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By D. R. Bomberger, M. Deul

An automatic microscope has been developed to measure the size and populations of macerals and minerals in fine coal particles. Differentiations are made on the basis of reflectance. This study is concerned with the size distribution of pyrite inclusions. Most fine coal cleaning processes do not remove pyrite as completely as a straight density separation. Consideration of the pyrite size distribution is suggested as a more accurate method of predicting sulfur reduction by a cleaning process. Analyses of float-sink results and Deister Table operation in terms of pyrite particle sizes are made. Other potential applications of automatic microscopy are also discussed. In the study of coal cleaning by pseudo-gravity methods (tables, cyclones, hydrotators, etc.), it is customary to express the deficiency of the process relative to float-sink measurements in some form of "percent efficiency". These have been calculated in many different ways in order to provide a means of extrapolation of test data to untested coal feeds. This works quite well with coarse coal (here defined as larger than one-eighth in.). Large, heavy pieces of refuse are rejected rather thoroughly by many cleaning processes, and the efficiencies relative to float-sink results approach 100%. In coarse coals, the difference in the sizes of fine pyrite is masked by the averaging effect of the large coal envelopes. The existence and fate of fine pyrite is often hidden in the larger numbers representing coarse (and easily removed) pyrite. There are cases where it is desirable to subject fine coal (here defined as smaller than one-eighth in.) to cleaning processes. This is true of naturally occurring fie coal streams and in cases where comminution followed by cleaning is necessary to provide the quality desired. It is in this area that the use of process efficiency relative to float sink fails. Percent efficiencies decline to very low figures, and equivalent separation densities become a matter for conjecture. The net result is that an attempt to estimate product quality from float-sink data and a process efficiency figure often results in large errors. This work represents a new approach to the problem by observing the fate of pyrite particles, grouped by sizes, in a cleaning process. Examples are given which relate pyrite size measurements to float-sink washability and to a Deister Table operation. EXPERIMENTAL WORK The automatic microscope used here has been previously described.' Briefly, it is an instrument which measures the diam of particles (as defined by a range of reflectance) exposed on a polished specimen. The instrument scans a sample briquet, measures diam of exposed pyrite inclusions and records the data by size intervals. Preparation of the briquet is critical, due to the automatic nature of the process. The principal requirement is for an optically flat surface, so that focus will be maintained as the motorized stage moves the specimen under the lens. The various substances present must be polished to the same level in spite of the wide difference in hardness between coal substance and minerals. The polishing method must not pluck out small grains, which might be rather loosely held by surrounding coal. The procedure below was successful in producing all of these results. The coal sample (8 mesh or finer) was riffled (a micro vibrating riffle is essential) to obtain 15 g. One volume of Lucite powder (thermosetting plastic mounting medium) was mixed with three volumes of coal and mixed thoroughly. A briquet was formed using a cylindrical die (1 1/4 in. diam) at 3000 lb per in.* pressure and 150°C. Preparation of the optical surface was accomplished on automatic polishing equipment, according to the following schedule: 1) Grinding: 3 stages, using successively fine Carborundum grits of 180, 320 and 600 mesh. 2) Rough polishing: 2 stages, using 3µ alumina on cast iron, followed by 1µ alumina on lead. 3) Fine polishing: 2 stages, using 0.5µ alumina on napless broadcloth over bronze, followed by 0.1µ alumina on silk filament cloth over bronze. Raw data were corrected for the fact that the chords

Jan 1, 1964

By John Garcia

IN some districts of the bituminous coal field the problem of construct-ing bulkheads to seal off water under pressure is becoming increasingly important. Recently this matter has been brought very much to the front by the loss of a large Illinois mine due to failure of a bulkhead that separated it from several old, flooded mines. As this great misfortune has provoked much inquiry about proper bulkhead design, it-is felt that a description, of the successful and extensive water-sealing practice at three mines that have different natural conditions will be of considerable interest to those connected with properties having a present or future water problem and to engineers that may have to design safe bulkheads of economical construction. These three mines are the Saxton and Dresser, near Terre Haute, Ind., and the Hegeler, near Danville, Ill. All three have water conditions that make it necessary to regularly seal off all worked-out sections of the mine, and there are considerably over a hundred bulkheads in each. As far as the writers know, these three mines are the only ones in the bitu-minous coal fields of the United States with anything like so large number of water seals and experience, although a number of other mines are known to have a few bulkheads. More detail will be included herein on the Saxton mine than on the others, as the writers are more familiar with it.

