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By W. F. Rochow, W. C. Burke

Numerous designs of linings and accessories, including dams, lifters, and heat exchangers, contribute greatly to kiln efficiencies. Greater conductivity is achieved with basic brick than with fireclay and high-alumina refractories, depending largely upon the use of steel plates in radial joints between adjacent brick to increase heat transfer through the lining. Refractory lifters expose all portions of the load to radiant or convective heat and raise some portions to higher temperatures by cascading the load down through the path of the hot gases. AMONG the many factors involved in rotary kiln efficiency, advantageous use of refractories is of major importance. So far as kiln lining alone is concerned durability is most significant, as shutdowns for repairs are costly in fuel consumption and production losses. Aside from selection of refractories best suited to the widely varying conditions under which rotary kilns are operated, lining design and accessory constructions within the kiln are highly important. The refractory most economical for any combination of operating conditions can be selected from a wide range of alumina-silica and basic refractories, including insulating, castable, and plastic fire bricks. In several cases silica brick can be used to advantage. Alumina contents of alumina-silica refractories range from 35 to 90 pct in increments of 5 to 10 pct. In general, bricks of relatively low alumina content are best for abrasion resistance, an important property for the brick used in chain sections of cement kilns or in feed end sections of limestone kilns. High-duty fireclay bricks of approximately 40 pct alumina and 55 pct silica are used to line the intermediate zones. Super-duty fireclay brick at slightly higher cost is warranted in operation of kilns with high intermediate zone temperatures and severe spalling conditions. Alumina-silica refractories with an alumina content of 50 pct and higher, termed high-alumina brick, are available in commercial classes of 50, 60, 70, 80, 85, and 90 pct alumina content. These refractories are generally used as high temperature zone linings or placed adjacent to the basic brick-lined sections when the treatment they are required to withstand is excessively severe. Use of basic refractories is confined mainly to zones of maximum temperature and most severe chemical action. Basic refractories ordinarily employed for high temperature zone linings of many rotary kilns comprise the classes shown in Table I. Each class is peculiarly well suited to various particular combinations of working conditions. The approximate chemical analyses of these classes also illustrate differences in compositions with respect to the major components.

Jan 1, 1956

By O. B. Ellis, Eric R. Jette, John Chipman

In the study of the chemical reactions orcurring in the open-hearth furnace, it is frequently assumed that a condition of equilibrium between slag and metal is attained. In order to test this assumption it is necessary to have dependable operating data as well as an exact knowledge of the equilibrium state. Considerable progress has already been made in the study of slag-metal equilibria, notably in the earlier work of Hertyl and of Oberhoffer and Schenck2 and in the more recent researches of Krings and Schack-mann3 and of Koerber and Oelsen.4 None of these investigators, however, have employed basic slags comparable to those encountered in basic open-hearth practice, so that up to the present time our only information regarding the equilibria of these slags is based upon observations drawn from steelmaking practice in which there is little assurance that actual equilibrium was attained. The original plan of this investigation was to secure simultaneous slag and metal samples at intervals during the making of an open-hearth heat, recording the heat history in detail and obtaining complete allalyses of slag and metal, then to bring these slag samples into equilibrium with liquid iron in the laboratory induction furnace and thus to determine directly whether or not the observed relationships in the open hearth represent conditions approaching equilibrium. This plan was only partly successful. While slags were obtained from the open hearth under satisfactorily recorded conditions and these were re-melted in the laboratory under equilibrium conditions, changes in slag composition, which accompanied the remelting operation, were so great that the final slag from the induction furnace bore little resemblance to its open-hearth parent and the direct comparison was therefore abnndoned. The results, however, lie within a range of slag composition that is of interest in the making of low-carbon steel. As far as we are aware, they represent the first published laboratory study of equilibria involving slags that contain all the con stituents of basic open-hearth slag. Experimental Heats The first set of measurements on slag-metal equilibrium was made in the Research Laboratories of the American Rolling Mill Co, at Middletown, Ohio. This will be known as series A. The second set was made in the Metallurgical Rescarch Laboratories at Massachusetts Institute of Techology, and will be referred to as series B. Series A.—The induction furnace used has been described. Approximately I kg. of a special ingot iron containing less than

