnfield, Ben Williams

The A5 road in the United Kingdom forms an ancient and well-used route through the hills and mountains of North Wales. In the 1990?s a programme of work was conducted to upgrade the road to modern standards. As part of this work a new cutting was constructed to bypass a portion of road routed through a gorge close to the village of Ty Nant. This new cutting was formed by drilling and blasting and included much pre-splitting and extensive rock bolting. This operation caused much concern to local residents relating to vibration, air overpressure and flyrock.

Jan 1, 2011

By G. L. Fredrickson, T. A. Johnson, B. R. Westphal, J. C. Wass, S. X. Li, D. Vaden

"Recovery of uranium from the Mk-IV and Mk-V electrorefiner vessels containing a LiCl/KCl eutectic salt has been on-going during the pyrometallurgical processing of used nuclear fuel for 14 and 12 years, respectively. Although austenitic stainless steels are typically utilized for LiCl/KCl salt systems, the presence of cadmium in the Mk-IV electrorefiner dictates an alternate material. A 2.25Cr-1Mo alloy (ASME SA-387) was chosen due to the absence of nickel in the alloy which has a considerable solubility in cadmium. Using the transition metal impurities (iron, chromium, nickel, molybdenum, and manganese) in the electrorefined uranium products, an algorithm was developed to derive values for the contribution of the transition metals from the various input sources. Weight loss and corrosion rate data for the Mk-V electrorefiner vessel were then generated based on the transition metal impurities in the uranium products. To date, the corrosion rate of the 2.25Cr-1Mo alloy in LiCl/KCl eutectic is ""outstanding"" assuming uniform (i.e. non-localized) conditions.IntroductionLow-enriched uranium products are being recovered from the Experimental Breeder Reactor-II (EBR-II) and Fast Flux Test Facility (FFTF) used nuclear fuels by a pyrometallurgical treatment process at the Idaho National Laboratory (INL). The treatment process comprises a set of operations designed to neutralize bond sodium, recover uranium from radioactive fission products, and place the fission products into acceptable waste forms [1-2]. Reactive sodium metal, essential for heat transfer purposes during reactor operations, is readily converted to chloride during the process. Electrorefined uranium products are currently being stored pending a final disposition decision. Treatment of the EBR-II used driver fuel was initiated in June 1996 while blanket fuel processing started in September 1998. These treatment processes continue on the balance of the used fuels."

Jan 1, 2011

By E. Ghali, J. F. Dorion

This paper presents the results of on-going investigations on the influence of corrosion on the performance of support systems in selected underground gold mines. Rock support is exposed to various conditions that can be aggressive. Samples of corroded support were analysed using SEM and photomicrography to determine the main corrosion forms. Tests are on-going in controlled corrosion chambers to qualify and quantify the impact of rock and minerals particles on steel corrosion. As more data become available these relationships can lead to useful information on the choice of support systems and reliable estimates of their longevity.

Jan 1, 2011

By Kenneth M. Maas

The U.S. Bureau of Mines began a five-year study of the 7.0 million acre Ketchikan Mining District during 1990. This study is part of the Bureau's ongoing statewide mining district evaluation program. The study area was subdivided and then prioritized by mineral potential into work units. Bureau field work in 1990 focused on the southern portion of Prince of Wales Island and vicinity. Extensive mineral resources have been mined historically in the area and are presently being evaluated by private industry. Information in this report is based on an extensive literature search and Bureau field work. Over 150 mines, prospects, and mineral occurrences were visited in 1990; an aggregate of 1,300 rock, placer, and limestone samples were taken; and nearly 3 miles of underground workings were mapped. Many prospects, some untouched for more than 80 years, were mapped and sampled. High metal values at several prospects were confirmed by Bureau sampling. Reconnaissance sampling along logging roads on Southern Prince of Wales Island revealed mineralized areas not previously recorded. Follow-up work at many locations is planned for the 1991 season.

Jan 1, 2011

By Mohammed Sakr

The use of helical piles as a deep foundation option has considerably increased in the recent years to support a variety of loads, from small loads for several applications such as residential housing, solar farms, utilities and retrofit projects, to large loads for many applications such as commercial, power transmission lines, oil facilities and industrial applications. Therefore, it is necessary to qualify and quantify their axial capacities and performance characteristics. This paper presents the first full-scale axial compression and tension (uplift) testing program executed on large capacity helical piles installed in cohesionless soils. A total of eleven pile load tests using either single or double-helix piles with shaft diameters that varied between 324 mm to 508 mm (12¾ in to 20 in) were carried out, including seven axial compression tests and four tension (uplift) tests. The results of the axial compressive and tensile pile load tests as well as field monitoring data of helical piles installed in dense sand are presented in this paper. Based on the results of this study it was found that helical piles have developed significant resistance to axial compressive loads up to about 2920 kN (656 kips) and tensile loads up to 2900 kN (652 kips).

