Search Documents

By Sigmund J. Andersen, Eva A. Mørtsell, Jostein Røyset, Randi Holmestad, Oddvin Reiso, Yanjun Li, Øyvind Paulsen, Calin D. Marioara

"With the purpose of increasing the extrudability of lean alloys, we reduce levels of the alloying elements Mg and Si in a 6xxx extrusion alloy. To avoid sacrificing strength, we investigate the compensating effect of smaller amounts of lithium and germanium, alone and in combination. Recent studies by atomically resolved high angle annular dark-field scanning transmission electron microscopy (HAADF-STEM) together with density functional theory (DFT) calculations have demonstrated that while Li replaces Mg, Ge substitutes Si in the columns in the hardening ß’’-phase. Several studies have shown that Ge replaces Si in other precipitates as well, and that both Li and Ge promote precipitation and can improve macroscopic properties, like strength and thermal stability. The scope of the current work has been to investigate and document the combined effect of the two alloying elements. Of the investigated alloys, the one containing both elements displayed highest hardness, corresponding with a significant increase in precipitate number density. We used HAADF-STEM to determine the extent of Li and Ge in the precipitate structures.INTRODUCTION The two most important alloying agents, with respect to age hardening of the 6xxx alloy series, are Mg and Si. In general, 6xxx alloys are formed into their final shapes by rolling or extrusion, before being age-hardened at elevated temperatures around 180°C. The hardening effect during this stage is due to the formation of metastable, semi-coherent, precipitate needles along the three < 001>Al directions generally following the precipitation sequence (Marioara, Nordmark, Andersen, & Holmestad, 2006): Supersaturated solid solution ? atomic clusters ? Guinier-Preston-zones (pre-ß”) (Edwards, Stiller, Dunlop, & Couper, 1998) (Marioara, Andersen, Jansen, & Zandbergen, 2001) ? ß” (Andersen, et al., 1998) (Hasting, et al., 2009) ? ß’ (Vissers, Huis, Jansen, & H. W. Zandbergen, 2007), U1 (Andersen, Marioara, Vissers, Frøseth, & Zandbergen, 2007), U2 (Andersen, Marioara, Frøseth, Vissers, & Zandbergen, 2005), B’ (Vissers, Marioara, Andersen, & Holmestad, 2008) ? ß, Si (stable)"

Jan 1, 2018

By Nigel Saunders, Zhanli Guo

"Quench sensitivity of heat-treatable aluminium alloys is closely related to the precipitation process taking place during quenching. Faster cooling results in less precipitation of coarse phases during cooling, leaving more solutes in the solution before ageing. An alloy in such state would be of greater hardening potential as larger amounts of hardening phases may precipitate out during ageing. Hence, to understand the quench sensitivity of an alloy, it is essential to understand its precipitation process. Precipitation is a diffusion-controlled process and the diffusion is made complicated by the so-called quenched-in vacancies. These vacancies form during solution treatment, become “excess” when temperature goes down, and annihilate during the following cooling and ageing treatments, making diffusion now a function of both temperature and time. This paper first investigates the formation and annihilation of quenched-in vacancies and their effect on diffusion. The diffusion affected by quenched-in vacancies is considered in the kinetic models to realise the calculation of TTT/CCT diagrams for aluminium alloys. The calculated CCT diagrams have been used to explain the observed quench sensitivity and age hardening behaviour of various commercial alloys. The transformation from GP zones to other hardening phases during ageing is also discussed.INTRODUCTION The heat treatment of aluminium alloys mainly consists of three stages: a solution treatment at an elevated temperature, quenching from this solution treatment temperature to room temperature, followed by an ageing treatment to allow the precipitation of strengthening phases(Davis, 1993).The following statements generally describes how quench sensitivity is observed in heat-treatable Al-alloys: faster cooling results in,(i) less precipitation of coarse phases formed at high temperature during cooling, (ii) more solutes kept in solution before ageing, and (iii) larger amounts of hardening phases being formed, i.e. a greater hardening potential. Thus, the quench sensitivity of an alloy is closely related to its precipitation kinetics."

Jan 1, 2018

By H. Fujiwara, T. Ito, T. Mizuguchi, K. Kawasaki

"In this study, we characterize the high-temperature deformation of typical “Class I” solid solution Al-Mg alloys as a superplastic elongation attributable to the solute drag creep of dislocations. The second-phase particles formed by adding Fe or Si as impurity atoms to the Al-Mg alloys impeded the gliding motion of dislocations, thereby decreasing their hot ductility and resulting in cavity formation. High-temperature tensile tests were performed with initial strain rates in the range of 1×10–3 to 1×10–1 s–1 at air temperatures 673–723 K. The dominant high-temperature deformation mechanism in these alloys was the solute drag creep controlled by the interdiffusion of Mg in Al. In this study, the calculation of critical length, defined by the diffusion-based relaxation of the stress concentration region around second-phase particles, is reported using the Needleman–Rice parameter. An analysis of the impact of cavity formation based on a comparison of the Needleman–Rice parameter and second-phase particle size is also reported.INTRODUCTION Aluminum alloys with high specific strengths are utilized as structural materials for transportation machines to minimize their weight, which consequently maximizes fuel efficiency, environment preservation, and so on (Miller et al., 2000; Heinz et al., 2000; Starke & Staley, 1996; Polmear, 1996; Immarigeon et al., 1995; Burger, Gupta, Jeffrey, & Lloyd, 1995; Ye, 2003). Microstructure refinement by severe plastic deformation (SPD) has been performed on a laboratory scale to achieve a higher strength of crystalline materials (Valiev et al., 2006; Song, Ponge, Raabe, Speer, & Matlock, 2006; Beyerlein & Toth, 2009; Sabirov, Murashkin, & Valiev, 2013; Sauvage, Wilde, Divinski, Horita, & Valiev, 2012). At room temperature, grain refinement strengthens the material, as given by the Hall-Petch relationship (Hall, 1951; Petch, 1953); at higher temperatures, superplasticity can be expected (Sherby & Wadsworth, 1989; Edington, Melton, & Cutler, 1979; Furukawa, Horita, Nemoto, & Langdon, 2001; Langdon, 2006). However, the synthesis of large-size materials by SPD processes is not yet feasible."