Jan 1, 1941

By John Chipman, Eric R. Jette, O. B. Ellis

In the study of the chemical reactions orcurring in the open-hearth furnace, it is frequently assumed that a condition of equilibrium between slag and metal is attained. In order to test this assumption it is necessary to have dependable operating data as well as an exact knowledge of the equilibrium state. Considerable progress has already been made in the study of slag-metal equilibria, notably in the earlier work of Hertyl and of Oberhoffer and Schenck2 and in the more recent researches of Krings and Schack-mann3 and of Koerber and Oelsen.4 None of these investigators, however, have employed basic slags comparable to those encountered in basic open-hearth practice, so that up to the present time our only information regarding the equilibria of these slags is based upon observations drawn from steelmaking practice in which there is little assurance that actual equilibrium was attained. The original plan of this investigation was to secure simultaneous slag and metal samples at intervals during the making of an open-hearth heat, recording the heat history in detail and obtaining complete allalyses of slag and metal, then to bring these slag samples into equilibrium with liquid iron in the laboratory induction furnace and thus to determine directly whether or not the observed relationships in the open hearth represent conditions approaching equilibrium. This plan was only partly successful. While slags were obtained from the open hearth under satisfactorily recorded conditions and these were re-melted in the laboratory under equilibrium conditions, changes in slag composition, which accompanied the remelting operation, were so great that the final slag from the induction furnace bore little resemblance to its open-hearth parent and the direct comparison was therefore abnndoned. The results, however, lie within a range of slag composition that is of interest in the making of low-carbon steel. As far as we are aware, they represent the first published laboratory study of equilibria involving slags that contain all the con stituents of basic open-hearth slag. Experimental Heats The first set of measurements on slag-metal equilibrium was made in the Research Laboratories of the American Rolling Mill Co, at Middletown, Ohio. This will be known as series A. The second set was made in the Metallurgical Rescarch Laboratories at Massachusetts Institute of Techology, and will be referred to as series B. Series A.—The induction furnace used has been described. Approximately I kg. of a special ingot iron containing less than

Jan 1, 1941

By John I. Yellott

SINCE the days of Newcomen and Watt, when men first sought to turn the energy of fuels to useful purposes, coal-generated steam has supplied most of the power needed for both stationary and mobile applications. The low efficiency and large water requirements of the nineteenth century steam-power plant caused many engineers to turn their thoughts toward more direct means of converting heat into power. As far back as 1791, John Barber secured an English patent on a combination' which he might well have called a "gas turbine." He proposed to generate procducer gas from coal or charcoal, to burn it under pressure in air obtained from a reciprocating compressor, and to drive a turbine wheel with the resultant hot combustion products. With the optimism characteristic of the inventor, he hoped that the turbine would not only operate his compressor but also perform useful work. There is no record that Barber ever built his machine, but if he had done so he would have learned that useful power can result from such a combination only when both turbine and compressor are highly efficient and when the temperature of the gas entering the turbine is not far below 1000°F. Hot-air prime movers continued to attract attention, and both Stirling in England and Ericsson in America2 built reciprocating engines that operated with some success upon coal-heated air. The internal-combustion engine, burning liquid fuels, supplanted the hot-air type, and, for the first time, challenged the supremacy of both the steam cycle and its familiar fuel, coal. LIQUID FUELS COMPETE WITH COAL As the increasing use of the automobile multiplied the demand for gasoline, the supply of residual fuel increased rapidly, and heavy oil declined in price to the point where it became competitive with coal. First in the marine field and later in stationary plants in areas adjacent to refineries, oil began to be widely used. Oil's greater convenience and higher heating value per pound of weight or per cubic foot of bunker space have caused it to take over much of the marine field. The introduction of the highly efficient diesel engine, capable of burning a fuel that is cheaper than gasoline, again threatened the position of coal, for the operating costs of the diesel became directly competitive with those of coal- burning equipment. In isolated power plants and smaller marine installations, the diesel provided the medium by which oil again successfully invaded fields formerly dominated by coal. The diesel engine, provided with an

Jan 1, 1946

By Alexander Coucoulas

FABRICATION of thin-film circuits deposited on glass substrates requires the formation of permanent electrical contacts. Since thin films are in the order of a few thousand angstroms thick and are deposited on nonconductive surfaces such as glass, new methods of lead attachment are being pursued in the microelectronics industry. Ultrasonic welding is being considered in thin-film technology since joining can be accomplished between a wide variety of dissimilar materials.l,' Ultrasonic welding is accomplished by a transducer-coupling-tip system which converts high-frequency electrical energy into mechanical vibrations and delivers it into the weld region. During the process the tip oscillates in a direction parallel to the surface of the weldments, inducing shear stresses in the work pieces which are clamped between the tip and anvil. Though the basic bonding mechanism is not clearly understood, it has been described as closely akin to friction welding. In the course of an investigation concerned with ultrasonic we!ding of aluminum wires to tantalum thin films (1400A) deposited on glass, low weld strengths were related to glass failure. Upon investigating this condition, an improved method of bonding was developed where the aluminum was held at a temperature where a minimum amount of strain hardening occurred during the introduction of ultrasonic energy. Experimental Procedure. Aluminum wires (0.015 in,) were bonded to tantalum thin films with an optimized set of welding parameters (power, time, clamping force) employing a commercial 100-w 60-kc ultrasonic welder. Forty-five degree shear-peel tests, where the lead is pulled at a 45-deg angle with respect to the substrate at 0.2 in. per min, produced a large variation from zero to the strength of the wire, Table I. Inspection of the weld region generally revealed: glass cracking before and after testing; the removal of glass nuggets from the substrate by the lead during testing, Table I; thin-film penetration. In an effort to improve the shear-peel strength, the aluminum between the tip and substrate was heated above ambient temperature through an argon gas media prior to and during welding with the same parameters employed above. With the addition of heat: wire deformation was increased; shear-peel tests all failed at the weld-wire junction, leaving the bonded portion undisturbed; no evidence of glass cracking or film penetration prior to or after testing was observed. In order to prevent failure at the weld-wire junction due to excessive wire deformation, 0.035-in. aluminum wires were welded to tantalum thin films with an optimized set of welding and heating parameters. As

