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By E. T. Hayes, A. H. Roberson, M. H. Davies

ZIRCONIUM has been produced on a pilot-plant scale for only a few years, but the potential uses have led a large number of research establishments to engage in a thorough study of the metal and its alloys. The work described in this paper is part of a cooperative project between the Bureau of Mines and the Air Materiel Command. The Zr-Cr system was one of the first investigated because of the possibilities of improving the properties at elevated temperatures, the chemical corrosion resistance, and the mechanical properties of zirconium in a manner similar to the enhancement of the properties of titanium by additions of chromium. There is no published work on the Zr-Cr system but from the similarity of the metals involved it was expected that it would be similar to the Zr-Fe' and Ti-Cr' systems. The materials used in this investigation were prepared in the Bureau of Mines laboratory at Albany, Ore. Zirconium was produced by magnesium reduction of zirconium tetrachloride, and a typical analysis is as follows: Fe, 0.06 pct; Ox, 0.08; N?, 0.01; C, 0.02; and other impurities such as Al, Pb, Ni, Ti, and Si less than 0.01 pct each. High purity chromium was prepared by treating crushed electrolytic chromium in a stream of dried and purified hydrogen." The resulting powder contained about 0.01 pct 0 and about 0.1 pct total metallic impurities. All alloys were prepared by arc-melting 50 g briquetted compacts of the desired composition in a Kroll-type" arc furnace using an inert atmosphere. The furnace was evacuated twice and backfilled with helium, which was gettered by melting a center zirconium button immediately before the alloys were melted. Alloys were remelted at least once to insure greater uniformity of composition and subsequently were annealed in vacuum at 1250°C for 48 hr. Fairly homogeneous alloys were obtained by this means; a slight loss of chromium from the surface by evaporation during the high temperature homogenization was noted. All alloys were analyzed for chromium and gave results in good agreement with the nominal composition. Spot checks on tungsten and nitrogen showed pick-up of these elements to be negligible. Over 70 alloys were prepared for use in this investigation; only the critical ones are shown in Table I. Alloys containing up to 10 pct Cr were amenable to hot working at 850°C and a number of these were sheath rolled to 1/16 in. thickness. Specimens were cut from the sheet for use as metallographic samples. For the thermal analysis a differential couple was used in conjunction with an X-Y recorder, the temperature of the specimen and the difference in ternperature between it and the standard nickel body were recorded simultaneously. Heating and cooling rates of 5°C per min were used. The sensitivity of the instrument was such that a difference in temperature between the specimen and standard equivalent to 0.1 mv produced a deflection of 1 in. on the recording chart. The chromel-alumel thermocouples were checked against a Bureau of Standards calibrated thermocouple. Melting-point determinations were made in a high vacuum induction furnace using an optical pyrometer. The pyrometer, calibrated against nickel, copper, and zirconium (iodide process) under near black body conditions, was focused on the base of a hole drilled in cylindrical samples. A North American Philips Geiger counter X-ray spectrometer was used for all diffraction studies. This instrument, in addition to supplying precise intensity measurements of planar reflections, has an added advantage in that metallographic specimens mounted in bakelite can be used directly, and this