Jan 1, 1937

By AIME AIME

IN an address before the New York Section. A.I.M.E., Oct. 20, Alex L. ter Braake, speaking on the tin industry of the Netherlands East Indies, interjected a few remarks, at the chairman's request. on the mineral stock-piling project now before Congress in a bill sponsored by Senator Scrugham. The full text of Mr. ter Braake's paper was published in the Nov. 6 issue of the American Metal Market. Following mention of the buffer stock scheme as applied in the tin industry, Mr. ter Braake continued:

Jan 1, 1943

By W. A. Wood, H. M. Bendler

Cylindrical fatigue specimens of OFHC* copper were subjected to alternating torsion while under axial tension. The superimposed tension strongly influenced the fatigue life of the specimens as well as causing characteristic changes in the structure of the fissures that form and develop throughout the life of the specimen. A further effect of the superimposed tension is a continuous extension of the specimen throughout its life in a manner formally similar to creep at elevated temperatures. RECENTLY, studies of the structural changes leading to fracture of metals by fatigue have been made by a technique which reveals, in section, the lattice distortion arising from slip movements inside the metal and the disturbances built up by these slip movements at the metal surface.1'2 According to this approach, fatigue develops as follows: a) fine slip movements concentrate in bands, producing little strain-hardening and thus permitting abnormal totals of plastic strain before fracture and, therefore, abnormal amounts of lattice distortion along each slip band; b) both forward and backward slip movements occur in each band which, according to their distribution across the band, may build up surface disturbances that include sharp notches; c) these notches early in the life of a specimen penetrate the distorted slip zones and transform them into deep, fine fissures; d) the fissures on continued cycling locally saturate the metal and cause local collapse in the form of a microcrack. Thus, the significant consequence of fatigue or cyclic

Jan 1, 1962

Mounting pressures to increase efficiency and yield, conserve energy, or minimize pollution have all taken their toll on the minerals industry. As management and technical personnel take a harder look at their operations for ways to shave cents off operating costs or to squeeze a bit more productivity out of existing equipment, instrumentation often comes up as the most effective answer. When Amax Lead installed an automatic grind control system in its Buick mill, ore throughput increased by 3 to 5%. Mill operators calculate that the initial investment is returned to them several times annually.

Jan 2, 1978

By W. Shockley

THIS lecture can best begin with a statement of the chief conclusion: The metallurgical industry will find profit in supporting fundamental research on dislocations. This support should be done both in their own laboratories and in universities. My lecture consists of an exposition of the basis for this conclusion. The experience on which I base it is drawn largely from two fields in solid state physics—one field is transistor electronics and the other is dislocation theory. At present the relationship of solid state physics to technology is different in these two fields. In electronics without question, the physics has led the technology. In metallurgy, on the other hand, the technology in the form of metallurgical art is far ahead of the fundamental science. In transistor electronics, physics has suggested and can still suggest previously unachieved combinations of matter that will have new and useful properties; that is, the physicist can make specific predictions. The physicist can also have some confidence that the predicted devices will actually come into existence in a matter of months or years and that they will live up to the predictions. In metallurgy, the physicist cannot to a comparable degree make predictions and have the same hope that they will lead to something new and valuable. There are a number of reasons for this difference. The first is simply historical. Transistor physics is young. It may be regarded as dating from the announcement of the transistor, in which case it is about four years old, or from the first real control of semiconductors as materials (this was accomplished largely by metallurgists, by the way) in which case it is about ten years old. Metallurgical art, on the other hand, is thousands of years old. There is no doubt that the advance of this art has been and will be hastened by a good fundamental understanding of the quantum theory of atomic phenomena. It, is too much to expect, however, that theory will soon catch up with the lead that practice has gained in a thousand years, and that theory will then point out specific pathways to better materials. It seems more probable that modern atomic theory will serve to interpret and organize information much as thermodynamics has done through phase diagrams. In this lecture, I shall emphasize an important feature common to both solid state electronics and to metallurgy. This common feature is the harmonizing principle that justifies discussing electronics and metallurgy as related topics in solid state physics. In both cases the important properties of the materials arise from imperfections. By imper- fections I mean deviations of the materials from perfect single crystals. The imperfections may be of many forms. From the point of view of utility they may be either good or bad, and a given type may be good or bad depending on circumstances. The technical material of my lecture will be divided into two parts. The first will be chiefly concerned with four types of imperfections in germanium crystals. The control of these imperfections makes possible the fabrication of useful electronic devices. A good example of such control is the junction transistor, which I shall discuss from this viewpoint later. The junction transistor, as some of you may have heard, can be used as an amplifier of electrical signals and in a number of respects surpasses what has hitherto been achieved with vacuum tubes. The second part of my technical material will be concerned with dislocations. For about fifteen years the theoretical physicist has had dislocations in mind as the most important kind of imperfection in metals. He has, however, until recently had experimental material of a highly speculative nature to back up his assertions. I am fortunate in the timing of this lecture to be able to describe some recent results that put dislocations on a far more definite basis than has been the case in the past. In fact there are now some experiments which reveal the characteristic properties of dislocations almost as clearly as experiments in transistor physics reveal the properties of holes and electrons, properties that I shall soon describe. It is this advance in the status of dislocations that emboldened me to make my initial assertion that the metallurgical industry will profit from supporting fundamental research on dislocations. Transistor Electronics In order to discuss imperfections in semiconductors, it is necessary to visualize a reference condition that may be regarded as perfect. In the cases of silicon and germanium, which find application in transistor electronics,' the perfect structure is the diamond structure shown in Fig. I. In this structure, each atom is surrounded by four neighbors with which it forms four covalent or electron-pair bonds. These bonds use all of the four valence electrons possessed by each of the silicon or germanium atoms. The electronic structure of the crystal is thus complete and perfect. A crystal of silicon or germanium with a perfect electron-pair bond structure would be an insulator, In order for electrical conduction to occur, it is necessary for imperfections to arise in the electronic structure. In this lecture, I shall discuss four possible imperfections whose symbols and relationships are indicated in Table I. We shall consider first, as an example, a crystal of silicon containing an arsenic atom as an impurity.