Jan 1, 1967

By B. M. Larsen, W. E. Shenk

This paper describes a method of reversal control of the open-hearth furnace that obtains in practice those effects considered below as essential to a completely automatic control, without appreciable interference with the natural rise and fall in temperature of the regenerative portions of the furnace system. Growing out of some studies of radiation pyrometry in open-hearth regenerators, it was developed during 1934-1938, and has been successfully applied to a number of commercial furnaces. The goal of open-hearth furnace operation is the highest rate of production of steel of proper quality consistent with good refractory life and fuel economy. This requires rapid heat transfer from furnace to charge, which in turn is dependent upon heating the furnace refractories to the highest safe operating temperature. The greater the heat input to the melting chamber, the sooner this limiting temperature will be reached, so that control methods in general that are designed to protect against overheating of refractories should help to maintain maximum fuel input and production rate. For the typical open-hearth system, with fixed regenerator capacity and with rate of fuel input usually restricted in its range of variation, our basic assumption is the idea that the only other important variable —that is, the time interval between successive reversals—should also be held constant or within a small range. The present reversal control was designed therefore so that, under normal operating conditions, no arbitrary limitation is imposed other than to keep the reversal interval within the optimum time range. However, since a near approach to completely automatic operation involves protection of refractories through the balancing of furnace end temperatures as well as emergency protection against temperature peaks above some upper limit, it was also felt essential to employ, as an integral part of the control unit, a temperature-measuring instrument to register the true temperature of the refractory surfaces at some critical region in the hot ends of the regenerative zones. As the basic elements of the control, we thus have one "maximum" and one lLminimum" time relay and a potentiometer recorder-controller, combined with switches and relays to operate as follows: I. Reversal normally occurs within an optimum range limited by the maximum and minimum settings to about 4 to 6 min. variation, but the actual interval usually is less variable and closer to the minimum setting. 2. The margin between minimum and maximum time is utilized, together with a "floating temperature limit" in the potenti-ometric control instrument, to correct any tendency toward temperature unbalance between ends of the furnace. 3. A second "maximum temperature

Jan 1, 1945

By Max Y. Seaton

THE scope of this paper will be limited to finished materials that contain a large preponderance (around 80 per cent or more) of magnesium oxide. The large and commercially important production of refractory dolomite and modified dolomites is not discussed here, and the production of magnesium basic carbonate for use as a heat insulator is barely mentioned. The discussion is confined mainly to magnesias produced in comparatively great quantity by direct processing of naturally occurring raw materials and hence excludes secondary or highly purified products such as pharmaceutical products or U.S.P. light and heavy calcined magnesias of commerce. NOMENCLATURE The nomenclature of the magnesia products that will be discussed is somewhat confusing, in that it is customary in the trade to designate as "calcined magnesite" the materials that result from the calcining of magnesite to temperatures that remove the contained carbon dioxide. The finished product, therefore, is not magnesite at all but simply a more or less pure magnesium oxide or magnesia. Furthermore, partly for statistical and partly for commercial reasons, it has been customary, during recent years, to classify as "calcined magnesite" products that result from the heat-treatment of magnesium hydroxide precipitated from magnesium-containing brines; products that, obviously, have no relationship whatever to magnesite. In the listing of magnesia-containing materials, tonnages of which are regularly reported by the Bureau of Mines, reports ordinarily are made under two headings: "caustic calcined" magnesite, in which all of the varieties of products treated at relatively low temperatures are lumped; and "dead-burned" magnesite, in which are included both high-purity and low-purity, and particularly both high-iron and low-iron, materials that have been so heat-treated that the magnesium oxide occurs predominantly as crystalline periclase-materials used almost entirely for refractory purposes. In 1940 the apparent domestic consumption of "caustic calcined" magnesite was approximately 17,000 tons, about 95 per cent of which was produced in this country. The apparent consumption of "dead-burned" magnesite was approximately 172,000 tons, some 82 per cent of which was domestically produced. In both total quantity and percentage of material produced within the United States, these figures are record highs for many years past. UTILIZATION As indicated by these figures, the major tonnage outlet for magnesia is the refractories industry, in which magnesia is employed principally in three ways: (I) as dead-burned grain magnesite for the construction and maintenance of the hearths or bottoms of basic open-hearth furnaces; (2) in the form of refractory magnesite bricks and shapes; and (3) as a chemical