Jan 1, 2018

By K. Negishi, H. Izui, Y. Komiya

"Aluminum has the disadvantage of low strength. In order to obtain the high strength composites, crystals were refined in the composites. Grain refinement was approached at two process points, generating new grains and grain growth. It is important for refinement how to control the grain growth. Spark plasma sintering (SPS) technique and TiB2powder addition prevent grain growth. To investigate effects of strain and additives to the alloy, aluminum powder was sintered at 70 MPa and 80 MPa, changing the content of TiB2additive powder by SPS method. As the results, the crystal grain size was finer in the composite sintered at higher sintering pressure and with larger amount of additive, though over 1.0mass% TiB2addition dissuades grain refining. These grain refinements improve hardness and tensile strength of sintered aluminum alloys.INTRODUCTIONAluminum matrix composites have low density, high specific strength, and low cost. Their applications are growing continuously in the field of automotive and aerospace industries. Recent studies to improve their good mechanical and tribological properties use different ceramic materials such as Al2O3(Das, Munroe, & Bandyopadhyay, 1996; Ashwatha & Anthony Xaviorb, 2014),SiC(Hassani, Bagherpour, & Qods, 2014), B4C(Ehsan, Masoud, Touradj, Amir Hossein, & Ali, 2015),TiC(Ehsan, Ali, Masoud, Kamyar, & Touradj, 2017), and TiB2(Fei & Zhong-Hua, 2013).On the other hand, grain refinement is also an important techniques for improving the properties of aluminum alloys. Finer grains improve the mechanical properties of the alloy. For cast and wrought alloys, addition of grain refiners in molten alloys accelerates generation of nucleus and suppresses grain growth. Al-Ti-B alloy is generally added as grain refiners in the molten aluminum alloys(Easton & Stjohn, 2001). Especially, TiB2has very high melting point, low density, and excellent hardness. Therefore, TiB2was selected as additions into aluminum alloys. Liquids reaction leads to high cost, oxidation, discoloration of molten alloy, and clustering of additive powder as compared with solid reaction such as sintering. However, sintering of aluminum alloy powder with ceramic powders is difficult for oxide layer surface. Recently, we take attention to spark plasma sintering (SPS) as advanced sintering process. SPS process can easily sinter a high quality specimen at a lower sintering temperature and in a shorter time than conventional sintering processes. By SPS process, we have sintered titanium powders that are as difficult to be sintered by any other processes as aluminum powders, and improved mechanical properties by adding hard ceramic powders TiC and TiB(Kamegawa, Izui, Komiya, Kobayashi, & Arimoto, 2015; Sampei, Izui, Komiya, Shigimura, & Suzuki, 2015). Furthermore, it is important to consider not only pure aluminum but alloys for solid-solution or precipitation strengthening. Actually, pure Al does not have enough strength compared with the alloys. Al-Cu alloy and Al-Mg alloy demonstrate adequate strength for industrial and commercial sectors. Al-Mg alloy retains good formability, and has high resistance to corrosion. It is therefore used for many applications. We must consider alloying processes. The most cost effective process is blended elemental technology where alloying elements are added to base powder as elemental or master alloy powder (Smugeresky & Dawson, 1981; Yasue, Radjai, Miwa, & Sakaguchi, 2003; Bolzoni, Esteban, Ruiz-Navas, & Gordo, 2012)."

Jan 1, 2018

By J. Starkey

A comminution circuit in recent history, is one of the most difficult parts of a mineral processing plant to design with confidence. It is usually the most costly part of a plant to build, and it can consume up to half or more of the energy used on a mine site. To suggest that comminution energy usage is sustainable in the long term is not possible at this time. What we have to choose from today, based on more than 50 years of experience, does include the best available technology, and the best way to design it. There is controversy in the industry as to how to properly approach the subject of comminution design, with many of the optional solutions requiring a level of training and expertise beyond the ability of a non-specialist engineer. Semi-autogenous grinding technology in particular, has not been properly appreciated because of many recent mistakes in its application and design, which have blurred the positive perception about what SAG technology is, how it can be used, and how it needs to be designed and built. In order to change this, mine owners and senior managers need to take responsibility for, and learn to understand the fundamental challenges that a comminution circuit poses to the project, to the design process, to the operators who use the equipment, and to the resulting metallurgy. This address is intended to summarize these challenges and offer fundamental engineering solutions, which are clear, specific and in a format which is directly applicable to the mining and mineral engineering community.