Jan 1, 2011

By Neal Lee

Often the effects of wet boreholes are not taken into consideration when designing a blasting program to exhibit a certain amount of explosive energy per unit of rock such as design by powder factor, expressed in lbs./bcy (pounds explosives per bank cubic yard) or kg/bcm (kilograms per cubic meter), often the effects of wet holes are not considered. This paper examines different methods of loading wet holes and the effects they have on actual explosive quantities/unit of rock. In particular, we are looking at the amount of water trapped within the explosive column (bulk loading from the collar), or the annular space left void of explosives product around and between cartridges (wet-bags) with many of the current wet hole loading methods in use. We will focus on the effect this has on actual powder factor relative to “as designed” dry hole loading values, as well as the effect on performance of the explosives.

Jan 1, 2011

By Rodney Trevor Jones, Arthur Robert Barnes

Anglovaal Minerals acquired the Nkana slag dump from Zambia Consolidated Copper mines (ZCCM) in 1998 and embarked on an ambitious project to pioneer the recovery of cobalt from slag using DC smelting technology. Anglovaal Research Laboratories performed initial pioneering smelting tests in a 250 kW DC furnace over a 3-year period before engaging Mintek for three piloting campaigns at the 1.5 MW level. Mintek had previously developed a reductive smelting process, patented in 1995, using a DC arc furnace for the recovery of cobalt from slags. The results of the pilot-plant test campaigns were used as the basis for engineering the commercial 40 MW operation installed at Chambishi Metals plc in Zambia in 2001. This paper traces the development of understanding of the metallurgical fundamentals ultimately used to predict furnace performance, reviews some of the extreme technical challenges faced, how solutions were identified and highlights some of the critical issues identified during piloting and how these impacted both positively and negatively on the final commercial operation.

Jan 1, 2011

By Jingwei Lou, Bing Li, Suzhen Li, Miao Shen, Jianguo Yu

"As a main impurity in primary lithium metal, magnesium is difficult to remove because of the very close relative volatility of the two metals. Electrochemical refining provides a possibility to completely remove Mg in the LiCl-KCl melt prior to Li reduction. MgCl2 reduction processes in LiCl-KCl- MgCl2 melt were investigated by cyclic voltammetry (CV), square wave voltammetry (SWV), chronoamperometry and chronopotentiometry. Then potentiostatic electrolysis was carried out and Mg (II) ion was reduced onto a liquid lead cathode from the LiCl-KCl-MgCl2 melt at the Mg deposition potential. The results show that Mg ( II ) is reduced in one step with two-electron transfer. The reduction potential of Mg ( II ) was well defined. The reduction of Mg( II) results in Li ( I ) underpotential deposition at 0.2V more negative potential than that of Mg( II) reduction. Therefore, in order to prevent Li ( I ) from codeposition with Mg, accurately controlling Mg ( II) reduction potential during the potentiostatic electrolysis was necessary. Ninety three to 99 % removal rate of MgCl2 was achieved after 8-12 h electrolysis when liquid lead was used as cathode.IntroductionMetallic Li has been widely used in batteries, light weight alloys and in fusion reactors because of its excellent properties. Currently, the only way in industry to produce metallic Li is by electrowinning from molten LiCl-KCl at about 450 °C [l-5]. LiCl-KCl is the only electrolyte used, because they presents a lower eutectic temperature and KCl shows a slightly higher theoretical decomposition voltage than LiCl, as shown in Table l .The produced metallic Li generally contains 1-2 wt% impurities including Na, K, Al, Ca, Mg, Si, etc. [6l, which are derived from the corresponding metal chloride compounds or metal oxide compounds existing in the LiCl and/or KCl raw materials. These impurities have to be removed by subsequent vacuum distillation at high temperatures to meet the requirements for metal Li purity in the final products. Separation of Mg from Li by vacuum distillation is difficult because their relative volatilities are very close, as shown in Table 2."