Jan 1, 1953

By R. E. Rick-Secker, W. M. Baldwin, R. McC. Baker

The development of residual stress in strip during rolling has not been systematically studied. A few scattered papers1 -3 mention the existence of residual stresses in rolled strip or touch upon some of their consequences,4 but there is no report of experimental studies in the literature describing the effect of roll diameter, strip thickness, reduction per pass, metal or metal temper on the magnitude of residual stresses developed in strip. A knowledge of the effect of these factors is of utmost importance since the present trend in some mills to roll thicker castings brings the rolling operation directly into that set of conditions which, as will be brought out in the present paper, can develop residual stresses of a high order of magnitude. Fundamentally, residual stresses are developed when a metal is inhomogeneously unloaded from a plastic stress state. A quantitative treatment of the problem requires a reasonably complete understanding of both the plastic stress state existing in the metal during deformation and the elastic stress state that would exist in the metal if the metal deformed as a perfectly elastic body. Our knowledge of either state during rolling is so meager that we can make no more than certain limited predictions. The external stress state* operating between the roll and the metal consists of Fig i—External stress state operating on metal being rolled (after siebel and LUEG5) compressive stresses acting almost perpendicularly to the strip surface but varying in intensity both across the width of the strip and along the length of contact between the roll and the strip. An example of such a stress distribution is shown in Fig I. The nature of the internal stress state, produced by this distribution, is not known. Various investigators,5-7 however, have felt that a qualitative similarity must exist between the internal stress state so produced and that produced in a wide strip that is compressed between two flat-nosed punches. In the latter case the external stress state is represented by a uniformly distributed compressive stress acting per-pendicularly over the face of the tool. The