Jan 1, 2018

By S. Nakamura, K. Fujiwara, S. Hirosawa, S. Tsukamoto, Y. Koshino, Y. Aruga

"In this study, hardness test, differential scanning calorimetry(DSC)and transmission electron micros copy were carried out to investigate the age-hardening behavior of Al-Mg-Si alloy with a Mg+Si concentration of 1.5mass%, and a Mg/Si ratio of 1.0. Pre-aging treatment was conducted for the solution-treated and then water-quenched specimen at 100, 80, 60, 40, 20 (natural aging), 0 and -20°C for 20min or 5h, followed by artificial aging at 170°C for 20min. It was found that when pre-aging time is prolonged from 20min to 5h, the bake-hardening response is deteriorated irrespective of the pre-aging temperature. In particular, the specimens subjected to pre-aging at 20-40°C for 5 h hardly increased the hardness with the subsequent artificial aging. From the results of DSC measurement, it was suggested that as pre-aging temperature is lowered, the amount of solute clusters formed during pre-aging, i.e. Mg-Si clusters and Si-rich clusters, is decreased, but the ratio of Si-rich clusters is increased, resulting in the deteriorated bake-hardening response.INTRODUCTIONIn recent years, Al-Mg-Si alloys have been widely used forautomotive body panels due to their excellent characteristics such as high strength-to-weight ratio and good formability. Their strength is increased not only by artificial aging during paint-bake treatment; i.e. “bake-hardening”, but also when kept at room temperature(RT);i.e. “natural aging”, in association with the suppressed bake-hardening response. Such a “negative effect of two-step aging” has been a serious problem because Al-Mg-Si alloy coils are unavoidably maintained at RT in the manufacturing process of body panels; e.g. shipping and storage. However, it was reported that pre-aging above 70°C before the two-step aging can restore the bake-hardening response, and such an improvement is related to the formation of solute clusters(Sato, 2006; Abidet al., 2010; Takaki et al., 2014; Zandbergen et al., 2015). From the comprehensive analysis by three-dimensional atom probe (Aruga et al., 2014 and 2015), it is believed that Mg-Si clusters formed during pre-aging transform into the strengtheningß"" phase, whereas Si-rich clusters formed during pre-aging act as a detrimental precursor of ß""phase. In this study, it was aimed to investigate the effect of pre-aging conditions, especially pre-aging temperature and time, on the formation of solute clusters during pre-aging, in order to elucidate the mechanism of the age-hardening behavior of an Al-Mg-Si alloy."

Jan 1, 2018

By M. Rafieazad, P. Fathi, M. Mohammadi, A. M. Nasiri

This study examines the impact of low-temperature heat-treatment cycles on microstructure and corrosion performance of Direct Metal Laser Sintered (DMLS) AlSi10Mg_200C alloy. It is known that the morphology and the size of eutectic silicon are the two most critical factors affecting mechanical properties of the AlSi10Mg alloy. Although high-temperature heat-treatment cycles are common practice for the strengthening of the cast Al-Si-Mg alloys, in the case of DMLS fabricated AlSi10Mg alloy, high-temperature solutionizing and low temperature annealing cycles result in mechanical properties degradation primarily due to a dramatic decrease in the solubility of Si in the super-saturated a-Al matrix of the as-printed alloy. In this study, low-temperature heat-treatment cycles that only promote precipitation of Mg2Si accompanied by the interruption of the silicon network were investigated. SEM and XRD analysis were utilized to observe the evolution of microstructure after different annealing heat-treatments at 200, 250, 300, and 350°C for 3 h. Increasing the heat-treatment temperature contributed to the Si networks interruption and an increased precipitation of Mg2Si phase. Low-temperature annealing from 200 to 350°C was found to promote the homogeneity of the microstructure characterized by a uniform distribution of eutectic Si in ??-Al matrix. Additionally, in order to investigate the impact of different heat-treatment cycles on corrosion resistivity of DMLS-AlSi10Mg_200C, the potentiodynamic polarization testing and electrochemical impedance spectroscopy were performed in a 3.5 wt.% NaCl solution. The results revealed more uniformly distributed pitting attack on the corroded surface by further increase in the annealing temperature, which was attributed to the uniformity of Si dispersion. In comparison, low temperature annealing at 200°C led to a penetrating selective corrosion attack along the melt pool boundaries, resulting in a higher corrosion rate associated with the lower absolute value of impedance of the protective passive film on the surface.

Jan 1, 2018

By H. Fujihara, K. Uesugi, H. Toda, A. Takeuchi, K. Shimizu

"Hydrogen is trapped at a variety of microstructures, for example grain boundaries, dislocations and particles. It is thought that hydrogen trapped at trapping sites is redistributed to the other sites under loading and then brittle fracture occurs with hydrogen accumulation. In order to understand hydrogen embrittlement behavior, it is necessary to investigate the time evolution behavior of hydrogen accumulation at each trap site. In the present study, changes in hydrogen distribution are observed under stress using Kelvin force microscopy (KFM) that can visualize hydrogen concentration distribution on material surface at high resolution. Spot-like hydrogen enriched regions are observed on the surface of a material. In addition, hydrogen depleted regions are observed around those enriched regions, and the appearance of hydrogen trap due to particles existing near the material surface is revealed. On the other hand, hydrogen trapped at grain boundary can be visualized. From in this result, it was suggested that crystallographic factors influence hydrogen accumulation. The relationship between initiation and propagation of intergranular crack and hydrogen accumulation under stress will be discussed.INTRODUCTIONHydrogen present in a metal sometimes has significant effects on various properties. Hydrogen in a metal is trapped at a variety of microstructure, for example dislocations and grain boundaries. Grain boundaries, dislocations and micro pores are the major trap sites in aluminum alloys. Some researchers considered that hydrogen redistribution and accumulation between these trap sites in a material with loading plays an important role in the brittle fracture behavior. In general, in intergranular fracture and quasi-cleavage fracture, the hydrogen trapped at grain boundaries and dislocations contributes to fracture behavior, respectively. Recently some researchers have shown that the ductile fracture in aluminum alloys is resulted from growth and coalescence of hydrogen micro pores. Analysis using first principles calculation indicates that intergranular fracture occurs when hydrogen concentration reaches 20 atom H/nm2ongrain boundary. From this report, it is considered that hydrogen redistributed during deformation accumulates locally in order to cause hydrogen brittle fracture. In order to understand hydrogen embrittlement, it is necessary to investigate the time evolution behavior of hydrogen accumulation at each trap site. In the present study, we evaluate the relationship between hydrogen accumulation behavior and fracture behavior in Al-Zn-Mg based alloys. In-situ observation was made by combining the tensile test with Kelvin force microscope (KFM) that can visualize the hydrogen concentration distribution on the material surface with high resolution. We also investigate the relationship between hydrogen distribution behavior and crystal orientation."

