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By W. T. Millar

Field reconnaissance and laboratory tests an clay from South Windsor, Hartford County, Conn., indicate that the clay is suitable for lightweight aggregate raw material. Exploration of the deposit supports the conclusion that the reserves of clay are sufficient for economical mining operations to produce lightweight aggregate. Preliminary tests indicated that the clay has a short bloating range. Initial expansion occurred at 2,000° F, and at 2,100° F the clay was slightly overfired and sticky. Rotary kiln tests verified the preliminary data, and these tests showed that the clay would make a good lightweight aggregate if the processing temperature and the kiln feed sizes were closely controlled. Lightweight concrete made from the processed aggregate had properties comparable to those of concrete made from a commercial clay aggregate.

Jan 1, 1964

By Dogan Paktunc, Larry J. Hulbert, Robert C. Carne, D. Conrad Gregoire

A thin layer of stratiform Ni-Zn-PGE sulfide mineralization of sedimentary-diagenetic origin was deposited during the Middle to Upper Devonian in the euxinic "Nick basin". The mineralized unit (=3 cm thick), which seems to have been developed over the entire sedimentary basin of > 80 km2, consists of pyrite, vaesite (NiSz), and sphalerite. The average grade of the mineralization is about 5.30/0 Ni, 0.73% Zn, =770 ppb (pGE+Au), and up to 61 ppm Re. Anomalous Se, As, Mo, P, Ba and U are present. A minimum of 0.90 x 106 tonnes of Ni were deposited in the basin (based on a bed thickness of 3 cm) during the Devonian. The unique metal association, extensive lateral distribution, persistent metal grade, mineralogical makeup, and stratigraphic control demonstrate that this is a new deposit type and a new geological environment for Ni and PGE + Au. The sulfide layer occurs at the base of a Phosphatic Chert Member which is underlain by a distinctive marker unit consisting of concretionary limestone structures. The limestone spheroids may represent a vent-specific carbonate facies developed adjacent to faults that emanated nutrientrich hydrothermal discharges just prior to the main mineralizing event. The suite of elements associated with the Nick mineralization suggests that the ore-forming metals were originally bound to organic matter derived from decaying marine organisms. Discharge of hot brines bearing organic matter-bound metals took place along numerous conduits within basin faults that are now manifest as bitumen veins. Our syndiagenetic model proposes that these fluids were discharged laterally from the conduits into the unconsolidated bottom sediment (ooze). The introduction of this metalliferous fluid, rich in organic matter, stimulated biological activity and bacterial reduction of its contained 804 to sulfide. Hot, dense, laterally migrating hydrothermal fluid precipitated thin sulfide-rich larninae within bottom sediment. Published thermodynamic studies suggest that the diagnostic vaesitepyrite assemblage crystallized at approximately 138°C. The 034S values range from -14.7 0/00 to -10.00/00 and are up to 340/00 lighter than locally surrounding sulfides and age-equivalent mineralized strata elsewhere in the Selwyn Basin. The Ol3C values of calcite in the footwall of the mineralized unit (- 12 0/00 to -6 0/00) are isotopically much lighter than regional values. The lighter isotopic character is attributed to the hydrothermal discharge of fluids enriched in organic compounds. Although geochemical profiles of the lower Earn Group sediments that host the Nick mineralization reveal that these black shales are not distinctive, the unusual Ni, Zn, PGE, U, Ba, and P elemental associations and their anomalous concentrations in stream sediments can be used to explore for this deposit type.

Jan 1, 1992

By George B. Clark

The "Munroe effect" of shaped explosive charges was discovered by Charles E. Munroe more than 50 years ago (in 1888), but it was not until World War II that it was put to any practical use. Both Allied and Axis armies used the principle effectively in bazooka projectiles, artillery projectiles and in fixed shaped charges. The first two were used primarily to combat tanks and other armor and the latter to assault pillboxes and other fixed concrete emplacements. Many engineers and others who saw the military application of the jet effect of shaped charges believed application would be possible in many industrial fields where blasting is used, such as mining and quarrying. Some work has already been done on the problem of making shaped charges applicable to mining operations. Experimentation conducted at the National Tunnel and Mines1 was directed primarily along the lines of use of shaped charges for secondary blasting in connection with long-hole stoping methods. Experimentation initiated earlier and conducted by the author2 at the University of Utah on a more scientific basis was directed at revealing the basic principles of the functioning of shaped charges, as well as the feasibility of using them in mining operations after the principles of their operation had been clearly defined. It was found that: (I) a given design of charge required an optimum standoff to make it most effective, either in penetrating solid rock or steel (see Fig 3); (2) for a given design of charge there exists an optimum ratio of charge diameter to charge height above which the increase in effectiveness of the charge decreases rapidly (see Figs 4 and 5); (3) partial confinenlent has the effect of making charge performance much more consistent; (4) the higher power and higher velocity explosives tested are much more effective than relatively low-strength explosives; and (5) shaped charges may be adaptable to mining operations in secondary breakage and drilling blasting holes. Fig I is a diagrammatic sketch of the action of a shaped charge for two types of cavities, while Fig 2 shows the approximate manner in which the jets are believed to be formed when an explosive wave encounters the cavity, approaching it from the top. The experimentation already completed has laid the foundation for further research in the study of shaped charges. Standoff effects, effect of the strength of explosives and other features have been fairly well established. Such elements in the design of shaped charges as (I) geometry of cavity liners, (2) relative horizontal dimensions of explosive column, (3) effect of various metals and alloys in cavity liners, (4) percentage studies of jet energies, and