Jan 1, 1949

By W. C. Clarke

An empirical study of the nature of the embrittle-ment which occurs in martensitic and semiaustenitic precipitation hardening stainless steels upon exposure at temperatures of from about 550" to 875°F has been undertaken. This work was aimed at determining cazusation and means of controlling this phenomenon. A commercial copper bearing precipitation hardening alloy was used as a basic material for study. The effect of heat treatment variables was studied as was the effect of variations in analysis. It is concluded from the evidence that martensitic and semiaustenitic precipitation hardening stainless steels are subject to 885°F ernbrittlement similar to that observed in the straight chromium stainless steels. A characteristic of precipitation hardening stainless steels which has limited their use in certain applications is that they embrittle when held at temperatures in the range of from about 550" to 900°F. This is true to a more or less degree in all currently available alloys, either the basically martensitic type or the semiaustenitic type. The rate of embrittlement varies markedly with exposure temperature, being low at 550" to 600°F and in-creasing as the temperature increases. In spite of this embrittlement, these alloys with their unique combination of high mechanical strength, reasonable toughness, and good corrosion resistance are used in many hundreds of applications. Nevertheless, there are potential applications where the embrittle-ment described is a limiting factor. The purpose of this investigation was to study the embrittlement of these alloys and to find a way to control or eliminate it. GUIDELINES USED IN PRESENT WORK The work reported in this paper is based on a study of 17-4 PH*, a very widely used alloy. It has been used *Trademark of Armco Steel Corp., licensor. in pressurized water and boiling water atomic reactors operating at about 550°F for a number of years. As the life of such equipment is extended or operating temperatures are raised, the possibility of embrit-tlement becomes of increasing concern to materials engineers. Much investigation work was done with respect to the use of 17-4 PH at 550°F. K. C. Antony' states "Such estimation" (of an activation energy for the diffusion of chromium in iron) "would indicate W. C. CLARKE, Jr. is Senior Research Engineer, Advanced Materials Division, Armco Steel Corp., Baltimore. Md. This manuscript is based on a talk presented at the symposium on New Developments in Stainless Steel, sponsored by the IMD Corrosion Resistant Metals Committee, Detroit, Mich., October 14-15, 1968. significant secondary aging is improbable at temperatures less than 700°F within normal component service life". This statement is modified however by the recognition of the accelerating tendencies of applied stress and internal stress as well as the possible effect of irradiation. In this investigation of 17-4 PH, the H 1100 (1900°F-1 hr oil quench or air cool + 1100°F-4 hr-air cool) condition was used, partly because this condition is normally used in atomic reactors. As shown later, the precipitation hardening temperature has no real bearing on the rate of embrittlement. An exposure temperature of 800°F was selected since embrittlement at 800°F is rapid, permitting development of relative data in time periods of 400 to 500 hr. For those not familiar, a nominal present day analysis of 17-4 PH is: C Mn P S SiCrNiCuCbN 0.04 0.30 0.015 0.015 0.60 16.00 4.30 3.25 0.23 0.030 TYPICAL BEHAVIOR OF 17-4 PH Figs. 1 and 2 show the behavior of a commercial heat of 17-4 PH under the conditions defined. Characteristically, 800°F exposure causes a rapid drop in Charpy V-notch impact strength. Tensile and yield strengths gradually increase and a gradual loss of elongation and reduction of area occur, accompanied by an increase in hardness. Notched tensile strength increases to 125 hr exposure and then sharply decreases after exposure for 500 hr. The notched vs un-notched tensile ratio remains virtually constant to exposure for 125 hr (1.67 to 1.56) but drops to 1.15 after 500 hr. Tensile ductility is not alarmingly affected even after much longer exposure times than these. For example, samples aged at 1100°F for 1 hr exposed at 800°F for 4000 hr showed a drop in elonga-tion of from 13 to 11 pct and in reduction of area of from 58 to 37 pct. Notched impact is the property SmIgth KSI 3JJ[/__________^UTS-Nrteh 260 ;/- 240 —^ 200 UTS-Smooth________._, o ioo mo Sob" m Too Hours Exposure Fig. 1—Effect of exposure at 800°F for various times on notched tensile strength and smooth tensile and 0.2 pct yield strength of 17-4 PH in the H 1100 condition.

Jan 1, 1970

By Oscar Weiss

STILFONTEIN and surrounding areas gave negative results in all prospecting attempts since about 1904 when Goerz and Co., a forerunner of Union Corporation Ltd., first drilled in the region and on the farm Stilfontein. Subsequent efforts by African and European Investments Co. and Anglo American Corp. from 1934-37 were completely unsuccessful. Holes drilled by these companies on the farms Rietfontein, Hessie, and Palmietfontein were stopped in the Lower Witwatersrand system without finding payable reefs.

Jan 10, 1951

By T. MacDONALD

ATHOUGH flotation has been a commercial process for over twenty years, the last two years have witnessed a sudden and phenomenal increase in our knowledge of how to separate minerals heretofore not considered amenable to flotation at all. As remarked by Professor Locke in the January issue. "Either commercial or laboratory flotation is reported on zircon, ilmenite, carnotite, kyanite, scheelite, chromite, fluorite, feldspar, cassiterite, wolframite, barite, and clay. Attractive patents on soap flotation are U. S. Nos. 2,000,656 and 2,040.187. A survey by Ralston in the February E. & M. J. adds many other minerals to this impressive list. The simple but pregnant fact is that any mineral can be coated, directly or indirectly, with a water-repellent coating, and since this is true, it follows that any mineral can be floated. Fundamentally, this is no new discovery, where, for instance, is the mineral that cannot he washed from a pair of dirty hands by means of soap and water, given the absence of refractory greases or oils which would have no proper place in flotation ?

Jan 1, 1937

By E. H. Jr. Dix

THE importance of aluminum-silicon alloys in the light alloy field is now generally recognized. Where silicon was once considered detrimental to the properties of aluminum, useful alloys now contain as much as 13 per cent. Furthermore, silicon is present as an impurity in aluminum of even the purest grades. Iron is another important impurity in aluminum and like silicon is found in small quantities in the purest aluminum available today. The manner of occurrence of iron and silicon in commercially pure aluminum and many of its alloys exerts, a very pronounced influence upon their properties. The effect of large quantities of iron in aluminum-silicon alloys is so detrimental that it has been found necessary to limit the allowable maximum percentage to as low a figure as is consistent with quantity production and satisfactory physical properties. The intimate relation existing between iron and silicon in aluminum and aluminum alloys makes necessary a more complete knowledge of this ternary system. This paper is divided into two principal parts, dealing respectively with aluminum-silicon solubility equilibria and the constitution of aluminum-iron-silicon alloys.