Jan 1, 2018

By A. H. Mumin, A. Prikhodko

"This paper provides an understanding of interpreting and evaluating airborne time domain electromagnetic (TEM) surveys as applied to massive sulfide exploration. Variations in the conductive morphologies of massive sulfide ore systems are discussed, followed by forward modelling exercises examining the derived TEM response to these morphologies and discussion of the subtleties of data interpretation. Deposit morphology in the orientation at formation and the variations occurring due to later deformation are considered. Images of corresponding resistivity–depth models are provided. The combined modelling results provide a low-cost method for initial interpretation and screening of TEM anomalies. RÉSUMÉ Cet article nous permet de mieux comprendre l’interprétation et l’évaluation des levés élec-tromagnétiques aéroportés en domaine temporel (TDEM, de l’anglais time-domain electromagnetic) appliqués à l’exploration du sulfure massif. Y sont débattues les variations au niveau des morphologies conductrices des systèmes de minéralisation du sulfure massif, suivies d’exercices de modélisation prospective qui examinent la réponse dérivée des TDEM à ces morphologies et d’une discussion sur les subtilités de l’interprétation des données. L’étude envisage la morphologie de l’orientation originelle non déformée des gisements ainsi que les variations résultant d’une déformation ultérieure. Des images des modèles correspondants de résistivité-profondeur sont fournies. Les résultats combinés relatifs à la modélisation proposent une méthode peu onéreuse d’interprétation et de contrôle initiaux des anomalies dans les TDEM.INTRODUCTION Electromagnetic geophysical surveys are an indispensable foundation of many mineral exploration programs and can account for as much as half of the predrilling exploration costs. Quantitative mass interpretation of the survey results remains difficult due to the infinite variation of deposit morphologies, their complex physical properties, and the presence of barren conductive materials that can mimic or mask the response of targeted ore. Many modern geophysical investigations that focus on time domain electromagnetic (TEM) data interpretations are devoted to problems with inversion and modelling and their algorithms. Although a few of these investigations have resulted in commercial software products, these require highly qualified and experienced users and usually include geometric assumptions. Furthermore, without the input of known physical properties and geometric constraints, the inversion results are highly ambiguous. A number of case studies document the geophysical responses to known targets in well-defined and diverse geo-electrical environments, providing a high degree of correlation between field obser-vation and the results of the modelling used in this style of investigation (Hone, 1980; Schneider & Emerson, 1980; Tyne, Idnurm, & Malone, 1981; Bishop & Lewis, 1992; Hopgood & Hungerford, 1994; Meju, 2002; Yang & Oldenburg, 2016). The uniqueness of the target/environment parameters and their specific features limits the use logy is poorly understood. The responses are therefore that are devoid of complicating environmental factors (e.g., highly conductive overburden and hostrocks or nonuniform target conductivity) as a first approach to the interpretation process of such case studies as the main reference for interpreting TEM survey responses in areas where the underlying geomodelled from generalized and typical geological models"

Jan 1, 2018

By Lebeau M., P. Duguay

"The cost of occupational injuries and diseases in the mining industry in Quebec was estimated for the period of 2010 to 2012. The method used takes into account the financial and human costs assumed by employers, workers, and the community. To better direct research and prevention toward issues with the most significant consequences, the results are presented in various ranking tables, which stakeholders might find useful.RÉSUMÉ Le coût des accidents du travail et des maladies professionnelles dans l’industrie minière au Québec a été estimé pour la période 2010-2012. La méthode utilisée prend en compte les coûts financiers et humains endossés par les employeurs, les travailleurs et la communauté. Afin de mieux orienter les recherches et la prévention vers les problèmes ayant les plus graves conséquences, les résultats sont présentés dans divers tableaux de classement, qui seront d’une grande utilité aux parties prenantes. INTRODUCTIONThe mining industry is much safer today than it was 30 or 40 years ago, mainly due to a more qualified workforce, the use of automated equipment, and a corporate culture more focused on occupational health and safety (OHS); however, the number and the severity of occupational injuries and diseases continue to make this industry one of the most hazardous. In the province of Quebec, the mining industry accounts for approximately 0.4% of paid workers but is the source of 4% of fatal work accidents. It is, therefore, important to continue the prevention efforts already underway in the mining industry.The difficult global economy, which has affected the mining industry in the last few years, is an opportunity to reaffirm that sound management of OHS can have a positive impact on companies’ productivity and profitability. Occupational injuries and diseases are costly for the companies concerned and for society as a whole. Reducing their occurrence makes it possible to reduce not only the size of workers’ compensation board contributions but also several other financial and human costs."