Jan 1, 2011

By Xi-chang Shi, Yun-feng Fu, Bai-zhen Chen, Hui Xu, Xiang Xiao

"Extracting boric acid from saline brine by boron specific ion-exchange resin was investigated. Effects of resin amount, temperature, time and stirring speed on boron adsorption rate were studied in the experiments. The results indicated that the XSC-700 resin showed excellent boron absorbability and it performed better property for elution. The maximum boron adsorption capacity was 6.16 mg/ml in the optimum conditions: the resin concentration of 5 ml/(100 ml brine), the temperature of 60°C, the time of 5-6h and the stirring speed of 100 r/min. Boron was eluted from the resin with HCl and boric acid was crystallized by evaporating the eluate. The product of boric acid was in pure form as confirmed by XRD and other analysis techniques.1 IntroductionBoron has a number of minerals in nature such as tincal, colemanite, ulexite, and kemite, etc. [1-2]. Boron and its compounds are chemical materials of significant value. The principal industrial uses of boron compounds are in the production of glass, porcelain, enamels and detergents. Other uses include fertilizers, metallurgy, and nuclear shielding [3-4]. In recent years, because of the large-scale mining boron ore, ore resources are drained gradually. With the development of science and technology, the boron mineral resources will be unsatisfied with the future requirement. There exits abundant boron resources in salt lakes which cover about 40% of the total reserves in China. If we can obtain boron from salt lakes, it will produce great economic interests [5-6]. Therefore, actively seeking boron from salt lake and other resources in suitable conditions has become a hot spot in the research organizations of boron resources development and utilization in the world [7].There are many methods such as acid crystallization, solvent extraction and ion exchange processes suggested effective for boron extraction from aqueous solutions. Acid crystallization method has the shortcomings of complicated procedures, the pollution caused by hydrochloric and other ingredients returning to salt lakes during the extraction process. Although solvent extraction process increases the boron acid recovery efficiency, the cost of production is high [8-9]. However, Chelating resin extracting boron has the characteristics of simple process, easy operation and no pollution. It was reported that chelating resins containing functional groups show a high selectivity for boron extraction [10-12]. Therefore, ion exchange technique which is now the most practical application of significance and most extensively used ha"

Jan 1, 2011

By R. Patterson

Tracer gas sampling methods are useful for monitoring ventilation systems, especially in remote or inaccessible areas, and can be utilized for analysis of the ventilation system immediately following a mine emergency. However, the success of this technique is largely dependent on the accuracy of release and sampling methods. Analysis of sampling methods is crucial for rapid response and dependable results during emergencies. For the purpose of this study, four well-accepted sampling techniques currently used in the mining industry were compared using solid-phase microextraction (SPMe) fibers with sulfur hexafluoride (SF6), an industry standard, as the tracer gas. Current sample collection techniques include plastic syringes, glass syringes, Tedlar bags and vacutainers. SPMe fibers are used in a variety of industries, from forensics to environmental sampling, and are a solventless method of sampling analytes. To analyze these sampling methods, samples were taken from a 0.01 % standard mixture of SF6 and nitrogen and analyzed using electron capture gas chromatography. A relative standard error of less than 10% validated results to compare the accuracy of various methods. The technical and practical issues surrounding each sampling method were also observed and discussed.

Jan 1, 2011

By Michael W. Hinds

X-ray Fluorescence Spectrometry (XRF) is used at various stages of gold refining. Initially, incoming impure gold is analysed for deleterious elements such as As, Cd, Hg, Se, and Te. Based on the levels of these impurities the material can be returned to the client or accepted for refining. XRF is also used to determine the metal concentrations after the impure gold has been melted and sampled. This information is used to assist the final Fire Assay determination of gold and silver. An energy dispersive XRF is used to determine the end point of chlorination refining step.