Jan 1, 1942

By B. M. Larsen, W. E. Shenk

THIS paper describes a method of reversal control of the open-hearth furnace that obtains in practice those effects considered below as essential to a completely automatic control, without appreciable interference with the natural rise and fall in temperature of the regenerative portions of the furnace system. Growing out of some studies of radiation pyrometry in open-hearth regenerators, it was developed during 1934-1938, and has been successfully applied to a number of commercial furnaces. The goal of open-hearth furnace operation is the highest rate of production of steel of proper quality consistent with good refractory life and fuel economy. This requires rapid heat transfer from furnace to charge, which in turn is dependent upon heating the furnace refractories to the highest safe operating temperature. The greater the heat input to the melting chamber, the sooner this limiting temperature will be reached, so that control methods in general that are designed to protect against overheating of refractories should help to maintain maximum fuel input and production rate. For the typical open-hearth system, with fixed regenerator capacity and with rate of fuel input usually restricted in its range of variation, our basic assumption is the idea that the only other important variable that is, the time interval between successive reversals-should also be held constant or within a small range. The present reversal control was designed therefore so that, under normal operating conditions, no arbitrary limitation is imposed other than to keep the reversal interval within the optimum time range. However, since a near approach to completely automatic operation involves protection of refractories through the balancing of furnace end temperatures as well as emergency protection against temperature peaks above some upper limit, it was also felt essential to employ, as an integral part of the control unit, a temperature-measuring instrument to register the true temperature of the refractory surfaces at some critical region in the hot ends of the regenerative zones. As the basic elements of the control, we thus have one "maximum" and one "minimum" time relay and a potentiometer recorder-controller, combined with switches and relays to operate as follows: x. Reversal normally occurs within an optimum range limited by the maximum and minimum settings to about 4 to 6 min. variation, but the actual interval usually is less variable and closer to the minimum setting. 2. The margin between minimum and maximum time is utilized, together with a "floating temperature limit" in the potentiometric control instrument, to correct any

Jan 1, 1945

By Max Y. Seaton

THE scope of this paper will be limited to finished materials that contain a large preponderance (around 80 per cent or more) of magnesium oxide. The large and commercially important production of refractory dolomite and modified dolomites is not discussed here, and the production of magnesium basic carbonate for use as a heat insulator is barely mentioned. The discussion is confined mainly to magnesias produced in comparatively great quantity by direct processing of naturally occurring raw materials and hence excludes secondary or highly purified products such as pharmaceutical products or U.S.P. light and heavy calcined magnesias of commerce. NOMENCLATURE The nomenclature of the magnesia products that will be discussed is somewhat confusing, in that it is customary in the trade to designate as "calcined magnesite" the materials that result from the calcining of magnesite to temperatures that remove the contained carbon dioxide. The finished product, therefore, is not magnesite at all but simply a more or less pure magnesium oxide or magnesia. Furthermore, partly for statistical and partly for commercial reasons, it has been customary, during recent years, to classify as "calcined magnesite" products that result from the heat-treatment of magnesium hydroxide precipitated from magnesium-containing brines; products that, obviously, have no relationship whatever to magnesite. In the listing of magnesia-containing materials, tonnages of which are regularly reported by the Bureau of Mines, reports ordinarily are made under two headings: "caustic calcined" magnesite, in which all of the varieties of products treated at relatively low temperatures are lumped; and "dead-burned" magnesite, in which are included both high-purity and low-purity, and particularly both high-iron and low-iron, materials that have been so heat-treated that the magnesium oxide occurs predominantly as crystalline periclase-materials used almost entirely for refractory purposes. In 1940 the apparent domestic consumption of "caustic calcined" magnesite was approximately 17,000 tons, about 95 per cent of which was produced in this country. The apparent consumption of "dead-burned" magnesite was approximately 172,000 tons, some 82 per cent of which was domestically produced. In both total quantity and percentage of material produced within the United States, these figures are record highs for many years past. UTILIZATION As indicated by these figures, the major tonnage outlet for magnesia is the refractories industry, in which magnesia is employed principally in three ways: (I) as dead-burned grain magnesite for the construction and maintenance of the hearths or bottoms of basic open-hearth furnaces; (2) in the form of refractory magnesite bricks and shapes; and (3) as a chemical