Jan 1, 2018

By S. Y. Tshipeng, A. T. Kaniki

"RÉSUMÉ La lixiviation acide d’un minerai oxydé cupro-cobaltifère en milieu non réducteur et en milieu réducteur en utilisant le Fe2+ et le métabisulfite de sodium (SMBS) a été étudiée et les résultats ont été comparés. Les tests de lixiviation ont été effectués à température ambiante, dans une pulpe à 30 % solide, avec une vitesse d’agitation de 600 tr/min, un potentiel redox de 350 mV pour les tests en milieu réducteur, et un pH de 1,8. Les tests de lixiviation avec usage du SMBS comme réducteur ont donné la meilleure cinétique de lixiviation du cuivre. Pour le cobalt, c’est l’usage du Fe2+ qui a donné la meilleure cinétique de lixiviation. L’augmentation de la dose du fer dans la solution au-delà de 5 g/L a influencé négativement les rendements de lixiviation du cuivre et du cobalt. ABSTRACT Acid leaching of a copper-cobaltiferous oxide ore in a non-reducing environment and in a reducing environment using Fe2+ and sodium metabisulfite (SMBS) was studied and the results compa¬red. The leaching tests were performed at room temperature, in a 30% solids pulp, with a shaking speed of 600 rpm, a redox potential of 350 mV for the tests performed in the reducing environment, and a pH of 1.8. The leaching tests using the SMBS as a reducing agent produced the best copper leaching kinetics. As for cobalt, the best leaching kinetics was achieved using Fe2+. An increase in the amount of iron in the solution above 5 g/L negatively influenced copper and cobalt leaching yields. INTRODUCTION La République Démocratique du Congo (RDC) est un pays reconnu dans le monde pour son sous-sol qui regorge d’énormes quantités de cuivre et de cobalt (USGS, 2014; Palisade Research, 2016). La technique qui semble être la plus recommandée pour extraire à la fois le cuivre et le cobalt des minerais oxydés cupro-cobaltifères est la lixivia-tion acide en milieu réducteur. Cette technique est appliquée par la majorité des sociétés minières qui exploitent ces minerais dans l’ex-province du Katanga en RDC, à savoir: Tenke Fungurume Mining, Mutanda Mining, Kamoto Cop¬per Company, Sicomines, Gécamines, Boss Mining, Chemaf, Ruashi Mining et Somika. L’usage d’un agent réducteur est indispensable pour l’obtention d’un bon rendement de lixiviation du cobalt. En effet, plusieurs chercheurs s’accordent sur le fait que le cobalt trivalent de l’hétérogénite (CoO·2Co2O3·6H2O) est insoluble à l’action de l’acide seul; il ne devient soluble qu’après réduction en cobalt bivalent (Mwema, Mpoyo, & Kafumbila, 2002; Mulaba-Bafubiandi, Ndalamo, & Mamba, 2007; Ferron, 2008; Seo, Choi, Kim, & Tran, 2013; Stuurnam, Ndlovu, & Sibanda, 2014)."

Jan 1, 2018

By J. Fellowes, Z. Liang, J. Robson, M. Kenyon

"Dispersoids play a significant role in the recrystallization and texture development for wrought Al-Mg-Si (6xxx series) alloys by inhibiting grain boundary motion. It is therefore important to understand the precipitation kinetics of such particles. It is the additions of Mn and Cr in Al-Mg-Si based systems that can lead to dispersoid phases being formed. These phases are currently thought to nucleate on ß’-Mg2Si via an intermediate semi-coherent precipitate. Scanning transmission electron microscopy (STEM) has been conducted to study the precipitation of a-Al(CrFe)Si and a’-AlCrSi dispersoids. Corresponding electron dispersive spectroscopy (EDS) has been used to distinguish the dispersoids. The volume fraction and size distribution of dispersoids has been measured as a function of distance across a grain. Electron probe microanalysis (EPMA) has been conducted to study the inhomogeneity of elements in the cast structure and the effect on dispersoid precipitation. Dispersoid free regions have been observed in the microstructure correlating to regions depleted in the dispersoid forming elements.INTRODUCTION Al-Mg-Si (6xxx series) based alloys are increasingly being used in the automotive industry. The primary reason is to reduce the weight of vehicles, resulting in a reduction of CO2 emissions and increased fuel efficiency. The demand for 6xxx series is predicted to increase over the coming decade. Due to the high cost and CO2 emissions produced by raw extraction of aluminium, close loop recycling of these alloys becomes a more important process. However recycling of automotive alloys can be difficult due to pick up of impurity elements such as Mn, Cr and Fe. The addition of these elements can form dispersoid particles during early heat treatment processes. Although a controlled population of dispersoids is necessary to control the grain structure during thermo-mechanical processing, a significant change to the dispersoid population due to a composition change could profoundly influence the final microstructure, affecting the final properties of the material. More research is required on the precipitation and effect of additional minor alloying elements; in order to increase the 6xxx series alloys recyclability."

Jan 1, 2018

By T. P. Weldum, W. Conger

"These studies address the relationship between mill media sizing and its grinding efficiency. Starting with the results from a review of the literature, the issues of initial media sizing for a new ball milling circuit, and then optimal media sizing for an existing milling operation, were studied. The Functional Performance parameters “Mill Grinding Efficiency” and cumulative “Mill Grinding Rates” from both plant and test-scale equipment were used, and provide valuable new insight into this topic. A plant media sizing diagnostic tool is presented, as are newly developed testing equipment and evaluation methods, and recent case studies.REVIEW OF MEDIA SIZING LITERATURE For a plant metallurgist to answer the question “How can I maximize plant profit by manipulating this grinding circuit variable?” she must know what effect the variable has on grinding circuit efficiency. Despite the significant cost of grinding media and its potential effect on production capacity, the ‘best’ media sizing remains ill-defined for any given ball mill circuit in the industry today. The underlying reasons for this will be discussed. But the importance of this issue drove Metcom and its industrial partners to take on the challenge of how to engineer the ball charge for an existing grinding circuit. In the absence of any proven method, the first step was a review of the literature. Sponsored by Cleveland-Cliffs, Inc., a broad review of the literature was undertaken, producing “The Effect of Media Sizing on Ball Milling Efficiency” (McIvor, 1997). Among hundreds of publications that were reviewed that discuss the topics of media sizing or wear, forty-five were studied in detail. These were grouped into: plant experiences; laboratory and pilot plant investigations; media wear studies; population balance modeling studies; and general papers on ball milling which included the topic of media sizing. The reader is encouraged to refer to that review. The findings remain unchanged, although some relevant papers have been written since (e.g. Staples et al, 1997; Banasi et al, 1999; Orford et al, 2006; LaMarsh, 2015). The main findings of the review were as follows:"