Jan 1, 1953

By J. F. Martin, L. M. Melnick, R. Rapp, R. C. Takacs

Recent studies on the determination of hydrogen in steel have shown that the hot-extraction method for removing hydrogen from a solid sample is preferable to its removal from a molten sample by vacuum fusion or by fusion in vacuum with tin. A number of techniques are available, however, for determining the hydrogen so extracted. They include: thermal conductivity, gas chromatography, pressure measurement before and after catalytic oxidation of the hydrogen to water and removal of the water, and pressure measurement before and after diffusion of the hydrogen through a palladium membrane. These techniques have been evaluated on the basis of initial cost, maintenance, speed and accuracy of analysis, and applicable concentration range. The results of this study showed that the palladium-membrane technique is best suited for routine use. FOR some time investigators have been concerned with the origin, form, and effect of hydrogen in steel. In such stdies', the analysis for hydrogen constitutes one of the most important phases. It is quite apparent that the results for hydrogen concentrations in a given steel are dependent on the method of obtaining the sample, storage of the sample until analysis, preparation of the sample, and analysis of the sample, including all the facets inherent in the calibration and operation of an apparatus for gas analysis. There are a number of means available for determining hydrogen. This is a critical study of some of the more common techniques in use today. In most conventional melting and casting methods, hydrogen concentrations of 4 to 6 parts per million (ppm) in steel are quite common. Because of the undesirable effects of hydrogen on steel there has been increased use of techniques such as vacuum melting,' vacuum casting, and ladle-to-ladle stream degassing, which lower the hydrogen content to levels on the order of 1 to 2 ppm. Therefore, the method used for determining hydrogen in steel must be sensitive and precise. In any analytical procedure for gases in metals there are two distinct operations—the extraction of the gas from the metal and the analysis of the extracted gas. To extract the gas from the steel, three methods have been employed: 1) fusion of the sample with graphite at high temperature; 2) fusion with a flux, such as tin, at a lower temperature; and 3) extraction of the hydrogen from the solid sample at a temperature below the melting point of the steel. Fusion with graphite is the least-acceptable method. The blank in this method is higher and more variable than in either of the other two methods. The hydrogen fraction of the total gas composition usually is between 10 and 50 pct; thus, a larger analytical error is possible. The vacuum-tin fusion4 extraction of hydrogen is probably the most rapid method in use today; the extraction time is usually about 10 min. However, with this system a bake-out of the freshly charged tin for 2 hr is necessary and a change of crucible and a charge of fresh tin are required after each day of operation whether one or thirty samples have been analyzed. In addition, frequent checks of blank rates are required since CO and Na are continually being given up by the steel samples dissolved in the tin bath. The composition of the gas in this method lends itself readily to analysis; although the hydroge concentration may fall to as low as 50 pct, more often it is above 90 pct, thus allowing a more precise analysis (because of less interference from other gases). In 1940 ewell' published the hot-extraction method for extracting hydrogen from the solid sample, comparing analysis for hydrogen extracted at 600°C with similar analysis for the gas extracted at 1700°C by fusion with graphite. Good agreement for hydrogen was obtained between these two methods, provided sufficient time was allowed for extraction at the lower temperature. carsone obtained good results in his comparison of this hot-extraction method with vacuum-tin fusion. Subsequent work by Geller and sun7 and Hill and ohnson' has shown that steel samples should be heated to at least 800°C to effect the release not only of the diffusible hydrogen but also of the "residual" hydrogen that may be present as methane. Since the rate of evolution of hydrogene9l0 depends on such factors as sample size and composition, thermal history, and extent of cold work, a fixed extraction time is not possible. Extraction times of 30 min are normal, but 2 hr are not unusual. Induction or resistance heating may be used in the hot-extraction method. With resistance heating the

Jan 1, 1964

By C. H. Wayman, D. W. Fuerstenau

The effect of bubble size and concentration of certain reagents on the terminal velocity, shape, path, and drag coefficients of single air bubbles in distilled water has been investigated. Bubbles of a certain size range rise considerably faster than Reynolds number-drag coefficient relationships predict, whereas a small amount of frothing agent reduces their terminal velocity. The rapid velocity at which bubbles rise in distilled water appears to result from slip at the boundary and from circulation within the bubbles. Surface-active agents retard bubble motion through prevention of both circulation and slip at the boundary. A surface tension concentration gradient helps maintain bubble sphericity. HE gas phase is one of the indispensible in-gredients in flotation operations. Flotation depends on the collision of an air bubble and a mineral particle in a pulp and their ability to remain in contact long enough for adherence to take place. Before it is possible to understand the mechanics of air bubble-mineral particle encounter, it is necessary to learn more about the nature of bubbles themselves before collision with a mineral particle has taken place. To date, little work has been done on air bubbles in flotation systems. In 1945 Fahren-wald' presented a study of the role of frothers on air bubbles and on aeration in flotation, and recently Wark and Sutherland' discussed the work of Rosenberg- in relation to flotation. The research reported in this present article was undertaken to investigate systematically the effect of bubble size and the concentration of certain reagents on the terminal velocity, shape, path, and drag coefficient of single bubbles in distilled water. Most of the work is concerned with the effect of a-terpineol on bubble motion in water, but studies were made with potassium chloride, potassium hydroxide, potassium ethyl xanthate, and potassium amyl xanthate. Experimental Method and Materials: To obtain free bubble rise and reduce wall and surface effects, the investigators used a tank of 5½x5½x30-in. internal dimensions, filled with water to within 4 % in. of the top.' The tank was made of acrylic plastic so that the walls would have good optical properties. Distilled water, which was re-distilled in a block tin still and saturated with air before each test, was used in all the experiments. All solutions were made with reagent-grade chemicals. During each experiment the water was at room temperature, and during the course of an experiment the temperature did not fluctuate more than 0.5°C. Since the experiments were performed over a period of six months, the temperature varied between 25° and 27°C. The temperature at which each series of experiments was conducted is recorded with the data. The experimental apparatus is presented dia-grammatically in Fig. l. Individual air bubbles were generated from purified compressed air through a capillary of 0.003-cm internal diameter at a rate