Jan 1, 1942

By Max Y. Seaton

The scope of this paper will be limited to finished materials that contain a large preponderance (around 80 per cent or more) of magnesium oxide. The large and commercially important production of refractory dolomite and modified dolomites is not discussed here, and the production of magnesium basic carbonate for use as a heat insulator is barely mentioned. The discussion is confined mainly to magnesias produced in comparatively great quantity by direct processing of naturally occurring raw materials and hence excludes secondary or highly purified products such as pharmaceutical products or U.S.P. light and heavy calcined magnesias of commerce. Nomenclature The nomenclature of the magnesia products that will be discussed is somewhat confusing, in that it is customary in the trade to designate as "calcined magnesite" the materials that result from the calcining of magnesite to temperatures that remove the contained carbon dioxide. The finished product, therefore, is not magnesite at ali but simply a more or less pure magnesium oxide or magnesia. Furthermore, partly for statistical .and partly for commercial reasons, it has been customary, during recent years, to classify as "calcined magnesite" products that result from the heat-treatmerit of magnesium hydroxide precipitated from magnesium-containing brines; prod- ucts that, obviously, have no relationship whatever to magnesite. In the listing of magnesia-containing materials, tonnages of which are regularly reported by the Bureau of Mines, reports ordinarily are made under two headings: "caustic calcined" magnesite, in which all of the varieties of products treated at relatively low temperatures are lumped; and "dead-burned" magnesite, in which are included both high-purity and low-purity, and particularly both high-iron and irow-iron, materials that have been so heat-treated that the magnesium oxide occurs predominantly as crystalline periclase— materials used almost entirely for refractory purposes. In 1940 the apparent domestic consumption of "caustic calcined" magnesite was approximatcly 17,000 tons, "bout 95 Per cent of which was produced in this country. The apparent consumption of "dead-burned" magnesite was approximately 172,000 tons, some 82 per cent of which was domestically produced. In both total quantity and percentage of material produced within the United States, these figures are record highs for manY Years past. Utilization As indicated by these figures, the major tonnage outlet for magnesia is the refractories industry, in which magnesia is employed principally in three ways: (1) as dead-burned grain magnesite for the construction and maintenance of the hearths Or bottomS of basic open-hearth furnaces; (2) in the form of refractory magnesite bricks and shapes; and (3) as a chemical

Jan 1, 1942

By Max Y. Seaton

The scope of this paper will be limited to finished materials that contain a large preponderance (around 80 per cent or more) of magnesium oxide. The large and commercially important production of refractory dolomite and modified dolomites is not discussed here, and the production of magnesium basic carbonate for use as a heat insulator is barely mentioned. The discussion is confined mainly to magnesias produced in comparatively great quantity by direct processing of naturally occurring raw materials and hence excludes secondary or highly purified products such as pharmaceutical products or U.S.P. light and heavy calcined magnesias of commerce. Nomenclature The nomenclature of the magnesia products that will be discussed is somewhat confusing, in that it is customary in the trade to designate as "calcined magnesite" the materials that result from the calcining of magnesite to temperatures that remove the contained carbon dioxide. The finished product, therefore, is not magnesite at ali but simply a more or less pure magnesium oxide or magnesia. Furthermore, partly for statistical .and partly for commercial reasons, it has been customary, during recent years, to classify as "calcined magnesite" products that result from the heat-treatmerit of magnesium hydroxide precipitated from magnesium-containing brines; prod- ucts that, obviously, have no relationship whatever to magnesite. In the listing of magnesia-containing materials, tonnages of which are regularly reported by the Bureau of Mines, reports ordinarily are made under two headings: "caustic calcined" magnesite, in which all of the varieties of products treated at relatively low temperatures are lumped; and "dead-burned" magnesite, in which are included both high-purity and low-purity, and particularly both high-iron and irow-iron, materials that have been so heat-treated that the magnesium oxide occurs predominantly as crystalline periclase— materials used almost entirely for refractory purposes. In 1940 the apparent domestic consumption of "caustic calcined" magnesite was approximatcly 17,000 tons, "bout 95 Per cent of which was produced in this country. The apparent consumption of "dead-burned" magnesite was approximately 172,000 tons, some 82 per cent of which was domestically produced. In both total quantity and percentage of material produced within the United States, these figures are record highs for manY Years past. Utilization As indicated by these figures, the major tonnage outlet for magnesia is the refractories industry, in which magnesia is employed principally in three ways: (1) as dead-burned grain magnesite for the construction and maintenance of the hearths Or bottomS of basic open-hearth furnaces; (2) in the form of refractory magnesite bricks and shapes; and (3) as a chemical