Jan 1, 1927

By M. Deighton, R. N. Parkins

The metals Cd, ,Wg-, Sn, TI, Zn, and Zr reach a peak hardness after a criticfir1 deformation by rolling- and then soften with fwther rolling-, thereby exhibiting wovk softening. Optical metallography on Cd, Mg, and Zn shows that work softening is accompanied by a change in grain size occurring during deformation. The creep of zinc from -1l° to +60°C at stresses in the range of 7.9 to 17.3 kg per sq mm is given by € = e0 -t- Bt + Kt +at6. The third and second rate constcints are related by the equation a = K~ K6 and their stress and temperature dependence can be represented by the equations K = A, . exp - (u, - Bu)/kT. A model based upon the stress activated glide of sub-boundaries is proposed which qualitatively accounts for the metallog-raphic observations. Expressions, which are in reasonable quantitative agreement with the ex-pe~inzental observations, are derived for the creep of zinc. THE term "work softening" has been used previously by Polakowski1 and by Cottrell and stokes2 to describe phenomena where further strain of a deformed material leads to a decrease in flow stress. In both cases, however, the conditions were changed for the second straining. Here, the term "work softening" is intended to refer to a decrease in flow stress after continued straining in the same direction at the same temperature: work softening is the antithesis of "work hardening". Work softening of zinc was reported by chadwick3 and in discussion of that paper Jenkins4 indicated that cadmium also work softens. More recently work softening has been reported5 in two magnesium alloys, -99.5 pct Mg. Chadwick found that the hardness, 0.2 pct Proof Stress and the UTS of electrolytic zinc all increased with progressive cold reductions up to 30 pct and then progressively decreased with further rolling. Gay and Kelly6 used a back-reflection X-ray technique to study the effect of cold rolling zinc and found that although deformations greater than 2 to 5 pct reduction in thickness produced some recrystallized grains, deformations greater than 40 pct caused com-plete spontaneous recrystallization. At deformations greater than 60 pct the material was found to consist solely of recrystallized grains, -20 pm diam, the size of which decreased with increasing reduction and was much less than the initial grain size of the annealed material (-300 pm diam). Similar results were also reported for cadmium, tin, and lead.6 Gay, Hirsch, and Kelly' suggest that these experiments indicate recrys-tallization takes place when the dislocation density exceeds a certain value. However, no measurements of MATERIALS AND EXPERIMENTAL PROCEDURE The purity of the metals used in this work is indicated by the following figures: Zn (99.99); Cd (99.94); Mg (99.95); T1 (99.99). The zirconium was iodide crys tal bar with a probable purity of about 98 pct. The metals were obtained in the form of 0.25 in. thick strip or 0.425 in. diam rod by various fabrication methods and then annealed to ensure complete re-crystallization. Hardness-deformation curves were obtained at room temperature by rolling 4 in. thick strip under conditions which left a surface adequate for diamond pyramid hardness tests immediately after rolling. The hardness was taken as the niean of five impressions made using a 5 kg load and the time elapsing between rolling and making the last impression never exceeded 5 min. The zinc specimens for creep testing were from 3 by 3 by 4 in. cast slabs which were rolled to 0.10 in. thickness starting at 350°C and finishing cold. The resulting strip was cut into pieces 1 in. wide and annealed in batches. With suitable choices of annealing temperature between 100" arid 400°C five different grain sizes varying from 4.54 x 10' to 3.03 x l05 grains per sq cm (530 to 20 um diam) were obtained. Creep tests were done in compression using a sub-press, based on a design after Ford,8 in which the strip is compressed between dies 0.100 in. wide under conditions of plane strain. Since there is no lateral spread of the material, the area of contact between the dies and strip remains constant throughout the test and the application of a constant load, using the load maintaining device of a hydraulic testing machine, resulted in a constant stress. Covering the dies with strips of P.T.F.E. reduced frictional effects to a minimum. The creep strain was obtained by measuring the travel of the crosshead of the testing machine to a sensitivity of 0.1 pct reduction in thickness. The complete subpress assembly was contained in a steel box and for tests above the ambient this was filled with liquid paraffin and heated electrically. Temperatures below the ambient were obtained with a cooling mixture of acetone and solid carbon dioxide in the box. The liquids were stirred and the temperature of the specimen, which was controlled to ±0.5"C dur-ing a test, was measured by a thermocouple placed near the dies. Compression testing of cylindrical specimens was also carried out in the subpress using hardened flat discs separated from the test material by P.T.F.E. sheets which obviated barrelling of the specimens. Various initial strain rates were supplied by the hydraulic testing machine, and the deformation was measured by a clock dial gage resting on the cross-

