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By P Wilson

The Mt. Wright Underground Mine is located near the town of Ravenswood in North Queensland and is operated by Carpentaria Gold – a wholly owned subsidiary of Resolute Mining Limited. The establishment of the world’s first Sub Level Shrinkage (SLS) mine from a tradition Sub Level Open Stoping operation has proven to be a geotechnical challenge which has required tailored solutions to overcome unique issues. This paper will be broken into two distinct sections that will outline: a brief overview of the mining method and how the SLS method was chosen; and how the SLS is managed and key geotechnical learnings. The story of the world’s first SLS originated from the need of a bulk mining method to ensure the viability of Mt. Wright into the future. Traditional bulk mining methods such as; Block or Sublevel Caving were originally ruled out due to the low natural ‘cavability’ of the orebody and the proximity of the orebody to existing major infrastructure (Decline, Ventilation Rises and Egresses). The first section of the paper will outline the key geotechnical information that helped decide the SLS method in addition to how continuous backfill influenced the design. The second section is intended to address issues that the geotechnical engineers encountered since the inception of the SLS. The feature topic of this section is mining induced stress. Like most bulk mining methods, Mt. Wright had success when the production front was running parallel to the stress (production front being ‘shadowed’ from the stress). This was until a design change, forced by a splitting ore body resulted in this shadowing effect becoming harder to achieve. As a result, rehabilitation and production hole re-drilling become a regular occurrence, which teamed with a strict set of access controls made the production cycle longer and harder to complete. CITATION:Wilson, P, 2018. Mt Wright – geotechnical learnings from a sub level shrink, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 119–132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By Charles Tkaczuk

In order to remain competitive the mining industry must keep up with changes in technology. Many innovative technologies from the mining perspective are commonplace in other industries. A ?Global? review of technologies will often reveal existing technologies that can be innovatively applied in the mining industry. Industries, which are rife with proven solutions include, medicine, biotechnology, security, manufacturing, telecommunications, etc. This paper addresses the communications aspect of mining where greater productivity, lower costs and the ability to quickly react to mining related events is obtained through an increase in remote monitoring and operating control. A review of the communications systems in place globally reveals technologies that, with minimal modification, can be immediately applied to the mining environment. We discuss the concept, advantages and implementation of existing communications technology from an industry that is not usually associated with the mining industry. This technology will form the basis of a solid platform on which can be built a state-of-the-art process monitoring, control, and communication system. This lays the groundwork for providing one solution to the underground mining industry?s most difficult problem, establishing a reliable, maintainable and cost-effective underground bi-directional wired/wireless data, video and analog communications system. We need look no further than our own doorsteps to find such a solution. The cable that you see coming from the simple green or brown box on the boulevard into your home contains hundreds of television broadcast channels, FM radio channels and data channels. And if you have a set-top box, you are in control of it all. The Cable Television Broadcast Distribution System suppliers of today are at the leading edge of converging all the different methods of communications onto a common carrier, coaxial cable or fibre optic cable. There is no fundamental difference between providing a reliable communications network to a city/neighbourhood/home/personal computer than there is to a mining operation/underground level/equipment or person. The principle is the same. Only the application is different. Realizing this, we can capitalize on the efforts of other industrial sectors, to solve our communications problem. Where else can you find a solution to a problem that is mature, having been developed with the input of thousands of engineers, and having hundreds of millions of dollars spent on research and development, manufacturing, distribution, global presence and engineering support?