Jan 1, 1942

By A. C. Losekamp, J. B. Conway

Thermal-expansion data for, tungsten, rhenium, tantalum, .molybdenum, niobium, W-25 pct Re, Ta-10 pct W, ant1 Mo-50 pct Re are presented covering the range from room tempature to 2500°C. In these measureMents, made in a resistively heated tungsten tube furnace operating in a helium atmosphere, data for rod and sheet specimens were found to be identical; in addition, arc-cast and sintered tungsten were found to yield essentially identical results. Optical rneasurenlents of thermal expansion .made in any atmosphere other- than vacuum are subject to a refraction error which can be quite substantial. Specimens tested in helium appear shorter than when tested in racuum and hence a special correction factor must be applied to the helium data in order to obtain accurate results. WHILE it is true that linear thermal-expansion data for many of the refractory metals have been measured to very high temperatures, it is also true that except in a few instances the data from various investigators are not in good agreement. This is particularly evident in the case of tantalum and niobium although some tungsten data have been reported which differ by as much as 40 pct from the data of other investigators. Due to the sensitivity of both tantalum and niobium with respect to impurity absorption during exposure to high temperatures, it is probable that this single factor accounts for the majority of the discrepancies in the thermal-expansion data for these metals. However, this same factor can probably not be employed to explain the existing differences in the tungsten data. In all probability, these are due to errors in the measurement technique, to material composition variations, or to changes which take place in the material during the heating process (e.g., additional densifica-tion resulting from heating a sintered specimen above the original sintering temperature). In view of the discrepancies which exist in the linear expansion data reported for many of the refractory metals, the current study was initiated in an attempt to resolve such differences. Also, no high-temperature linear thermal-expansion data were found to be available for several refractory metals. Providing such data was another objective of the current investigation. MATERIALS In this study test specimens were employed in either rod or sheet form and in several instances both arc-cast and sintered material were employed. Material compositions are presented in Table I. Helium gas was fed to the furnace at a rate of about 0.5 SCFH and no special purification procedures were employed. However, the helium contained less than 50

Jan 1, 1967

By Allan Martin, R. A. Swalin

Diffusion rates of manganese, aluminum, titanium, and tungsten in nickel were measured at temperatures between 1100° and 1300°C. Activation energies, Q, and values of the frequency factor, Do, were calculated for each system. Values of Q were found to be within 15 pet of that for self-diffusion of nickel in agreement with present theories of diffusion. ONE of the most interesting problems in diffusion concerns factors governing the order of diffusion coefficients of various solutes in a common solvent metal at low solute concentrations. An early suggestion by Rhines and Mehl' was that diffusion coefficients might each approach that of the self-diffusion coefficient of the solvent itself. Later Thomas and Birchenall' pointed out correlations between the order of the diffusion coefficients and the freezing point depressions of the solvent by the various solutes. Other correlations have been sought. To settle this question it seems likely that much more data will be needed and, in particular, data collected at low solute concentrations. This type can be obtained by special analytical techniques as well as by use of radioactive tracers. The following study was made of diffusion of manganese, aluminum, titanium, and tungsten in a common solvent, nickel, at relatively low solute concentrations: 1—Production of alloys of nickel with manganese, aluminum, titanium. and tungsten at concentrations of the order of 1 atomic pet. 2—Use of pressure-welded diffusion couples in cylindrical form. 3—Diffusion anneals in the temperature range of 1100" to 1300°C. 4—Lathe sectioning of the diffused couples. 5—Spectrophotometric analyses of lathe turnings for the solute being studied. 6—Calculation of the diffusion coefficient for each of the solutes as a function of temperature. 7—Interpretation of results with current theories of diffusion. Experimental Work Materials—Two types of nickel were used in this research. The grade designated as Vacuum melted Mond nickel was used for all diffusion systems except the Mn-Ni system for which the Vacuum melted electrolytic nickel was used. Analyses of the two grades are given in Table I. The manganese used in making alloys was 99.9 + pet pure, aluminum 99.99 pet pure, titanium 99.9 pet pure, and tungsten of C.P. grade powder. Alloys used in this investigation were prepared by melting in vacuo or under a low pressure of argon. After melting, all heats except those of nickel-manganese were poured into a cylindrical copper mold 3 in. long and 1 in. ID. In the case of nickel-manganese, the alloys were solidified in the melting crucible. For nickel-aluminum heats alumina crucibles were used and for all other heats, zirconia crucibles.