Jan 1, 1959

By Luther Wagoner

Having given in a former paper1 the results of assays of sea-water, bay-mud, dredgings from San Francisco bay, etc., and believing it might be interesting to extend the work to include some deep-sea dredgings, I procured from the Smithsonian Institution six samples taken by the U. S. steamer Albatross, and marked as follows: Depth in No. station. Locality. Latitude. Longitude. Fathoms. 1. 2103. Off Delaware bay. 38' 47' 20" N., 72o 37' W., 1,091. 2. 2265 to Between Chesapeake 35° 37' N., 74O to 75O W., 49 to 70. 2297. bay and Hatteras. 3. 2420. Off Chesapeake bay. 37' 03' 20" N., 74O 31' 40" W., 104. 4. 2528. East of Georges 41° 47' N., 65o 37' 30" W., 677. bank. 5. 2572. SE. of Georges bank. 40° 29' N., 66O 041 W., 1,769. 6. 2681 South of Nantucket. 39' 43' N., 70' 29' W., 990. The above samples were assayed by the cyanide-method, described in my former paper (p. 807), about 30 g. of sample being used, and the following results were obtained: Value in Milligrams Per Metric Ton. No. Station. Gold. Silver. 1. 2103. 145 1,014 2. 2265 to 2297. 44 304 3. 2420. 15 353 4. 2628. 267 1,963 5. 2572. 125 377 6. 2681. 66 414 No. 4, Station 2528, consisting of red clay and volcanic ash, mas re-assayed ; 35 g. was roasted at a low heat for one hour and weighed 34.05 g. after roasting; the color was changed to a deep brick-red; and when assayed by the cyanide-method

Jan 1, 1908

The papers presented at the International Congress, held in San Francisco, Cal., Sept. 20 to 25, 1915, are published in 11 volumes of Transactions. In addition, an index volume is published, containing .besides the author and title index, a report of the business meetings of the Congress, and a brief digest of each paper presented. The following is a schedule of the volumes: Index and Digest.-General proceedings, indexes and digests. Vol. I. Panama Canal. II. Waterways and Irrigation. III. Municipal Engineering. IV. Railway Engineering. V. Materials of Engineering Construction. VI. Mechanical Engineering. VII. Electrical Engineering and Hydro-electric Power Development. VIII. Mining Engineering. IX. Metallurgy. X. Naval Architecture and Marine Engineering. XI. Miscellaneous. Aeronautics; Refrigeration; Agricultural Engineering; Engineering Education; Heating and Ventilation. Remember the New York Meeting, Feb. 14 to 17, 1916.

Jan 12, 1915

By George F. Becker

A Nere record of Emmons's professional career would very inadequately represent the man. That he was eminent mc know, and our successors will realize in due time; but they must depend upon us for knowledge of a singularly ~vholesome, modest, unselfish personality, and of a character that did honor to a profession in which trustworthiness is indispensable. Those members of the Institute who met Emmons are his friends, and I never knew .one of these who was not the better for that friendship. Emmons was born in Boston, Mar. 29, 1841, the son of Xathaniel H. and Elizabeth (Wales) Emmons, and was named Samuel Frankliri after an ancestor who was of the sarne family as Benjamin Franklin. He took the degrcc of Bachelor of Arts at Harvard in 1861, and soon afterwards went abroad to complete his education. From 1862 to 1864 he attended the courses at the fieole Impkriale des Mines at Paris, Elie de Beaumont arid Daubrke being among his professors. The year 1864-1865 he spent at Freiberg under Cotta and other famous teachers; after which he spent another year in traveling through Europe. Like many other renowned geologists, he approached his ultimate profession from its economic side, and was thus from the first imbued with a sense of high responsibility in the promulgation of scientific opinions or conclusions. With hypotheses which were interesting merely because they were ingenious or even plausible, he would have nothing to do. In 1867 he joined the Geological Exploration of the Fortieth Parallel at its organization under Clarence King, serving at first as a volunteer, but soon receiving a regular appointment. This expedition was the first one of purely geological character sent out by the United States government. As Emmons has shown in his admirable presidential address on " The Geology of Government Explorations," its work was founded on a com-