May 1, 2003

By G. M. Brown, B. J. Ebacher, W. G. Koellner

Introduction There is a continual economic push to increase the productivity of mobile material handling equipment used in open pit mines. This includes the largest electrical machines: excavators (draglines and shovels) and haul trucks (Figure 1). Existing DC drive systems used on this type of equipment are a mature technology. They have no further economic potential to accommodate larger equipment be-cause of the high maintenance costs and the trade-off between power, speed and space limitations of their DC traction mo-tors. In recent years the large-scale introduction of AC drives in the rail transportation sector1,and the availability of poworful GTO and IGBT modules have led to the devolopment of compact, powerful, an drugged AC inverter drives specifically adapted to the mining market2,3. The major advantage of AC drives stems from the squirrel cage induction motor which eliminates the DC commutator. This leads directly to higher speed, increased power density, higher reliability, greater efficiency and lower maintenance of the traction motors. In the context of excavators and haul trucks, additional benofits driving the move to AC are (i) increased production rate due to higher machine speed, and power density, (ii) increased reliability and lower cost inverters using 3.3 kV IGBT's, (iii) active front-end (AFE) technology that improves compatibility with the mine power grid and an proved dynamic response,(iv) intelligent converter design that provides increased fault tolerance, (v) contextual maintenance software that facilitates trouble-shooting, and (vi) remote diagnostic capabilities. This paper describes how these and other features of AC drives lead to higher productivity in mining shovels, draglines, and haul trucks. Minimize the cost per ton of material moved The overall goal that drives design and sales of excavators and haul trucks is the constant requirement to reduce the cost per ton of material moved. Whether this involves blasting, loading trucks, or hauling material to the crusher or waste dump, equipment that reduces the cost per ton of material moved contributes to a more profitable operation. An accurate determination of the true cost per ton to move material must consider every aspect of the equipment and the circumstances under which it is used. Procurement and capital costs, fuel, operating, and maintenance costs over the useful life, and eventually the cost of scrapping should all be taken into account to determine the real cost per ton of moving material. We will focus on two broad areas that relate to the equipment itself; factors influencing the amount of material moved (Table I) and factors influencing the cost of material moved (Table II). Emphasis will be given to those elements in the tables that most influence the productivity of excavators and haul trucks due to the application of AC drive technology. Maximize the amount of material moved Maximize production rate he production rate refers to the quantity of material that can be loaded or moved per hour. This generally involves larger, faster, and more powerful equipment that operates more reliably to minimize down-time. AC motors Figure 2 compares the hoist motor speed-torque response of two 77 t (85 short ton) shovels, one AC the other DC. The absence of commutation limits on the AC motors enables the AC shovel to operate with a greater area under the speed-torque curve, resulting in faster lowering speeds and reduced times for the swing to return to the pit. This is especially important for short swing angles where the operator may have to wait for the dipper to lower. Reducing the cycle time by 6 to 8 seconds at the shovel translates into an increase in shovel production of about 20%. Larger equipment The bucket capacity of excavators has increased approximately 100-fold over the last century. Figure 3

Sep 1, 2001

By P. Nicholls

Patent records show that the idea that the burning of fuels can be improved by mixing or pretreating them with chemicals 6 dates back to the early years of the last century. By 1845, English and French patents included the specific beneficiations of elimination or reduction of smoke, soot, and clinker; reduction of the ashes, presumably meaning the total weight of refuse from the ashpit; elimination of sulphur fumes; increase in the rate of burning; increase in the time a given charge of fuel would last; and, in most patents, a saving of fuel. The earlier patents specified additions up to 80 pounds or more per ton of fuel, but after 1860 the quantity was rarely more than 4 pounds. There is no record of the extent to which these patents were commercialized, but after 1884 many American patents were assigned to companies specializing in treatment of coal, so it is probable that the products were marketed on a considerable scale at least as early as that date. From 1900 on, many companies marketed proprietary products that were sold under the general name of "fuel savers." Since its establishment in 1910, the Bureau of Mines has continually received inquiries about these products and, at the request of other govern-mental departments, has tested some used in accordance with the instructions of the purveyors; the results were all negative and, within the accuracy of measurements, the products had no effect on the burning.

Jan 1, 1937

By Frank E. Cash

"INTRODUCTION The iron—ore ranges in the Lake Superior district are the Marquette in Michigan, Menominee and Gogebic in Michigan and Wisconsin, and the Cuyuna, Mesabi, and Vermilion in Minnesota. These ranges produce about 85 percent of the iron ore mined in the United States. Accident experience in connection with this production is better than that of the regions producing the remaining 15 percent. Production and shipments vary slightly from year to year but closely approximate each other over a period of years.This information circular supplements, continues, and combines the data in Information Circular 7321,2/ including figures of 1944 and 1945.During the 6—year period 1940 to 1945, inclusive, 481,485,475 long tons of iron ore was shipped from the Lake Superior district. 4/ Michigan and Wisconsin shipped 93,787,648 tons, or 19,5 percent of the total, and employed annually an average of approximately 14,300 men; Minnesota shipped 387,697,827 tons, or 80,5 percent, and employed annually an average of approximately 9,300 men. The tons produced per man employed is much greater in Minnesota than in Michigan and Wisconsin, owing to the large open-cut production in Minnesota."