Jan 1, 2011

By Donald Voit

"The reaction between zirconia/zircon, coke, and chlorine involves a slow reaction between the coke and the zirconia/zircon and a fast reaction with chlorine. Because of the fast chlorine reaction, the reaction rate for zirconia/zircon is nearly independent of chlorine concentration for most conditions. The reaction between zirconia/zircon and coke is particle size controlled and related to the degree of physical contact between the zirconia/zircon and the coke. Since particle-particle contact is critical, compaction of finely ground coke and zirconia/zircon produces the highest reaction rates. Uncompacted, coarse coke and zirconia/zircon has the slowest reaction behavior with static bed tests.SummaryZirconia reacts with chlorine in the presence of carbon to form zirconium tetrachloride, carbon monoxide, and carbon dioxide. A similar reaction occurs with zirconium silicate with the additional formation of silicon tetrachloride. The reaction rate depends primarily on temperature and the intimacy of contact between the zirconia and the coke. The reaction is multi-stepped with a slow reaction between coke and zirconia to form an intermediate that reacts rapidly with chlorine, causing the order of the reaction for chlorine to be near zero. Chlorination rates in the range of 1 µmole/hr/cm2 are seen for fluid bed reactors. Plug flow, and static bed reactors have reaction rates of the order of 1 mmole/hr/cm2, where the area is based on the zircon surface area in plug flow and fluid bed reactors and the boat cross sectional area in a static bed. Chlorination rates measured in zirconia/coke briquettes are higher with rates as high as 400 mmole/hr/cm2 reported. High chlorine diffusion resistance, not accounted for in the analysis of experimental results, has led to a lot of confusion in the literature interpretation of chlorination data.In general coke and zirconia/zircon particle size, coke and zirconia/zircon intimacy, coke to zirconia/zircon ratio, chlorine concentration, and temperature are important variables for chlorination. Decreasing the coke and zirconia/zircon particle size generally increase the reaction rate. The coke to zirconia/zircon ratio affects the reaction in a more complex way. Increasing the chlorine concentration generally increases the reaction rate, but the effect appears to be more related to the concentration dependency of diffusion than to its role in the kinetics. The reaction rate increases with temperature but the exact behavior is complicated by temperature effects on diffusion."

Jan 1, 2011

By R. Benito

This paper describes the development of a life of mine schedule (LOM) for one of the world?s largest known sedimentary Copper-Cobalt districts located in the Katanga Province, Democratic Republic of Congo (DRC). A particular feature of the Tenke Fungurume LOM schedule is the considerable number of pits/phases for scheduling, each competing to provide the best ore available to a capacity constrained process facility. This paper discusses the main scheduling objectives and constraints, data pre-processing as a scheduling aid, the mine scheduling approach, and results and conclusions.

Jan 1, 2011

By R. Padilla, M. C. Ruiz, R. Villa

"Bismuth is an impurity in copper minerals where it occurs mainly as the mineral bismuthinite (Bi2S3). In smelting of copper minerals, most of the bismuth reports to the white metal, as a result, a substantial amount of bismuth accompanies the copper to the electrorefined cathodes. Thus understanding the behavior of Bi2S3 at high temperatures is crucial to eliminate bismuth before electrorefining. In this paper, some experimental data on the decomposition/volatilization of bismuthinite in nitrogen- oxygen atmospheres is discussed. The results indicated that in nitrogen atmosphere, bismuth volatilization occurs through a fast decomposition of bismuthinite to metallic bismuth and sulfur with subsequent volatilization of bismuth in the range 850-1100 °C. Similarly, in the presence of oxygen, bismuthinite decomposes to bismuth too, followed by oxidation to the non-volatile bismuth trioxide at temperatures higher than 750 °C. Both, temperature and partial pressure of oxygen affect significantly the bismuth volatilization and the oxidation rates.IntroductionCopper sulfide minerals are the major source for the production of metallic copper by pyrometallurgical processes, which are the dominant processes in the production of copper by selectively oxidizing the sulfide sulfur to SO2 and the accompanying iron in the concentrates to iron oxide, which can be conveniently removed as a stable slag.Generally, copper concentrates contain some deleterious minor elements such as arsenic, antimony, bismuth and lead, which are present as sulfides. These elements depending on their concentration may originate problems in the copper smelting processes and they can ultimately lead to a final copper product with unacceptable high levels of impurities.During the treatment of these copper concentrates by smelting, the impurities generally distribute themselves in the condensed and gas phases and they are eliminated mainly through the gas phase [1-3]. Thus, smelter off gases contains substantial amounts of volatilized impurity elements. For example, in the case of bismuth, the estimated distribution of bismuth in flash furnace smelting [2] was 15 % in the matte, 5 % in the slag and 80 % in the gas phase, and recently, for Outokumpu flash smelting Davenport [3] reported the distribution of bismuth as 30-75% in matte, 5-30% in slag and 15 -65 % in the off gas."