Jan 1, 1912

By R. R. McNaughton

The Consolidated Mining and Smelting Company of Canada, Ltd. at Trail, B. C., inaugurated a comprehensive program of investigation about 15 years ago to develop the most economical process of recovering the metal in the large accumulated stock of by-products of the lead smelter and the zinc plant. Two principal methods of recovery were followed to a successful conclusion—an electrothermic process to treat zinc-plant residues and cold slag and the fuming of hot slag from the lead blast furnaces. The latter was selected because it showed a saving over the former in its ability to handle hot blast-furnace slag, thus obviating the necessity of granulating, handling and eventually remelting the same slag for the electrothermic process. The design of a fuming plant was commenced in 1928, and construction, which was started immediately, was completed in July 1030. Operating intermittently for a general tuning up, the plant was officially blown in for regular operation in August. During this month the vagaries of a slag-fuming plant were studied and an operating crew was trained. A history of slag fuming at Trail and the development of plant design is given in a paper by G. E. Murray in the Transactions of the Canadian Institute of Mining and Metallurgy for 1933. Fuming Plant The fuming plant at Trail (Fig. 1) is a separate unit although of necessity interlocked closely with the lead smelter. The plant consists essentially of a fuming furnace with its accessories, a waste-heat boiler followed by an economizer, and a suction-type baghouse. The plant was built as the first of two 400-ton units with the intention of adding the second unit within a year, so that flues, fans and buildings were built to handle double the original load. Furnace.—The furnace as originally built (Fig. 2) was of water-jacket construction, 10 ft. wide, 20 ft. long and 6 to 10 ft. high. The roof height was made variable to check experimental work, which had indicated that this dimension affected the rate of reduction. Coal and air were supplied

Jan 1, 1937

By Keith Leonard Sutherland

This paper is a study of the differential flotation of the sulphide minerals in the presence of salts of silver, lead and zinc. In practice, accidental activation due to these salts is more important than their use as reagents to replace copper sulphate. The general method of investigation has been based upon contact tests, the temperature of 35°C being chosen in conformity with earlier work. Potassium ethyl xanthate and potassium amyl xanthate were selected as collectors and pure sulphide minerals were used. The experimental procedure has been outlined in earlier papers and all solutions were kept carbonate-free.14 Contact, or spreading of an air bubble, at a mineral surface indicates the presence of an adsorbed collector film. Purity of Reagents The xanthates were purified in the usual manner.' Neither the cyanide nor the sodium hydroxide solutions contained sufficient carbonate to give a precipitate with barium chloride solution. The silver sulphate was prepared from pure silver nitrate by evaporation with concentrated sulphuric acid until there was no evidence of brown fumes, This solution was diluted and the difficultly soluble sulphate washed with water so that unchanged nitrate was dissolved. The resultant crystalline powder was pure white. The lead and zinc salts were prepared by dissolving especially pure lead and zinc in C.P. nitric and sulphuric acid solution and the crystals drained. The standard solutions were checked by titration. It was felt desirable to use the sulphate radical wherever possible, but since lead sulphate was insufficiently soluble for the purpose of the experiments, it was necessary to use some other lead salt. A.R. copper sulphate was used without further purification. Results The results are presented in the accompanying figures; the areas of noncontact (nonflotation) are shaded in Figs. 8, 9, 10 and 11; in the remainder they lie to the right of the curve. Zinc Sulphate The curves in Fig. I are to be compared with those for Fig. 2, for which zinc sulphate is absent. This comparison shows that the influence of the zinc ion is usually small. Its influence is more marked, however, for chalcopyrite in the absence of cyanide. The influence of zinc sulphate is also marked for copper-activated sphalerite, for which tests were made only in the "absence of cyanide. The results are of importance in the separation of pyrite from copper-activated sphalerite when zinc sulphate is added in the lead flotation section (p. 204 of ref. I). Sphalerite does not adsorb the collector (i.e., become floatable) under the conditions chosen.

Jan 1, 1943

By Keith Leonard Sutherland

This paper is a study of the differential flotation of the sulphide minerals in the presence of salts of silver, lead and zinc. In practice, accidental activation due to these salts is more important than their use as reagents to replace copper sulphate. The general method of investigation has been based upon contact tests, the temperature of 35°C being chosen in conformity with earlier work. Potassium ethyl xanthate and potassium amyl xanthate were selected as collectors and pure sulphide minerals were used. The experimental procedure has been outlined in earlier papers and all solutions were kept carbonate-free.14 Contact, or spreading of an air bubble, at a mineral surface indicates the presence of an adsorbed collector film. Purity of Reagents The xanthates were purified in the usual manner.' Neither the cyanide nor the sodium hydroxide solutions contained sufficient carbonate to give a precipitate with barium chloride solution. The silver sulphate was prepared from pure silver nitrate by evaporation with concentrated sulphuric acid until there was no evidence of brown fumes, This solution was diluted and the difficultly soluble sulphate washed with water so that unchanged nitrate was dissolved. The resultant crystalline powder was pure white. The lead and zinc salts were prepared by dissolving especially pure lead and zinc in C.P. nitric and sulphuric acid solution and the crystals drained. The standard solutions were checked by titration. It was felt desirable to use the sulphate radical wherever possible, but since lead sulphate was insufficiently soluble for the purpose of the experiments, it was necessary to use some other lead salt. A.R. copper sulphate was used without further purification. Results The results are presented in the accompanying figures; the areas of noncontact (nonflotation) are shaded in Figs. 8, 9, 10 and 11; in the remainder they lie to the right of the curve. Zinc Sulphate The curves in Fig. I are to be compared with those for Fig. 2, for which zinc sulphate is absent. This comparison shows that the influence of the zinc ion is usually small. Its influence is more marked, however, for chalcopyrite in the absence of cyanide. The influence of zinc sulphate is also marked for copper-activated sphalerite, for which tests were made only in the "absence of cyanide. The results are of importance in the separation of pyrite from copper-activated sphalerite when zinc sulphate is added in the lead flotation section (p. 204 of ref. I). Sphalerite does not adsorb the collector (i.e., become floatable) under the conditions chosen.