Jan 1, 2018

By F. Chachula, A. Molinaro

"Sulphide mineral flotation operations continuously strive for a balance between mineralogy, mineral liberation, circuit conditions and reagent solutions to maximize the production rate and recovery of payable metals. The Taseko Gibraltar copper – molybdenum mill operations underwent an extensive project focusing on the fundamentals to identify the effects of process conditions and mineral liberation to improve the bulk circuit copper – molybdenum recovery efficiencies in the bulk flotation circuits. This discussion will provide process data that demonstrates; 1) fundamental relationship between mineral liberation to recovery and grade, 2) flotation circuit condition testing and optimization, 3) reagent combinations resulting in efficient/economical mineral recovery, and 4) the development of a xanthate free reagent solution. The data presented and discussed will also touch on flotation parameters including pH, retention time, kinetics and the effect on bulk circuit recovery performance.INTRODUCTION Taseko's is the owner (75%) and operator of the Gibraltar copper-molybdenum mine, located in south-central British Columbia, the second largest open pit copper mine in Canada and the largest employer in the Cariboo region. Taseko restarted Gibraltar in 2004. From 2006 until 2012, the company invested ~$700 million to expand and modernize the operation which was originally scheduled for demolition when the company acquired it in 1999. In the spring of 2011, construction commenced for Gibraltar Development Plan 3 (GDP3). GDP3 included the construction of a standalone 30,000 ton per day concentrator, built adjacent to the existing 55,000 ton per day facility. The new design capacity of Gibraltar was designed to be 85,000 tons per day. An integral part of the project was a new molybdenum recovery facility. In addition to the new concentrator, the mining fleet was upgraded with a new mining shovel, production drill and ten haul trucks (Taseko, May 2015). In May of 2015, the Company completed an updated mine plan for Gibraltar featuring a 50% decrease in strip ratio. This new mine plan was a result of a detailed, six-month engineering study and forms the basis of an updated NI 43-101 compliant reserve (Taseko Announces Improved Economics At Its Gibraltar Copper Mine, 2015). The new mine plan took into account lower milling costs as a result of the modernized processing facilities (Taseko, May 2015)."

Jan 1, 2018

By Z. Zhang, M. -Y. Liu, X. -G. Chen, F. Breton

"The microstructures of AlSi10Mg foundry alloy in permanent mould (PM) and high pressure vacuum die (HPVD) castings were analyzed and compared. The as-cast microstructures of two castings mainly consisted of eutectic silicon particles, primary Mg2Si and Fe-rich intermetallic phases. The surface layer in HPVD castings, which has a unique feature and different structures, was carefully characterized. The dimension variation of microstructural phases along the cross section in PM samples is less than that in HPVD samples, although the size of microstructural phases in PM samples was much larger than that in HPVD samples. The mechanical properties of PM and HPVD samples were evaluated on as-cast and T6-treated conditions. The tensile properties of HPVD castings are remarkable better than those of PM castings on the as-cast condition. The T6 heat treatment greatly improves the tensile strength of PM castings while it has limited impact on the tensile strength of HPVD castings.INTRODUCTION The AlSi10Mg alloys are widely applied to the high pressure die casting (HPD) and high pressure vacuum die casting (HPVD). In the HPD process, the melt is injected into the die cavity under a high speed (30–50 m/s in the gate velocity for aluminum alloys), and solidified under a high pressure (up to 200 MPa in the cavity) and with a high cooling rate (up to ~103 Ks–1) (Gourlay, Laukli & Dahle, 2007; Ji, Wang, Watson & Fan, 2013). This results in a unique microstructure feature that is different to other casting processes under gravity. One major concern in HPD castings is porosity due to trapped air in the cavity (Ji et al., 2013), which seriously restricts the application of a heat treatment on the improvement of mechanical prosperities because of the formation of blisters on casting surfaces. For the process improvement, the high pressure vacuum die casting was developed in 1980s (Uchida, 2009). In this process, the melt is injected into the die cavity under reduced pressure (vacuum), which greatly reduces gas porosity in castings due to effectively avoiding the trapped air. Consequently, HPVD castings are heat-treatable without the formation of blisters on castings surface during heat treatment. The HPVD process has been widely applied to produce high quality structural castings in recent years attributed to reliable vacuum system development (Uchida, 2009). However, the microstructure features of HPVD castings are not systemically characterized yet."