Jan 1, 2011

By M. Hamarat

Freeport-McMoRan Copper & Gold (FCX) is committed to preserving and enhancing biodiversity in the areas in which we operate. As a member of the ICMM, FCX is committed to implement the 10 Sustainable Development (SD) Principles throughout our business. FCX is also a member of the Wildlife Habitat Council (WHC), a nonprofit coalition dedicated to protecting and enhancing wildl ife habitat. In alignment with ICMM SD Principle 7 and our Environmental Policy, FCX has set a performance goal to prepare a biodiversity inventory in 2010 and land management plan by end of 2011 for all active mining sites. In 2010 FCX established a Biodiversity Task Force to assist sites in biodiversity management; optimize use of resources around the globe; implement FCX goals and targets; and align biodiversity programs with ICMM principles and guidance. The task force consists of Environment and SD Department management, scientists and engineers from FCX sites, and WHC staff. The Task Force recently issued a biodiversity inventory guidance document to set expectations and provide consistency across the sites when developing a biodiversity inventory and land management plan.

Jan 1, 2011

By D. Q. Cang, G. Duan, H. X. Li, H. Bai

"Life cycle assessment (LCA) is a valid environmental evaluation method and enterprise environmental management tool used in industrial ecology areas. In this paper LCA was newly used to evaluate the environmental impact of manufacturing of alumina by Bayer process in china from two aspects of logistics and energy flow, GaBi software acted as analysis tools with evaluation model established, and several environmental impact assessment criteria were selected based on the actually typical date of Bayer alumina producing process. Evaluation results show that alumina manufacturing by the Bayer process has a great impact on the global warming and human health of respiration, even roasting process gives rise to the greatest impact of winter fog index. Scenario analysis proposed ways of reducing environmental load caused by Bayer process including: (1) the economic and efficient use of mineral processing technology; (2) optimization of energy use, saving power consumption or the use of new more economical source of energy; (3) actively promote the use of innovated technology and equipment in alumina manufacturing and waste such as red mud utilization process.1 IntroductionSince 2002, China is already the world's biggest producer of aluminium, in 2007, China aluminum production has accounted for above 1/3 all over the world, 2009 for 13 million tons and to the end of 2010, China aluminum production is expected increased to be over 15 million ton [1,2,3]. While as the raw material for producing aluminum the alumina production in china has up to 19.46 million tons of the world's total quarter in 2007, by the end of 2009 China alumina production has achieve to 23.78 million tons [4,5]. China has rich bauxite resources with proven reserves about 23 million tons, but the great majority of china bauxite is hard monohydrate diaspore type with low ratio of aluminium silicon, high impurity content and poor aluminum dissolution performance, that cause high energy consumption, long and complex process, high production costs and heavy environment load[6,7]. Before most used alumina production was sintering process rather than Bayer method in china, over the past decade Bayer method has been widely applied instead of sintering process or combination both forming joint process, premise is improving bauxite quality by mineral processing or adding imported rich bauxite mineral[6,8]. In general each ton production of alumina needs bauxite 1.6~2.20t, limestone 0.7~1.7t, soda 0.250kg, fresh water 12.30 cubic meters, in addition to consume large amounts of energy, and emission waste water over 8.0 cubic meters, dust 2.3~5.7 kg, red mud 0.8-1.5 tons. In china Red mud yield nearly 30.0 million tons every year, accumulated stock is approximately 0.2 billion tons, by 2015 accumulative total red mud is expected to reach 0.35 billion tons [9-13].We know aluminium industry and alumina production have produced large waste, make large energy consumption and its environmental impact could not be ignored. Expecting to optimize production processes and achieve resource recycling for this industrial process the proper environmental assessment is very necessary. Currently Life Cycle Assessment (LCA) is generally recognized as the approved tool to achieve the purpose. The essence of LCA tool is to examine, identify and evaluate a kind of materials, product, process, or a system of environmental impact in their whole life cycle. The life cycle of materials or products includes whole process from raw materials obtained to the final disposal, or more ideal with original or other forms of the whole process of recycling [14-17]."

Jan 1, 2011

By D. Sediako

Excessive residual stress in Al engine blocks may result in cylinder distortion which reduces engine operating efficiency. As such, neutron diffraction was used to measure residual strain along the Fe liners and Al, in the hoop, radial and axial orientations with respect to the cylinder axis, at the cylinder interbore region. Residual stresses were subsequently calculated using generalized Hooke's law and related to the microstructure along the cylinder bridge. The results suggest that the residual stresses in the Al interbore region are tensile and increased with depth in the axial direction of the cylinder. The increase in residual stress at the bottom of the cylinder coincides with a finer and more uniform microstructure in this region of the cylinder. The refinement in microstructure at the bottom of the cylinder likely increased alloy strength, thereby decreasing this section's susceptibility to distortion. This study successfully quantified the residual stress profiles in a heat treated engine block and related the stress profiles to an as-cast engine block.

Jan 1, 2011