Jan 1, 1943

By Robert Steinitz

SOFT iron parts for magnetic applications, particularly pole shoes, constitute a major portion of the ferrous products of powder metallurgy. The residual pores in pressed and sintered parts reduce values such as the magnetic permeability but service experience extended over a number [ ] of years has proven beyond doubt that in many instances the lower density of powder parts is not prohibitive to their use m replacement of machined magnetic parts The. magnetic requirements for pole shoes particularly the permeability, vary within wide limits, especially with the relative size of the air gap in the finished assembly. The overall permeability of an assembly, µ, is given by the formula [ ] where µm is the permeability of the core material, l the total length of the magnetic path, and a the length of the air gap. Fig 1 shows the variation of the overall permeability with the permeability of the core material, calculated according to Eq I for an air gap of 1 pct of the total length of the magnetic circuit. It is readily recognized that to use core materials hav-

Jan 1, 1948

By Robert Steinitz

Soft iron parts for magnetic applications, particularly pole shoes, constitute a major portion of the ferrous products of powder metallurgy. The residual pores in pressed and sintered parts reduce values such as the magnetic permeability but service experience extended over a number of years has proven beyond doubt that in many instances the lower density of powder parts is not prohibitive to their use as replacement of machined magnetic parts. The magnetic requirements for pole shoes, particularly the permeability, vary within wide limits, especially with the relative size of the air gap in the finished assembly. The overill permeability of an assembly, is given by the formula where is the permeability of the core material, I the total length of the magnetic path, and a the length of the air gap. Fig I shows the variation of the overall permeability with the permeability of the core material, calculated according to Eq I for an air gap of I pct of the total length of the magnetic circuit. It is readily recognized that to use core materials hav- A

Jan 1, 1949

By John H. Schemel

Large Zircaloy-2 hammer or press forged bars did not exhibit the uniform excellent corrosion resistance to steam normally expected of the alloy in wrought form. Weight gains of coupons cut from forged bars were 40 to 60 mg per sq dm compared to the 28 mg per sq dm obtained on hot rolled sheet and strip. The mechanism of this corrosion and its relation to microstructure is discussed. After these observations, a solution heat treatment followed by rapid cooling was tried on coupons from eight heats of forged bars. The basket-weave structure resulting from the quench did not show agglomeration of intermetallic compounds. These coupons showed uniformly good corrosion resistance with weight gains very close to the 28 mg per sq dm expected of Zircaloy-2 after the 14-day steam test. A large forging was solution heat-treated and tested for structure, mechanical properties, and corrosion resistance. Corrosion resistance was excellent and uniform throughout the section. The normally anisotropic mechanical properties were changed to completely iso-tropic. Strength levels were raised while there was a small loss in ductility at the service temperature. Tempering of the quenched structure below the ß transus did not improve the ductility at the test temperature of 600°F. ZIRCALOY-2 end caps for nuclear fuel elements Zircaloy-2 is an alloy of 1.5 pct Sn, 0.1 pct Fe, 0.1 pct Cr, and 0.05 pct Ni, balance hafnium-free zirconium patented by Westing-house Electric Co. used in pressurized water reactors are machined from large hammer-finished forged bars. The bars forged for this application range from 3 1/2 in. to 7 1/2 in. squares. One of the tests used to evaluate Zircaloy-2 for this service is a 14-day exposure to very high-purity steam at 75oF and 1500 psi pressure. Normally wrought products will exhibit a black lustrous film of zirconium oxide after the test and show a weight gain of approximately 28 mg per sq dm. Coupons representing the forged bars exhibited a wide variety of corrosion results ranging from acceptable black coupons to some covered with white crystals of zirconium oxide that had weight gains of nearly 100 mg per sq dm. One of the most common effects was a white corrosion product that looked like a stain to some observers and the outline of massive metal grains to others. Very careful specimen preparation prior to the corrosion test did not affect the result and metallographic examination did not reveal a structural feature of a size and shape that would correlate with the corrosion product. In addition to the relatively poor corrosion resistance, the forged product was not as ductile as desired. The problem of obtaining uniform and more acceptable properties in these heavy-forged sections seemed to be a function of the microstructure of the metal and, in particular, the distribution of the intermetallic compounds. None of the four alloying elements however are appreciably soluble in a zirconium and are present as compounds which usually appear scattered randomly throughout the structure. Moudryl showed that the distribution of these intermetallic compounds in Zircaloy could be related to a ostringero corrosion failure. Grozier et al. discussed another structural defect that causes a similar corrosion effect. In this case, an elongated gas-void was determined to be the cause. M. L. Picklesimer held in his discussion of the Grozier paper that at least a part of the observed =stringersn were caused by the distribution of the intermetallic compounds. He proposed a