Jan 1, 2018

By M. Dadvand, G. Kipuros, A. Dadvand

"The ability to codeposit fillers within a nickel matrix has led to the production of a new generation of cermet coatings with properties useful for various applications. Hexagonal boron nitride (hBN) is a ceramic-type particulate matter with thermal conductivity, thermal stability, inertness, and lubricity properties that allow it to be codeposited. In this paper, a method was developed for modifying hBN surfaces to allow them to be uniformly dispersed in water-based solutions such as an electroless nickel plating bath. hBN surface modification improved wear performance of the electroless plated cermet due to enhanced interaction between the particulate and nickel matrix. RÉSUMÉ La capacité à effectuer un dépôt simultané de charges dans une matrice nickel a abouti à la production d’une nouvelle génération de revêtements cermet (une combinaison de céramique et de métal) dotés de propriétés très utiles pour diverses applications. Le nitrure de bore hexagonal (h-BN) est une matière particulaire de type céramique utilisée pour ses excellentes conductivité et stabilité thermiques, son inertie ainsi que son caractère lubrifiant, qui permettent son dépôt simultané. Cet article explore une méthode mise au point pour modifier les surfaces du h-BN de manière à ce qu’elles se répandent uniformément dans des solutions aqueuses telles qu’un bain de dépôt autocatalytique de nickel. La modification des surfaces du h-BN a amélioré la résistance à l’usure du placage autocatalytique du cermet en raison d’une interaction accrue entre la matière particulaire et la matrice nickel.INTRODUCTION Electroless nickel alloy coatings can be used for many applications; however, the need for improved tribological properties such as higher wear resistance and better lubricity has increased interest in incorporating particulates (fillers) into the nickel matrix by codepositing the particulates with nickel during the plating process. The selection of the particulate type depends on the desired properties (Sahoo & Das, 2011; Sudagar, Lian, & Sha, 2013). In terms of tribological applications, electroless nickel-based composites are categorized mainly into lubricating and wear-resistant composite coatings depending on the type of particles incorporated. The electroless nickel-phosphorus (Ni-P) composite coatings are composed of codeposited solid lubricants such as polytetrafluoroethylene (PTFE), graphite, WS2, MoS2, and hexagonal boron nitride (hBN) and, compared to nanocomposite electroless Ni-P coatings, they demonstrate a lower coefficient of friction. On the other hand, the nickel-phosphorus wear-resistant composite coatings are composed of hard particles such as silicon carbide (SiC), aluminum oxide (Al2O3), boron carbide (B4C), silicon nitride (Si3N4), diamond, tungsten carbide (WC), and zirconium oxide (ZrO2) and, compared to nanocomposite electroless Ni-P coatings, they have higher hardness and better wear resistance (Sahoo & Das, 2011; Sudagar et al., 2013; Parucker, Klein, Binder, Ristow, & Binder, 2014; Chakarova, Georgieva, Petrova, Dobreva, & Stoychev, 2016)."

Jan 1, 2018

By D. L. Koch, J. W. Tester, L. K. Sinclair

"In this study, hydraulic conductivity (K) geostatistics were used to predict residence time distribution of well-to-well flow. Flow profiles, fracture density measurements, and pumping tests were available from the highly fractured Florence Copper in situ leaching site. The flow profiles were used to establish the statistical distribution and spatial autocorrelation of K. Two tests were used for validation. The first test confirmed that fracture density and K are autocorrelated over similar length scales. In the second test, Monte Carlo flow simulations successfully recreated the results of pumping tests. Flow sim¬ulations were used to stochastically model well-to-well residence time distribution. RÉSUMÉ Dans cette étude, nous utilisons la géostatistique de la conductivité hydraulique (K) pour prévoir la distribution des temps de séjour (DTS) de l’écoulement entre les puits. Des profils de l’écoulement, des mesures de la densité des fractures et des essais de pompage existaient pour le site fortement fracturé de lixiviation in situ de Florence Copper. Les profils de l’écoulement ont permis d’établir la distribution statistique et l’autocorrélation spatiale de K. Deux essais ont servi à la validation ; le premier a confirmé que la densité des fractures et K sont autocorrélés sur des échelles de longueur similaires ; quant au second, des simulations d’écoulements de type Monte Carlo sont parvenues à reproduire les résultats des essais de pompage. Les simulations d’écoulement ont servi à établir un modèle stochastique de la DTS de l’écoulement entre les puits.INTRODUCTION In situ leaching is the circulation of a dilute acid or base solution in the subsurface, via a series of injection and recovery wells, to dissolve a target metal. In situ leach modelling requires forecasting the residence time distribution (RTD) of flow between wells. In fractured formations such as copper porphyry deposits, order-of-magnitude variations in hydraulic conductivity (K) can result in highly channeled flow, resulting in a heavy tailed RTD (Becker & Shapiro, 2003; Kang, Le Borgne, Dentz, Bour, & Juanes, 2015). Channeling through preferential pathways has impacted copper recovery at several past in situ leaching field tests (Cathles, Glenn, Lenzi, Nigrini, Deans, & Huff, 1978; Ahlness & Pojar, 1983; Schmidt, Earley, & Friedel, 1994; Sinclair & Thompson, 2015). The aim of this work is to combine multiple types of hydrogeological measurements to stochastically forecast the well-to-well RTD in fractured rock for the purposes of copper in situ leach modelling."

Jan 1, 2018

By M. Myllymäki

"Pre-treatment of mill feed in a minerals processing plant enables for higher production efficiency per ton of product, reduction of consumables and diverting mineral feed types. Sensor based particle sorting allows for pre-concentration of the run-of-mine (ROM) material prior to other concentrating process. Various sensors provide different responses from the minerals in measured particles. The capability of “accepting” or “rejecting” particles based on sensor responses is investigated in specific test work for each project. Modern sorting machines use pneumatic actuators to divert the reject particles from the material stream. This paper discusses the incorporation of ore sorting test work in processing and plant design. When taking the effects of a sorting circuit into account early in the process planning phase, the downstream process can be adequately sized and impacts evaluated. Potential benefits include but are not limited to increased head grade, lower tonnage to the mill, increased mining operations, removal of deleterious elements and changed properties in the process feed. In a case study we present the Keliber lithium project in central Finland. The plant will produce 9000 tons of lithium carbonate per year from a spodumene ore. Ore sorting and flotation tests were carried out in laboratory and pilot scale. Process models were designed and simulations performed using Outotec’s HSC Chemistry Simulation software. Changes in the flotation performance (grade, recovery, impurity levels) were simulated with and without the pre-concentration of the ROM material. The metallurgical performance and mine economics of the different operational scenarios were evaluated using the Ore-Met optimizer module of the simulation software.INTRODUCTION Challenges in the recent years such as declining ore grades, increasing energy prices, scarcity of water and increasing environmental regulations raise the demand for more efficient processing technologies. Sensor based sorting offers a method for pre-concentration or waste rejection at an early process stage. The technology analyzes each rock particle separately for their unique physical and chemical properties, and diverts the particles into separate material streams by high pressure air jets. Successful implementation relies on ore heterogeneity, differential sensor response and suitable feed preparation."