Jan 1, 1957

By F. R. Hensel

PURE silver and silver-lead alloys have been studied as to their suitability for bearings.1-8 A review of the properties of thallium and the silver-thallium constitutional diagram was made by the author to analyze the possibilities of silver-thallium compositions for antifriction materials.† The silver-rich end of the diagram as reported in the literature9-11 was found to be sketchy and it was necessary to carry out considerable experimental work to arrive at definite conclusions. Some of the results of this work are reported in this paper. TEST MATERIALS In the beginning of the work, only fused alloys were investigated. Later, research [TABLE I. Composition of Fused Silver thallium Alloys Tested for Antifriction Properties PERCENTAGE ALLOY No.OF THALLIUM 15330.48 153406 231 HT2.04 2312.10 232 HT3.83Balance 2324.07Silver 233 HT5.86 2336.38 2349.84 234 HT10.07] was carried out on electroplating methods and diffusion processes. In preparing the fused alloys, care was taken to exhaust the toxic fumes caused by the thallium content. The compositions of the series of fused alloys are listed in Table I. The silver-thallium alloys were melted in clay-graphite crucibles and cast into preheated steel molds of 3/4-in. diameter. In the cast condition, they showed a cored structure, as indicated by the micrographs of Figs. I to 3. The etching reagent used was a mixture of 2 grams K2Cr2O7, 8 c.c. H2SO4, and 100 c.c. H2O. The cored structure is unsatisfactory for the type of corrosion resistance required for bearing applications, and homogenizing experiments were carried out at various temperatures, the results of which are shown in Figs. 4 through 8. The alloys with a lower thallium concentration, which were heated for 2 hr. at 525°C. show an almost completely homogenized solid solution type of structure. With higher thallium concentration, the homogenizing temperature was dropped to 475°C. to eliminate the formation of a liquid phase. It is evident that heating for 2 hr. at this temperature did not result in complete elimination of the cored structure. As would be expected, cold-working of the cast structure is an expedient in establishing equilibrium conditions. The fine homogeneous grain structure shown in Fig. 7 corresponds to the cold-worked area under the Rockwell ball penetration when the hardness was taken before heat-treatment. A detailed structural study was made on a cast silver-thallium alloy containing 3.67 per cent thallium. Three micrographs (Figs. 9, 10 and 11) show the transition

Jan 1, 1945

By W. A. Alexander, L. M. Pidgeon

Metallic magnesium and similar meta!s near the top of the electromotive series have been commercially produced by the electrolysis of a suitable molten salt. Despite the success of electrolysis, sufficient inherent objections exist to justify the search for a direct reduction method. Such a method would widen the choice of raw materials, relax the rigid electrolytic requirements of raw-material purity, and, by obviating direct current, over simplicity of plant equipment. This paper describes the pilot-plant development of one such method, which has subsequently formed the basis of operation of six commercial plants-—one in Canada and five in the United States. Unlike aluminum, magnesium is volatile at relatively low temperatures. This physical property, which produces its greater inflammability, also offers possibilities of direct reduction that are not available with aluminum. In the basic reaction MgO + X = XO + Mg if X is nonvolatile, the reaction may be forced to the right at high temperatures by the evolution of magnesium vapor, despite the large negative value of the heat of reaction which is almost bound to follow the use of any available commercial reducing agent. The cheapest X, of course, is carbon, but this notable advantage is modified by the production of a volatile oxide CO, so that both Mg and CO are evolved simultaneously. Elaborate devices are required to shock-cool the equilibrium mixture in order to prevent back reaction. At best, a pyrophoric powder is produced, requiring redistillation to provide marketable metal. The practical development of this process, is due to F. Hansgirg, and his methods have recently been given a trial on a grand scale in the plant at Permanente, California, and smaller plants were previously built in Austria, England and Japan. A second class of reducing agents is available, those which produce nonvolatile oxides. When XO and X are relatively nonvolatile, magnesium is the only volatile member of the system. It may be evolved in a simple distillation step and condensed without the formation of powder. Two basic requirements must bc fulfilled in order that such a reaction may proceed: I. The reducing agent when heated to a reasonable temperature in presence of MgO must cause the production of an appreciable equilibrium vapor pressure of magnesium. This magnesium must be removed continuously. z. A supply of heat must be maintained. In order to fulfill the first requirement, operations must be conducted in vacuo or in a stream of Hz. Owing to its greater efficacy and relative safety, vacuum has been employed in the work to be described. The choice of a suitable reducing agent formed the subject of an extensive series