Jan 1, 1962

By FOSTER HEWElT

THE scope of this paper is the description of two districts in Peru in which deposits of vanadium have been found, and the consideration of much laboratory-work that I and others have done to determine the nature of these deposits. It is with regret that I present some of the data in a state of evident incompletion, particularly the analyses of a few of the minerals, which leaves some doubt as to whether the true nature of the minerals is understood. I make no apology, however, since in this case, as in many others referring to ore-deposits, conclusive opinions cannot be stated until a great amount of work has been done, and the deposit has been thoroughly exploited. I believe that the data and the tentative conclusions here presented indicate a unique and interesting condition which may assist others in work along similar lines; and further, what is of more practical importance, stimulate a search for a metal which, though long considered rare, is probably so merely because proper care has not been taken to recognize it. An excellent bibliography on the occurrence of vanadium in nature is given by F. W. Clarke in his paper, Data of Geo-chemistry;1 and in the preparation of this paper I have consulted many of the references contained in the Bibliography of the Chemistry of Vanadium, by M. Moissan.2 A brief review of the subject having special reference to the metallurgy of vanadium is contained in the small book by P.. Nicolardot.3 One of these vanadium-deposits has already been briefly

Mar 1, 1909

By L. T. Sanchez, W. T. Rogers

This paper presents the results of a production experiment evaluating the effect of the use of oxygen in the bessemer converter with respect to its relation to blowing time, amount of steel scrap or cold pig iron which can be melted and teeming temperatures of the molten steel. THE simplest and probably the most efficient and economical means for producing steel from molten pig iron is the bessemer converter. This process is essentially a mechanism for bringing oxygen into contact with the molten metal thereby oxidizing the elements silicon, manganese, and carbon. The source of oxygen is that contained in the air and is limited by that amount. In theory, there is an intermediate chemical reaction due to the mass action of iron and air which is represented by the equation: 2Fe + O2- = 2Fe0 The FeO then becomes the oxidizing agent and reacts with the silicon, manganese, and carbon to produce silicon dioxide (SiO,), manganese oxide (MnO), and carbon monoxide (CO), in the order mentioned. The balancing of the various chemical reactions shows that in the ordinary bessemer process more than sufficient oxygen is delivered to satisfy these reactions, which indicates that a further increase in the oxygen content of the air would serve no useful purpose. In spite of this reasoning, however, it will be demonstrated that when melting stelel scrap, commercially pure industrial oxygen introduced into the normal air blast will permit the melting of a larger proportion of steel scrap than is possible with air alone and also will increase the production rate by a substantial reduction in blowing time. It will also be shown that when melting cold pig iron, it is possible to melt up to twice as much pig iron with the use of oxygen as can be melted without added oxygen with a nominal increase in blowing time. At the plant where this study was made, oxygen is purchased from a nearby supplier and piped directly into the plant. It is supplied to the bessemer converter by being introduced directly into the blast line through an automatic control system which may be adjusted by the bessemer operator or "blower." Normally, iron is supplied by five blast furnaces to an open hearth shop containing twelve 165-ton capacity stationary furnaces and a bessemer converting shop having three 30-ton converters. The molten metal from the blast furnaces is allocated to one shop or the other in a manner to best provide for maximum production. At various times, it is desirable to direct the maximum amount of available blast furnace production to the open hearth shop. This has the effect of reducing the production of the bessemer shop. When this condition exists, it is desirable to supplement the reduced iron charge at the bessemer with steel scrap or cold pig iron to the maximum possible extent in order to maintain high total ingot production. This condition becomes aggravated when one of the blast furnaces is taken out of production for any repair job and particularly for extended periods such as when relining is necessary. The purpose of the investigation and experimentation with oxygen was to determine whether or not it would contribute to increased flexibility in the use of the raw materials, molten iron, steel scrap, and cold pig iron. In addition to the effect of oxygen on flexibility of operation, it was also necessary to determine the relation of its use to production rate or "blowing time," final finishing temperature of the steel or "teeming temperature," and steel quality.