Jul 1, 1947

By C. Guney Olgun, Charles Elks, Sherif L. Abdelaziz, James R. Martin, Christopher Fox, Pier Luigi Iovino, Fatih Catalbas, Pierre Gouvin

"Energy piles are a new innovative renewable energy technology to access and exploit the relative constant temperature of the ground for efficient heating and cooling of buildings. Examples of energy piles include drilled shafts, continuous flight auger (CFA) piles, driven piles, and micropiles. A field test setup was installed at the Virginia Tech Geotechnical Research Facility to study energy piles. The field test consists of a total of five micropiles 25 cm (10 inches) in diameter, four of which were equipped with circulation loops. The test piles extend to a depth of 30.5 meters (100 feet) and are heavily instrumented with strain gauges and temperature sensors. Several observation boreholes were formed around the test piles to monitor ground temperatures. Thermal conductivity tests and field load testing were performed to investigate the behavior of Energy Piles. This paper presents results of the thermal conductivity tests and thermo-mechanical field load test performed as part of this field investigation.IntroductionThere is a developing trend around the world to explore alternative energy sources. The main driving forces are growing global energy demand, depleting natural resources and the adverse effects of greenhouse gas emissions from fossil fuel consumption. Geothermal energy is one of the promising renewable sources that can be utilized to offset such trends. However the use of geothermal energy has been limited mainly to certain hot spot areas where it is used either for district heating and/or electricity generation. Ground temperatures below a depth of about 6 meters (20 feet) remain stable compared to outside air temperatures, typically lying between 8-23°C (46-73°F) at most U.S. regions. The constant temperature and heat storage capacity of near surface soils in any region represent a tremendous potential of stored energy that can be used for heating and cooling of structures."

Jan 1, 2017

By William H. Shockley

THERE was an, extensive mining and industrial exploitation of Russia, about 20 years ago, by Belgian, French and British capitalists; but the results were discouraging. It is said that the Belgian and French public together lost approximately $400,000,000, chiefly in the coal and iron industry of southern Russia. This loss is largely accounted for by the fact that most of the companies were formed, as usual in " boom " times, to sell stock; and that thorough investigations were not made. In 1906, renewed interest was taken in Russian mines, especially in those of gold and copper, and a considerable literature is growing on this subject; but as yet I have seen no account of one of the large Russian mining estates. The following notes on such property, where the conditions are so different from those in the mining regions of the United States, should be of interest This inadequate and probably somewhat inaccurate account is made up, partly from my own notes made on the ground, in the summers of 1904 and 1905, and partly from a volume on the geology and resources of the estate issued several years ago, containing surface-and mine-maps, and from a pamphlet published in 1904, giving a general account of the condition and prospects of the property. This pamphlet includes a report made by Arthur L. Pearse, a member of this Institute, in 1899. Both these books are in Russian, and were prepared by the Bogoslovsk Mining Co., which owns and operates the property. Articles in many other languages have appeared dealing with various matters connected with the estate; but I know of no other general account of it. In numerous books and articles on the Urals and Siberia, however, localities are described in which somewhat similar conditions prevail. Recent papers by

Mar 1, 1908

By I M. Platten, S C. Dominy

The Clogau St DavidÆs gold mine has a recorded production of around 81 000 oz Au and it is the largest mine in the Dolgellau gold-belt and BritainÆs most prolific historical producer. The original mine was first worked for copper, however; in 1854, gold was found in waste material from the St DavidÆs section. In recent times the mine has operated intermittently between 1983 - 2007. The principal black shale-hosted gold-bearing reef (Main Reef) can be traced for about 3 km, striking approximately NE-SW and dipping steeply between 60¦ - 90¦ SE. The reef system pinches and swells, changes strike and splits into a number of smaller branches. Reef width is variable, ranging from over 6 m to a few cm and in places reducing to small irregular blobs. The reef is internally complex and composed of swarms of narrow (1 - 300 mm) subparallel veins separated by country rock sheets. The gold-bearing veins within the reef package are discontinuous; though generally possess bonanza grades running 10s - 100s oz/t Au. It has historically been shown that some gold-rich vein segments can grade up to 300 oz/t Au. The predictability of the gold-rich segments is poor, but has been shown to be related to presence of the Clogau (black shale) Formation, and/or the mechanical interactions of the reef with greenstone sills, reef branching and splitting and/or cross-fractures to form ore shoots. The mine is currently being re-evaluated as a potential small-scale selective operation.CITATION:Dominy, S C and Platten, I M, 2012. Geology, mineralisation and potential of the Clogau St DavidÆs mine, Dolgellau gold-belt, Gwynedd, Wales, in Proceedings Narrow Vein Mining 2012 , pp 101-120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 26, 2012