Jan 1, 1944

By J. P. Aiello

"INTRODUCTIONWhile this paper deals specifically with potential coal use at the Cold Lake Project of Esso Resources Canada Limited, a majority of the technical aspects of coal conversion could apply to any oil field and industrial boilers or stearn generators. In 1962, Imperial Oil Limited's production arm (the forerunner of Esso Resources), began examining methods of extracting bitumen from a 50 m thick layer of oil sand buried 450 m below the surface in the Cold Lake area. Almost two decades of research followed to develop an in situ oil sands recovery technology that made commercial production feasible.A $13 billion mega project that would have produced 22 000 m3/d (141 000 barrels/day) of synthetic crude oil (160 000 bpd of bitumen) was shelved in 1981, and ultimately replaced by a phased development strategy, involving smaller production units, to bring blended bitumen production on stream as markets and prices permit.The first two phases came into production in 1985. There are currently a total of six phases in production with four more in the construction stage. Each phase has 130to 140production wells (initially) and a central plant with water treatment, crude treatment and stearn generating facilities capable of producing 150 m3/d (9500 bpd of raw bitumen). The stearn generation section for each phase consists of three 180millionBtulhour oil fieldsteam generators.In its natural state, the bitumen is too thick to be recovered using conventional oil recovery techniques. At the Cold Lake Project, bitumen is recovered by a method called cyclic stearn stimulation. Water is pumped to the central plant where it is treated and heated to produce high pressure, high temperature steam. During the steam cycle, this steam is transported in insulated pipelines to the wells for injection into the oil sand formation. This cycle lasts from 30 to 50 days, heating the formation and causing the bitumen to flow. Following an initial flowback period, a surface based artificial lift system pumps the heated liquid bitumen, mixed with water and gas, out of the well and back to the central plant. The water and gas are separated from the bitumen, with the gas being used to provide some of the fuel for the stearn generators and the water being treated and recycled. Approximately 5% of the water cannot be recycled and is disposed of by injection into deep formations . The bitumen is blended with a diluent and shipped by pipeline to market."

Jan 1, 1989

By Bernd-Arno Behrens, Klaus-Georg Kosch

"In times of increasing energy costs automotive lightweight construction is gaining in importance. This paper deals with the production of hybrid steel-aluminum compounds by forging. The compound forging process is a promising method to successfully manufacture functional parts by applying resource-saving process steps. Nevertheless, challenges resulting from different material properties must be solved.The heating of hybrid material work pieces made of steel and aluminum is a great challenge. Steel is forged at a temperature of at least TSt =900 °C, while aluminum should not exceed a temperature of TA1= 500 °C. For achieving the required temperature gradient extensive experimental investigations have been carried out. Intermetallic phases form during the manufacturing process and can influence the bonding and the global part quality. In addition, methods for the characterization of the joining zone between the materials steel and aluminum are analyzed and the factors influencing the formation of intermetallic phases are determined experimentally.IntroductionIn times of increasing energy costs and stricter conditions relating to environmental protection, automotive lightweight construction is gaining in importance. The production of hybrid compounds by forging is a promising method to manufacture functional parts by applying resource-saving process steps. In compound forging a hybrid raw part consisting of a solid core, which is enclosed by a hollow casing, is joint in the forming process. This results in a graded material structure in the part in which the mechanical properties can be specifically adapted to the requirements. Compound forging is the form joining and/or firmly bonded joining of at least two different materials while plastic shape forming occurs (Figure 1)."

Jan 1, 2012

By B. J. Moore

This publication contains routine analyses and related source data for 547 natural gas samples from 22 States and three foreign countries. Of this total, 340 samples were collected during calendar year 1967. The remaining 207 analyses are of samples collected during previous years, but releases granting, permission to publish the results were not received until 1967. All samples were collected as a part of a continuous survey of the free world for occurrences of helium in natural gas. The Bureau of Mines has conducted this survey in the United States since 1917, and in 1965 it was expanded to include foreign gasfields. The analyses published herein were made by mass spectrometer and a special helium analysis apparatus which are described in Bureau of Mines Bulletins 4863 and 516.4 Nine previous publications have been made to present results of 7,618 gas analyses made by the Bureau of Mines Helium Activity prior to 1967. The first three, Bulletins 486,5 576,6 and 6177 contain analyses and related source data on 5,218 gas samples collected from 1917 through 1960. The other six

Jan 1, 1968

By Hong Ouyang

A unified computational model has been developed for the Bridgman growth processes of B-NiAI and CdTe crystals. To handle the geometrical and physical complexities, a two-level approach has been developed. At the gtobatlevel, conjugate heat transfer, phase change dynamics, and variable material properties along with the realistic geometries and thermal boundary conditions are accounted for inside the entire crystal growth system. Refined calculations are then made within the ampoule, with the boundary conditions supplied by the global simulations. This model can optimize the use of computational source, help understand solidification behaviors, and improve designs of crystal growth system.

Jan 1, 1996

By W. E. Robinson

Oil-shale kerogen was processed into oil and oil products before the first oil well was completed by Drake in 1859. However, because of economic and other advantages, natural petroleum has been the principal source of liquid fuels and lubricants since 1859 and is a convenient root of many [organic] chemicals in common use today. In recent years the difference has narrowed between the cost of producing liquid fuels from well petroleum and other sources. This narrowing of cost difference has resulted both from the increased cost of finding new sources of petroleum in the United States and the experimental demonstration of lowered costs for synthetic liquid fuels by the Federal Bureau of Mines and by industry. Available petroleum resources of this country are being reduced and eventually may be inadequate to meet the demand. Alternate means of assuring an adequate supply of liquid fuels for this country include the development of processes for utilizing other carbonaceous materials such as oil shale and coal.

Jan 1, 1960