Jan 1, 1970

By C. H. Herty

Almost every metallurgist who has given the Howe Memorial Lecture has had a personal contact with the distinguished gentleman to whose honor this hour is devoted. Unfortunately for me, such personal contacts were not possible. However, in the preparation of a thesis on the open-hearth process, one of my earliest tasks was to make a survey of the literature, and it was from Professor Howe's Metallurgy of Iron and Steel that I drew a number of references to previous work which formed the foundation for my reading. In his volume there is such a complete exposition of the then current thought on the subject of slags and on their role in the elimination of phosphorus from steel that I feel no hesitation in discussing in this Howe Lecture the subject of "Slag Control." In the present era of close specification, the drive for uniformity of product, and the close inspection of the product and of the cost sheet, the utmost efforts must be made to control the steelmaking variables to the best advantage of the steel producer. One of the major variables is the slag in the furnace and its effect upon the composition and quality of the metal. What advantages are to be gained from slag control? In the broad sense the advantages must be tremendous, because the very foundations of good steel melting are based on "shaping up" the slag to a point where, with proper temperature, the heat is ready for the final additions. Every melter works toward these ends through his experience with innumerable heats of steel. The elimination of undesirable constituents such as phosphorus and sulphur is entirely a matter of slag composition and physical nature, a point well known for over half a century. The role played by the slag in assisting in proper heat transfer from roof and flame to the steel has been equally well known. In more recent years there has come the problem of oxygen control in the more accurate gauging of additions for making high-grade rimmed steel for the new strip mills, and in the deoxidizing additions for grain-size control and cleanliness of forging steels, both carbon and alloy. In this problem the oxidizing characteristics of the slag are of prime importance.

Jan 1, 1940

By C. H. Herty

Almost every metallurgist who has given the Howe Memorial Lecture has had a personal contact with the distinguished gentleman to whose honor this hour is devoted. Unfortunately for me, such personal contacts were not possible. However, in the preparation of a thesis on the open-hearth process, one of my earliest tasks was to make a survey of the literature, and it was from Professor Howe's Metallurgy of Iron and Steel that I drew a number of references to previous work which formed the foundation for my reading. In his volume there is such a complete exposition of the then current thought on the subject of slags and on their role in the elimination of phosphorus from steel that I feel no hesitation in discussing in this Howe Lecture the subject of "Slag Control." In the present era of close specification, the drive for uniformity of product, and the close inspection of the product and of the cost sheet, the utmost efforts must be made to control the steelmaking variables to the best advantage of the steel producer. One of the major variables is the slag in the furnace and its effect upon the composition and quality of the metal. What advantages are to be gained from slag control? In the broad sense the advantages must be tremendous, because the very foundations of good steel melting are based on "shaping up" the slag to a point where, with proper temperature, the heat is ready for the final additions. Every melter works toward these ends through his experience with innumerable heats of steel. The elimination of undesirable constituents such as phosphorus and sulphur is entirely a matter of slag composition and physical nature, a point well known for over half a century. The role played by the slag in assisting in proper heat transfer from roof and flame to the steel has been equally well known. In more recent years there has come the problem of oxygen control in the more accurate gauging of additions for making high-grade rimmed steel for the new strip mills, and in the deoxidizing additions for grain-size control and cleanliness of forging steels, both carbon and alloy. In this problem the oxidizing characteristics of the slag are of prime importance.

Jan 1, 1940

By Z. T. Bieniawski, E. Unal, H. Reginald Hardy

INTRODUCTION Rock bolts are a major means of support in underground coal mines in the United States. However, two of the most crucial problems facing the mining engineer today are that of finding a well defined and standard method for testing the anchoring ability of rock bolts, and of selecting the most suitable type of rock bolt and bolting pattern for a particular mine or specific mine section (Anon., 1982). Such selection requires not only an understanding of the behavior of the rock mass and the rock-bolt unit itself, but also a knowledge of the basic mechanisms by which rock bolts provide support while they interact with the rock mass during various field loading conditions. A recent study in this area has shown the inadequacy of present methods used in selecting and testing of rock bolts and the lack of clearly defined guidelines for safe and economical design of bolting patterns (Bieniawski, et al., 1980). The present paper describes a research study aimed at developing laboratory instrumentation and associated techniques for the evaluation of bolt-rock interaction. The instrumentation system developed, procedures followed during various experiments, and typical results from a series of studies carried out on mechanical bolts are presented. DEVELOPMENT OF THE ROCK BOLT TESTING FACILITY General A block diagram of the experimental facilities are shown in Fig. 1. The system consists of three main sections. The first