By J. C. Vreugdenburg, B. A. Dippenaar, J. Muller, T. L. de Vries

Iron ore fines are agglomerated in the sintering process to produce sinter: an important feed material for blast furnaces worldwide. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed mixtures is evaluated. The model aims to predict sinter quality, including chemical quality and physical strength, as well as key sinter process performance parameters such as production rate and fuel consumption rate. The model uses the finite difference method (FDM) to solve heat and mass distributions within the sinter pot over the sinter bed height and time dimensions. This method can further be used for establishing empirical relationships with measured sinter properties. Inputs into the model include the feed material physical properties, chemical compositions, and boundary conditions that vary over time. Sub-models describe relationships between applied pressure differential and gas flow rate through the bed of granulated fine ore particles, combustion of carbonaceous material, calcination of fluxes, evaporation and condensation of water, and melting and solidification. Four sinter pot tests were performed and the model predictions validated against temperatures measured at depths of 100, 230, and 420 mm. Differences between predicted and measured temperatures indicated the need for optimization of some model parameters that are uncertain. Optimization resulted in an improvement in the correlation between the predicted and measured temperatures for all tests, although an acceptable level of agreement was not achieved in all cases. Using these parameter values, reasonable agreement was found in terms of typical performance parameters for three out of the four tests.

Jan 1, 2014

By R. J. Kuczynski

The U.S. Bureau of Mines Reno Research Center investigated, developed, and patented a high-temperature cyanide leaching process for recovering platinum-group metals (PGM) from automobile catalysts. A batch pilot plant was constructed at the center and operated to demonstrate this technology to industry. Approximately 1,600 kg of used pellet, monolith, and metal support catalysts containing 1,700 g (54 tr oz) of PGM was processed. Forty-five-kilogram batches of used catalysts were leached with sodium cyanide solution at 160°C for 1 h in a countercurrent processing sequence. This selectively dissolved the PGM. Average extractions from the used pellet catalyst were 96 pet Pt, 95 pct Pd, and 73 pct Rh. Average extractions from the used monolith catalyst were 84 pct Pt, 81 pct Pd, and 66 pet Rh. Heating the pregnant leach solutions to 275°C for 4 h destroyed the PGM-cyanide complexes, causing over 99.7 pct of the PGM to precipitate from solution. The PGM precipitate was predominantly a metallic powder concentrate, typically analyzing greater than 50 pct PGM. Heating destroyed the cyanide to less than 0.2 mg/L free and total cyanide. Both the pellet and monolith residues were evaluated for disposal using the toxicity characteristic leaching procedure developed by the U.S. Environmental Protection Agency.

Jan 1, 2010

By A. M. Cummings

Each mining district presents different problems as to the methods of ore extraction cad underground support, which are dependent upon the type of the ore deposit and the character of the inclosing rock. Mining costs, however, depend largely aeon the efficiency with which the methods employed underground are [applie] as well as upon the selection of the method best adapted to the physical conditions. The purpose of this paper is to present to the operator in other districts a detailed description of ho mining method used ins results obtained in tie exploitation of the bedded magnetite deposits of the Mineville district. The town of Mineville is situated in the Adirondacks, five miles west of Port Henry on Lake Champlain.

Jan 1, 1928

G. A. Moore—The tin-fusion method has been a very favorable possibility for many years. The authors apparently have settled the question that delayed the method for a long time by showing that no hydrogen is absorbed in the tin. This, of course, is very important. I want to make a few remarks concerning the absolute accuracy of analysis, which must be the final basis for deciding among the various methods. From the figures in the paper, there seems to be some re-maining slight discrepancy on the actual amount of hydrogen present in various samples which may be presumed essentially identical. (This is of the order of the precision of individual analyses but appears in averaged results.) From the analyst's viewpoint, the tally of hydrogen content can be regarded as occurring in three portions. First is a large portion which comes off easily and automatically during sample storage and later on heating in the apparatus. This is fairly easily analyzed. Second is an item which may be either positive or negative in the tally sheet. In warm or hot evolution, this is a portion which, in practice, can never be re-

Jan 1, 1951

By Jan Lückhoff

The introduction of the EAF Quantum furnace by Primetals Technologies represents an important milestone in the field of electric steelmaking during the last 15 years. In this process the latent and chemical heat of the off-gas generated during a melting process in an EAF is used to pre-heat scrap in an integrated shaft prior the melting of the scrap in the vessel. Combining proven own technologies, Primetals EAF Quantum enables nearly continuous process, cutting down idle times and enhancing availability for production. The essential benefits will be shown in this Paper.