Jan 1, 1953

By F. V. Lenel

This discussion is concerned with the method of manufacturing, the design possibilities, and the properties of pole pieces for direct-current electric . motors and generators made from iron powder. In such applications as pole pieces, the electric and magnetic properties of the material are of major importance, therefore they are discussed somewhat more fully. However, the main advantage in making pole pieces from powders lies in the rapid and inexpensive method of manufacturing these pieces, and in the flexibility of design, rather than in their superior electrical properties. As a matter of fact, pole pieces from iron powder have found their principal field of usefulness in small electric motors for controls and similar applications where the highest possible flux density in a given design is not required. Fig. I shows a number of different designs for pole pieces made from iron powder. The steps involved in fabricating them are: (I) briquetting—with each stroke of the briquetting press a complete . pole piece is produced; (2) sintering, and (3) sizing, which is a one-step coining operation in a hand-operated punch press. Conventionally small pole pieces are made from laminated electrical sheet steel stock by punching out the laminations and riveting them together (Fig. 2). The powder method has the advantage of being rapid and inexpensive; also, it makes possible the molding of pole pieces with a round hub, which are better from a design standpoint, as will be shown later. It is difficult to make such round-hubbed pieces from laminated stock. The pole pieces could, of course, be machined from solid stock, but this method is not widely used. The raw material for making pole pieces from powder is straight iron powder without the addition of any alloying ingredients. However, the grade of powder used is of considerable importance, as will be shown later when the influence of the grade of iron powder upon the magnetic properties is discussed. Pole pieces are briquetted in the same way that other iron-powder machine parts are made. Because the pole pieces are flanged—i.e., they have a hub and a wing section—they are made in presses that apply pressure from both ends. For best mechanical and magnetic properties, the density throughout the piece should be even and also should be constant from piece to piece. For that reason a powder of constant compressibility from batch to batch is needed for briquetting pole pieces. One method of obtaining the required magnetic properties is to sinter the pole pieces at temperatures higher than are used for most iron-powder parts. A temperature of 2400°F. and an atmosphere of hydrogen has been found satisfactory. No automatic furnaces of the roller hearth or mesh-belt type have yet been developed for such high temperatures. A box-type furnace heated with Globar heating ele-

Jan 1, 1945

By M. E. Lombardi

Discussion of the paper of AI. E. LOMBARDI, presented at the San Francisco meeting, September, 1915, and printed in Bulletin No. 105, September, 1915, pp. 2109 to 2114. C. D. KEEN, Shreveport, La.-Did Mr. Lombardi include in his figures the purchase price of the property? M. E. LOMBARDI, Berkeley, Cal.-No. C. D. KEEN.-Suppose I pay $1,000 per acre for it, and in four or five years it is worked out. M. E. LOMBARDI.-That is a question of depreciation and must be added to my figures. MARK L. REQUA, San Francisco, Cal.-You say it cost $35,000 to $40,000 a year to maintain 1,000-bbl. per day production? M. E. LOMBARDI.-Yes, 1,000 bbl: a day would cost $40,000 a year to maintain.

Jan 12, 1915

By C. M. Loeb, A. M. Gaudin, J. H. Brown

R. E. Carter (General Research Laboratory, Schenec-tady, N. Y.)—Brown, Gaudin, and Loeb in their study of intergranular comminution by heating attempt to find one explanation for all types of rock in terms of the properties of the phases present. The only necessary condition for intergranular cracking by heating is the setting up of high stresses at the grain boundaries. Such stresses may be set up in multiphase isotropic mixtures if the thermal expansions of the phases are different, in non-cubic single phases because of the anisotropy of thermal expansion in the various crys-tallographic directions, and in materials containing quartz because of the a-p' transformation at 575°C. In addition, for intergranular comminution by heating, the cooling and not the heating is most important.