Jan 1, 1982

By O. Jay Myers

The war effort has furnished the necessary impetus for better magnesium foundry practice. Four or five years ago, there were but a few formulas in general use for core-sand mixtures for magnesium castings. Certain sands, binders, and inhibitors were specified and the proportions of these materials in each mixture were maintained between very narrow limits. As more and more war industries entered the field, much research was carried out and methods and practices were improved. Magnesium founding is still in a state of flux; therefore it is not uncommon to find one foundry spraying inhibitors on its cores, and another foundry using sand mixtures with incorporated protective agents. The basic core or dry-sand mold mixture for magnesium in use today is compounded with sand, core oil or resin binder, cereal, and moisture. Core oil or resin binder are added for baked strength while the cereal binder and moisture are for green strength. The normal mixtures (based on the weight of the sand) contain from o.5 to 1.5 per cent of both cereal binder and core oil, and the moisture content variesbetween 1.5 and 5 per cent. The ratio of core oil to cereal binder varies from 60:40 to 40:60, while the correct amount of moisture depends upon the method of coremaking. Protective Agents In all magnesium practice, protective agents are used in conjunction with the core and molding sands to prevent oxidation of the metal. The use of these inhibitors is not novel, but publications covering this field are not entirely adequate. Beck1 says: Magnesium alloys decompose water to form magnesium oxide, hydrogen being liberated in the process (Mg + H2O ? H2 ?+ MgO). This reaction results in the blackening of the skin and the appearance of areas of porosity on the casting surface, the cavities of which are filled with a grey oxide powder (these are termed 'burns'). Although sand cores for magnesium castings are thoroughly dried during the baking cycle, burning will take place on the casting5 unless the metal is protected properly. This type of burning is more difficult to define than the "water-magnesium" reaction cited by Beckl A possible explanation may lie in the following equation: 2Mg + O2—> 2MgO Here, the source of the oxygen is not water, but the air in the mold cavity, together with the chemically combined oxygen in the core-binding media. Generally, two methods are used to prevent this reaction from taking place.

Jan 1, 1945

By Donald L. Katz, Marshall B. Standing

Density data are reported on 16 saturated hydrocarbon vapors at Pressures ranging from 1000 to 8220 Ib. per sq. in. and at temperatures ranging from 35° to 250°F. These data have been used to extend the compressibility-factor chart for natural gases up to 10,000 lb. per sq. in. The relatively large quantity of high-boiling constituents present in high-pressure vapors in equilibrium with crude oils makes it necessary to include in the analysis of the gas the molecular weight, density, and possibly boiling range of the heptanes and heavier fraction. Relationships have been presented by which the density of gases may be obtained directly from the temperature, pressure, and gas gravity provided the gases have a common source or are similar in composition. Introduction The densities of natural gases are necessary in many engineering in in petroleum production and utilization, Gas reserves, changes in reservoir pressure, gradients in gas wells, metering of gases, pipeline flow, and compression of gases are typical problems requiring the density of the gas. A decade ago, engineering computations used ideal gas laws with deviations up to 500 Ib. per sq. in.4 Recent discoveries of pools having Pressures UP to 7500 lb. Per sq. in., and installation of pressure-maintenance and recycling plants, have increased the need for data On gas density at high pressures. Methods of Computation The accepted method of computing the density or specific volume of natural gases is the use of the ideal gas law corrected by a compressibility factor. The method proposed by Kay7 of correlating compressibility factors for gaseous mixtures on pseudocritical properties5 appears to be satisfactory for natural gases.2 The meth-me-compressibility factor has been shown to deviate systematically from the behavior of natural gases2 and a chart giving these corrected factors is available. A method of computing specific volume of gaseous mixtures from partial molal volumes has been reported by sage and Lacey.8 Complete data for the computation are not yet available for all hydrocarbon gases. Most- of the reported data on gas densities have been in the single-phase region removed from the dew point or saturation condition. Since most gases in the reservoir Or while on contact with liquid '''ring flow are saturated, the determination of densities under conditions of saturation is particularly important. Although there is no reason to believe that the saturated gases differ in behavior from those consider. ably removed from their dew points, the usual experimental determinations find difficulty on approaching the dew-point conditions, This paper reports the density of I6 saturated gases in equilibrium with crude oils. The relationships developed to compute the density of gases to high pressure' have been modified and enlarged. A simpli-fied method of obtaining gas density is presented in the Form of charts, which apply for specific groups of gases.