Jan 1, 2018

By M. F. Gallerneault, V. Fallah, A. Howells, W. M. T. Gallerneault

"The occurrence of recrystallization in cold-worked aluminum sheet during the brazing process leads to loss of strength, an inhomogeneous grain structure and reduced corrosion resistance. AlMgScZr alloys are known for their extraordinary recrystallization resistance due to the influence of Sc and Zr addition on their microstructure. Here, we investigate the effect of alloy composition (i.e. Mn, Mg, Sc, Zr content), cold-roll reduction and pre-aging treatment on the recrystallization behavior of cold-rolled sheets at brazing temperatures typically used during the manufacture of heat exchanger units. The analysis of recrystallization behavior is carried out through microstructural characterization and the results are compared with the behavior of a commercial, AA3xxx-based heat exchanger alloy.INTRODUCTION Control of recrystallization is of critical importance during brazing, which is a widely-used joining technique for aluminum alloys in aircraft structures (Heinz, 2000) and automotive heat exchangers (Miller, 2000; Marshall, 1993). Due to excessive local heat at brazing temperatures, the cold work texture of aluminum alloys in the cold-rolled sheets may undergo a local recrystallization process (Marshall, 1993). This leads to the formation of an inhomogeneous microstructure and thus anisotropic mechanical properties (Miller, 2000) and low corrosion resistance (Marshall, 1993) across the sheet. X800, a commonly-used Al-Mn alloy series for automotive heat exchangers applications, has been developed specifically for a higher strength as well as an enhanced corrosion resistance as opposed to the traditionally-used AA3003 alloy (Marshall, 1993). X800 alloys, however, exhibit a low recrystallization resistance at normal brazing temperatures, i.e. 590°C. In contrast, Al-Sc-Zr alloys have been shown to exhibit an extraordinary recrystallization resistance at such temperatures (Riddle, 2004) while also being corrosion resistant and possessing a high room-temperature strength (Fuller, 2002). This has been shown to be due to the formation of coherent, nanoscale Al3(ScZr) precipitates that effectively impede grain boundaries while also exhibiting very slow coarsening kinetics at high temperatures (Riddle, 2004; Jones, 2003; Ocenasek, 2001). In this study, we analyze the recrystallization behavior of X800 alloys under brazing conditions through introducing Sc and Zr into the system as well as varying the Mn and Mg content. The effect of processing route is also studied by introducing a pre-aging stabilization treatment as well as varying the cold-roll reduction prior to the final brazing anneal."

Jan 1, 2018

By J. L. Nebreda, Z. Fan, J. B. Patel

"A380 alloy has been widely employed to produce thin-wall components via high pressure die casting (HPDC). During HPDC processing, there is a significant problem of property variation even with the very stable and precision automated casting procedure. The enlarged variation lowers the component performance and affects the steady and uniform property distribution along the whole component. In this study, high shear melt conditioning technology was developed and applied to the melt prior to pouring into the shot sleeve. Experimental results show that with application of intensive melt shearing, the variation of elongation was decreased from 21.8to 13.9%, and yield strength variation was reduced from5.5to 3.6%. The improved property variation is attributed to enhanced nucleation both in shot sleeve and the die-cavity, and to the improved distribution of porosity and secondary phases as a benefit of high shear induced grain refinement. With application of high shear, large number of the Spinel phase (MgAl2O4) particles with double size distribution in average diameter of 80and 300nm were formed. Due to the good orientation relationship and small misfit between alpha Al and MgAl2O4, the particles act as the effective nuclei in shot sleeve and die cavity, respectively.INTRODUCTIONA380 alloy had been widely used for produce automotive components by cold chamber high pressure die casting(HPDC) processing, due to its relative good mechanical properties and cast ability performance, and more important most of A380 ingots were produced by recycled Al alloys. Therefore, to promote utility of A380 will contribute to reducing emission of CO2and to the lightweight of automotive industry as well. When cold chamber HPDC was employed to produce the components, the mechanical properties of A380 alloy always have a distribution range (named variation herein), or in other words the properties were not stable. The reason was ascribed to the typical solidification characteristics occurred in HPDC processing. During HPDC processing, there are three steps of melt movement. The first step is that the melt was poured into shot sleeve at temperature of about 680°C, in which shot sleeve was preheated by few shots of melt filling, or by heater. During step one, the first solidification of melt was happened in shot sleeve and about 20% solid made of coarse a-Al grains was formed(Li, Xiong, & Guo, 2016).Such kind of grains will retain in the final products and deteriorate the properties variation. The second step is that the melt was forced moving forward slowly by plunger at about 0.2–0.3m/s until the liquid melt front to the inner gate of mold. The third step is that the melt moved very fast to complete the filling of die cavity and refilling the solidification shrinkage by fast movement of plunger about 2–3m/s. The second solidification was occurred in die cavity and fine a-Al grains will be formed by high cooling rate at about 500–1000°C/s. From the solidification point of view, the grain size was dominated by nucleation and growth. When HPDC was employed to produce components, the melt quality becomes the priority factor to control the solidification process as the other casting parameters were kept at the same."

Jan 1, 2018