Aug 16, 2017

By Michael Bourassa, Sonja Felderhof, Normand Champigny, Steve Vaughan

Introduction -Comparison of International Reporting Standards (Sonja) -Legal and Due Diligence Requirements for Reporting (Steve) -Flexibility to Recognize International Reporting Standards (Michael) -Obligation of SRO’s to Discipline (Michael) -Impact of Sarbanes Oxley on Reporting (Normand)

Jan 1, 2003

By Art Hamid, Manfred Wong, Carlos Jaramillo, Greg Raines, John Caulfield

"The Central Bayside System Improvement Project (CBSIP) is a critical element of the Sewer System Im-provement Program (SSIP), a 20-year, $6.9-billion investment by the San Francisco Public Utilities Commis-sion (SFPUC) to upgrade San Francisco’s 100+ years old seismically vulnerable combined sewer system. The CBSIP’s centerpiece, a proposed 10,000-foot-long (3,048-meter-long) Channel Tunnel, will provide reliable and redundant gravity conveyance and storage of combined wastewater flows from the northern and central parts of San Francisco to the Southeast Water Pollution Control Plant (SEP) while ensuring compliance with regulatory requirements for combined sewer discharges to the Bay. A tunnel with a diameter of 23 to 30 feet (7 to 9 meter) is being planned using pressurized-face tunnel boring machine technology. Project challenges include tunneling through Franciscan Bedrock, mixed ground conditions in close proximity to the Bay, connector tunnels and shafts, construction in congested urban environment, and challenging real estate issues for shaft access. BACKGROUND AND NEED FOR TUNNEL The City of San Francisco is one of the most beautiful cities in the world. About 850,000 people live in the city and many more come to work, for tourism, and for attending conferences. The SFPUC is a department of the City and County of San Francisco that provides energy, drinking water and wastewater services to San Francisco, wholesale water to three Bay Area counties, and green hydro-electrical and solar power to San Francisco municipal departments. The SFPUC wastewater system includes tunnels, large storage/transport boxes, 1000 miles of collection sewers, 28 pump stations, and three wastewater treatment plants. San Francisco’s combined sewer system collects both wastewater and stormwater in the same sewers, which is then pumped, treated to stringent state standards and discharged into the San Francisco Bay and Pacific Ocean. After decades of service, much of the sewer system is nearing end of its working life. During the 1989 Loma Prieta earthquake, damage to SFPUC water and wastewater infrastructure was extensive. The 11,200-foot-long (3,400-meter-long), 66-inch-diameter (1,676-mm-diameter) Channel Force Main, built in 1976, and a critical component of the SF wastewater system was also damaged. This force main carries 70 percent of the bayside dry weather sewage flow from the northern and central part of the city to the SEP. The force main is at the end of its life and was not constructed to the current seismic code; in addition it has no redundancy. Figure 1 shows the project background and the force main that will be provided redundancy by the new gravity tunnel."

Jan 1, 2016

By Dan Brown

Improvements in construction equipment and techniques in recent years have made possible the use of drilled shaft foundations in diameters and lengths not previously considered practical or feasible. Many highway bridge and other structures are now routinely founded on drilled shafts which -are 8 to 12 feet in diameter and extending over 200 feet in depth below grade. There are unique challenges associated with constructing such large and deep cast-In-place foundations and engineers should be aware of the special needs associated with site investigation, construction specifications, material requirements, and quality assurance. This paper outlines a number of special considerations for these foundations, along with strategies that may be employed to improve the reliability and quality of large drilled shaft foundations.