Jan 1, 1960

By R. McDonald, B. C. Maine

CERRO'S power system consists of three main hydroelectric plants and one steam-electric plant. These are located on the eastern slope of the main Andes range at altitudes between 12,000 and 13,000 ft. The hydroelectric group utilizes the watershed which extends for about 150 kilometers south from Cerro de Pasco, divided into two catchment areas which lie adjacent. The northern area serve,, the medium-head plant of Mal¬paso. while the southern area provides for the high-head plants at Pachachaca and Oroya. The rainfall, as registered at the rain gauging stations of the three hydroelectric plants, averages 33 in. per year; all these stations are subject to the same hydrological conditions, and the bulk of precipitation occurs between October and March. Rainfall during the dry season, April till September, has no appreciable effect on the total annual runoff. Table 1 shows the storage capacities of the main reservoirs of the hydroelectric group. The four plants are tied together electrically by a 50-kv. transmission network, the system being 3-phase 3-wire at 60 cycles with a solidly grounded

Jan 1, 1945

By Walter Miller

AFter a year's continued impact of war, the task of the petroleum-refining industry stands out clearly and looms up in larger aspect. This time it is not, as it was so largely in the first World War, simply a matter of increased quantity—more and more of the same petroleum products that had substantially been standard for years. In this era the emphasis is largely on newer and improved materials which had been produced, if at all, in comparatively insignificant quantities, and for which manufacturing equipment was not available on a large scale. At the beginning of 1942 four great product needs (besides a number of lesser ones) confronted the industry: 100-octane aviation gasoline, toluene for T.N.T. production, high-quality lubricating oils for aviation and Army equipment service, and petroleum chemicals for synthetic rubber manufacture. The difficulty in presenting a review of engineering progress in petroleum refining during 1942 is that there is so little one is free to say about so much which has been and is being accomplished. At the opening of 1942 the program was to increase the then existing capacity of 50,000 bbl. a day of aviation gasoline to over 150,000 bbl. daily by building new plants at an estimated installation cost of $150,000,000. Later in the year. after the announcement by President Roosevelt of a large increase in the program for war-plane building, additional contracts were made between the Reconstruction Finance Corporation and rehers to raise the capacity to 250,000 bbl. per day. The greatly increased scope of the war activities in all parts of the world, the obligation of the United States as the arsenal of the United Nations, and the greater importance and use of bomber, transport, and cargo planes will undoubtedly bring about plans and installations for a further increase in production of aviation gasoline over the present announced plan. In this connection, Jesse Jones, Reconstruction Finance Corporation Chairman, announced that as of Oct. 31 the R.F.C. had through its subsidiary Defense Plant Corporation entered into contracts for the construction, expansion, or equipping of 28 plants to increase 100-octane aviation gasoline production, but gave no data on 'capacity involved or completion dates. His list did not, of course, include a number of existing plants, and some installations being made by companies who are themselves financing the construction. Production from existing operating installations was materially increased in a number of instances as a result of pooling knowledge of improvements in operation and also by the exchange of Components going into 100-octane blend to enable greater quantities of aviation gasoline to be produced from the over-

Jan 1, 1943

By Walter Miller

AFter a year's continued impact of war, the task of the petroleum-refining industry stands out clearly and looms up in larger aspect. This time it is not, as it was so largely in the first World War, simply a matter of increased quantity—more and more of the same petroleum products that had substantially been standard for years. In this era the emphasis is largely on newer and improved materials which had been produced, if at all, in comparatively insignificant quantities, and for which manufacturing equipment was not available on a large scale. At the beginning of 1942 four great product needs (besides a number of lesser ones) confronted the industry: 100-octane aviation gasoline, toluene for T.N.T. production, high-quality lubricating oils for aviation and Army equipment service, and petroleum chemicals for synthetic rubber manufacture. The difficulty in presenting a review of engineering progress in petroleum refining during 1942 is that there is so little one is free to say about so much which has been and is being accomplished. At the opening of 1942 the program was to increase the then existing capacity of 50,000 bbl. a day of aviation gasoline to over 150,000 bbl. daily by building new plants at an estimated installation cost of $150,000,000. Later in the year. after the announcement by President Roosevelt of a large increase in the program for war-plane building, additional contracts were made between the Reconstruction Finance Corporation and rehers to raise the capacity to 250,000 bbl. per day. The greatly increased scope of the war activities in all parts of the world, the obligation of the United States as the arsenal of the United Nations, and the greater importance and use of bomber, transport, and cargo planes will undoubtedly bring about plans and installations for a further increase in production of aviation gasoline over the present announced plan. In this connection, Jesse Jones, Reconstruction Finance Corporation Chairman, announced that as of Oct. 31 the R.F.C. had through its subsidiary Defense Plant Corporation entered into contracts for the construction, expansion, or equipping of 28 plants to increase 100-octane aviation gasoline production, but gave no data on 'capacity involved or completion dates. His list did not, of course, include a number of existing plants, and some installations being made by companies who are themselves financing the construction. Production from existing operating installations was materially increased in a number of instances as a result of pooling knowledge of improvements in operation and also by the exchange of Components going into 100-octane blend to enable greater quantities of aviation gasoline to be produced from the over-

Jan 1, 1943