Jan 1, 1942

By Marshall B. Standing, Donald L. Katz

Density data are reported on 16 saturated hydrocarbon vapors at Pressures ranging from 1000 to 8220 Ib. per sq. in. and at temperatures ranging from 35° to 250°F. These data have been used to extend the compressibility-factor chart for natural gases up to 10,000 lb. per sq. in. The relatively large quantity of high-boiling constituents present in high-pressure vapors in equilibrium with crude oils makes it necessary to include in the analysis of the gas the molecular weight, density, and possibly boiling range of the heptanes and heavier fraction. Relationships have been presented by which the density of gases may be obtained directly from the temperature, pressure, and gas gravity provided the gases have a common source or are similar in composition. Introduction The densities of natural gases are necessary in many engineering in in petroleum production and utilization, Gas reserves, changes in reservoir pressure, gradients in gas wells, metering of gases, pipeline flow, and compression of gases are typical problems requiring the density of the gas. A decade ago, engineering computations used ideal gas laws with deviations up to 500 Ib. per sq. in.4 Recent discoveries of pools having Pressures UP to 7500 lb. Per sq. in., and installation of pressure-maintenance and recycling plants, have increased the need for data On gas density at high pressures. Methods of Computation The accepted method of computing the density or specific volume of natural gases is the use of the ideal gas law corrected by a compressibility factor. The method proposed by Kay7 of correlating compressibility factors for gaseous mixtures on pseudocritical properties5 appears to be satisfactory for natural gases.2 The meth-me-compressibility factor has been shown to deviate systematically from the behavior of natural gases2 and a chart giving these corrected factors is available. A method of computing specific volume of gaseous mixtures from partial molal volumes has been reported by sage and Lacey.8 Complete data for the computation are not yet available for all hydrocarbon gases. Most- of the reported data on gas densities have been in the single-phase region removed from the dew point or saturation condition. Since most gases in the reservoir Or while on contact with liquid '''ring flow are saturated, the determination of densities under conditions of saturation is particularly important. Although there is no reason to believe that the saturated gases differ in behavior from those consider. ably removed from their dew points, the usual experimental determinations find difficulty on approaching the dew-point conditions, This paper reports the density of I6 saturated gases in equilibrium with crude oils. The relationships developed to compute the density of gases to high pressure' have been modified and enlarged. A simpli-fied method of obtaining gas density is presented in the Form of charts, which apply for specific groups of gases.

Jan 1, 1942

By J. E. Tiffany

FOR blasting in coal mines the U. S. Bureau of Mines recommends that permissible explosives be used exclusively, that these shall be fired electrically, and that where feasible the working place shall be cut or sheared. These recommendations are made to promote safety and prevent mine explosions. Although permissible explosives are not flameless, their lower flame temperature and shorter duration of flame make their use safer than that of non-permissible explosives. Mixtures of air with both methane and bituminous coal dust, which are liable to occur in coal mines, may be ignited by coming in contact with any type of flame or spark of sufficient temperature and duration or by the firing of a blast. In a working place where a blast is to be fired, in addition to the use of permissible explosives, adequate ventilation for the dilution and removal of accumulations or outbursts of flammable gas should be provided. Bituminous coal mines should be rock-dusted as a means of rendering the coal dust harmless. The efficient use of permissible explosives depends upon the proper preparation of the working place, standardized drilling, the strength characteristics of the explosive, and the use of a proper weight of charge. Experienced shotfirers should load, tamp and fire all holes. The major part of the information and data here presented is based on the results of efficiency tests made in large producing mines of Pennsylvania and Illinois. Bureau of Mines Report of Investigations, Serial No. 2697, describes how a standard method of blasting was worked out and put into operation in a mine in southern Illinois.1 This paper contains a description of the methods worked out subsequently in another mine in that district.

Jan 1, 1928

By Ralph H. Sweetser

Carbon in pig iron is not only essential but, ordinarily, it is the most abundant metalloid present; iron without carbon could not be pig iron. Carbon in pig iron has been accepted, but seldom specified. How it gets into the pig iron as it is being smelted in the blast furnace, and why just about so much of it enters into the pig iron in certain blast furnaces, and more of it,; or less of it, enters the pig iron in other blast furnaces, or in the same blast furnace under varying conditions, are problems that have not yet been satisfactorily solved. During my own practical blast-furnace experience, I collected analyses of pig iron, including the graphitic and combined carbon, and recorded them in reference to the percentage of silicon present, having in mind the generally accepted explanation that "silicon drove out the carbon." To this actual experience, I have added some analyses given to me by J. B. Rogers, who was superintendent of the blast furnaces of the Ashland Iron & Mining Co., Ashland, Ky., and was making "silvery iron" at the time. These analyses are shown in Table 1. The analyses do not tell the whole story, but they show that with Pocahontas beehive coke, the total carbon was generally high. The data relating to the composition of the slag are lacking but my own customary practice was to have a rather basic slag. During my experience in making pig iron for the Bessemer and open-hearth departments, there were times when the steel men would complain about some mysterious quality in the pig iron that caused bad steel, in spite of the fact that the percentages of silicon, sulfur, phosphorus and manganese were within the specifications. Many reasons were advanced for this undetermined "poison" in the pig iron, but the favorite one offered by the steel men was that the blast-furnace man had "oxidized" the pig iron at the tuyeres in his eagerness to get big production and low cost. To these complaints of the users of steel-making pig irons were added those of the gray iron-foundry men and the malleable iron men. These groups are unaninlous in their conclusions that the trouble lies with the blast-furnace men; but there is not yet any harmonious conclusion as to the exact cause and remedy.

Jan 1, 1927