May 11, 2007

By Verya Nasri, James Sullivan, Alex Varas

"INTRODUCTION Many major cities in the United States have a combined storm water and sanitary sewer network. Regular rainfall overwhelms the system capacity and results in millions of cubic meters of untreated sewage being dumped into local waterways. One legally mandated solution includes several kilometers of large diameter shallow or deep rock or soil tunnels, a pump station as well as associated collection sewers, diversion structures and drop shafts. In this paper, the basis for design of different system elements including the drop shafts and pump station is explained in detail. Common construction methods used for different type of shafts including tangential vortex and baffle plunge, and also pump station alternatives comprising cavern or various shaft configurations are discussed. DIFFERENT TYPES OF PUMP STATIONS The dewatering pump station serves as the heart of any deep CSO tunnel system and is critical to the goal of reducing CSOs by providing a controlled release of the stored tunnel volume to the wastewater treatment plant. As the major mechanical component of the project, the station will require the greatest attention by operations and maintenance staff. Designing a durable and easily operated pump station requires addressing some major challenges, including the following: • Longevity – equipment, materials of construction, and station environment • Controlling odors • Safety for operators and maintenance personnel • Easy access to equipment • Protection from hydraulic surges Location. Owners face a fundamental decision relative to the location of the pump station, which will affect how these challenges are addressed. The pump station can be built within the tunnel launch shaft or within its own dedicated shaft. This decision is driven by cost and schedule. Use of the tunnel launch shaft may provide owners cost saving opportunities by not having to construct a separate pump station shaft. However, this will likely extend the pump station construction as much as two years until the tunneling has been completed. Furthermore, delays to the tunneling operation would delay the pump station construction work, potentially leading to delay claims. For this reason, it has been more common to utilize a separate pump station shaft on recent CSO tunnel projects (Nasri et al. 2015)."

Jan 1, 2016

By S. J. Aresco

The Bureau of Mines has been active in promoting the purchase of coal for Government use under specifications that define the requirements in terms of heating value of the coal, expressed in British thermal units, and the composition as shown by proximate analyses. To these, when required, are added the ash-softening temperature of ash, the free-swelling index, and the Hardgrove grindability index. Under most of these specification contracts the bidders guarantee the quality of the coal, and that guaranteed by the successful bidder becomes the standard of his contract. The deliveries are sampled in accordance with instructions~ issued by the Bureau of Mines; the samples are analyzed in the Bureau laboratory to determine whether the coal is of the quality guaranteed by the contractor and, if it is not, a price adjustment is made. Analyses of the delivered coal and tipple samples (samples collected at mine tipples as coal is being loaded into railroad cars or trucks) provide valuable data for use in evaluating future bids. In addition, the continuous sampling of coal as delivered is a check on the practical results obtained in burning the coal.

Jan 1, 1956

By H. S. Auvil

[Coals of low-volatile rank cannot be coked without admixing large proportions of high-volatile coal in the usual type of byproduct-coke oven, because they expand excessively and exert side thrust, which ruins the oven walls. Some medium-volatile coals also give trouble. Since high-rank coals produce a strong, blocky coke, it is desirable to have the rank as high as practicable, particularly in the manufacture of foundry coke. Accordingly, it has become the practice to mix or blend high-volatile shrinking, coals with as much low-volatile coal as possible and still have a mixture that will not deform the walls or cause difficulty in pushing the coke. Occasionally, the safe limit of low-volatile coal has been exceeded and ovens have been damaged. It is desirable, therefore, to rave a reliable method of determining the expanding tendencies of mixtures before they are charged into the ovens. Furthermore, coal charges somewhat in its properties as mining progresses, and therefore, mixtures found to be safe at one time may cease to be so subsequently, particularly if nearly the maximum allowable percentage of low-volatile coal is being used.]

Jan 1, 1938

By Y. Ono

In lightweight metal processing such as aluminum (AI) and magnesium (Mg), metal cleanliness is a crucial process parameter for refining, part manufacturing and recycling in order to obtain high quality parts and products. In this paper, techniques for cleanliness evaluation of molten AI and Mg using ultrasonic probes with clad steel buffer rods having high signal-to-noise ratio (SNR) are presented. Due to the high SNR of the ultrasonic probes used, backscattered ultrasonic signals from inclusions, which may be oxide films and/or particles, in molten Mg and those from silicon carbide particles, having an average size of 50f.Ull, added in molten AI are successfully detected with reflection configurations of pulse-echo and/or pitch-catch modes at an ultrasonic frequency of 10 MHz. In addition, relative cleanliness evaluation of molten Al and Mg is demonstrated. In order to establish the procedure and to investigate the optimum system configurations for cleanliness evaluation of molten metals, particle flow simulation system using water and polyvinyl chloride (PVC) particles has been constructed. Counting the number and measuring the size distribution of the PVC particles, having an average diameter of 128um, suspended in water with the PVC volume concentrations of 5ppm and 10ppm are performed with ultrasonic pitch-catch mode. The counted numbers of particles by the presented method and system have good agreement with the calculated results with a count error of less than 10% or two counts. Based on the results obtained with water simulation experiments, the prototype system for cleanliness evaluation of molten Mg by counting and sizing inclusions has been developed. Keywords: Ultrasound, Clad buffer rod, Molten metal, Aluminum, Magnesium, Inclusion detection, Cleanliness measurement, Counting, Sizing

Jan 1, 2003