Jan 1, 1949

By F Clark, J T. Carswell

Ore definition for final stope planning is often a challenging prospect in underground (UG) gold mines which exhibit high geological and grade variability. Unlike the grade control (GC) scenario in an open pit (OP), the ability for the mining geologist to plan a sampling campaign which effectively characterises the underlying mineralisation is fraught with difficulty. UG sampling patterns are strongly clustered and typically not dense enough to characterise the spatial and statistical properties. Very commonly, sample volumes are not large enough to provide a reliable grade estimate of the surrounding rock. These factors critically affect our ability to accurately map out ore positions and estimate metal quantities.At Sunrise Dam, traditional UG sampling and modelling techniques have proven to be an unreliable strategy for successful stope planning and extraction. The problem was first observed during the final cut-back in the open pit for which the mineral resource model was constructed from UG diamond drilling. Open Pit grade control reconciliations were strongly positive for both tonnage and grade compared to the resource model. Underground workings missed significant quantities of ore which was laterally defined by open pit reverse circulation (RC) GC drilling. Upon examination it was realised that the cause of the problem was one of inadequate sample density and sample support, the implications of which potentially affected the entire UG mine.As part of a broader study into underground grade control procedures, detailed reconciliation of initial stope production from the GQ domain also pointed to inadequate sampling as a major constraint to effective grade control and reserve conversion.To overcome this deficiency, dense 115 mm wet RC grade control drilling and conditional simulation modelling has been successfully implemented with the intent to replicate the grade control process in the open pit. The increase in sample density and sample volume has proven to be a very effective tool for mapping out highly complex mineralisation. A marked improvement in stope definition, reserve conversion and Mine to Mill reconciliations has been demonstrated on the back of an innovative approach to UG grade control.CITATION:Clark, F and Carswell, J T, 2014. Using reverse circulation drilling to improve sampling in a complex underground gold operation – an innovative approach to underground grade control at the Sunrise Dam Mine, Western Australia, in Proceedings Ninth International Mining Geology Conference 2014 , pp 143–152 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By John H. Johnson

This report covers the third and final year of work conducted under U. S. Bureau of Mines Grant G0166027, "Monitoring of Mine Air Pollutants". The report discusses work performed in three areas. These are the White Pine Mine (WPM) Experimental Unit, diesel mine-vehicle tailpipe emissions monitoring, and mine ambient air concentration data analysis. The WPM experimental unit was used to study diesel exhaust stratification in an 80 foot long dead-end heading while loading ore with a Wagner ST-5D scoop train LHD. The MTU Mine Air Monitoring Laboratory (MAML) was used to gather temperature and CO2 concentration data at 10 locations. Three different ventilation conditions were compared. The data substantiate the presence of strong buoyant forces of the hot exhaust gases which result in temperature stratification in dead-end headings. The diesel mine-vehicle tailpipe emissions monitoring study involved laboratory measurements of diesel undiluted exhaust pollutant concentrations by the portable tailpipe emissions measurement apparatus (EMA) assembled for in-mine use. The results were compared with simultaneous measurements by standard laboratory exhaust monitoring instruments. These results indicate that accurate field source quality control measurements can be obtained for CO2, CO and NO but NO2 results were low for all engine conditions. The mine ambient air concentration data analysis study included analysis of diesel pollutant concentration data in the Orchard Valley Mine air and comparison of the results with data collected earlier in the White Pine and Brushy Creek mines. The analysis included preparation of lognormal frequency distributions and calculations of C02-based concentration ratios and correlations. In the three mines compared, pollutant concentrations are distributed quite similarly, and the concentrations appear to be controlled to present standards.

Jan 1, 1979

By Y. Zhang, C. Zhou, M. Girman

Wireless technologies are increasingly being implemented in underground mines for various purposes such as communications, tracking, remote control, remote sensing, and environmental monitoring. However, the adoption comes with risks as common wireless systems, such as WiFi, Bluetooth, IWT (Innovative Wireless Technologies) wireless system, often operate in the unlicensed ISM (industrial, scientific, and medical) band. The shared nature of the ISM band can lead to interference among devices and consequently cause performance degradation and reliability issues. In this study, we developed two wireless communication evaluation boards as a tool to evaluate the performance and reliability of a wireless system with the presence of electromagnetic interferences (EMI) from other wireless systems in underground environments. We adjusted various parameters including signal power from adjacent frequency channels, noise power within the same channel, the movement of personnel, and communication packet size. Our findings indicate that, while the power of the EMI source plays a key role, the motion of personnel in the tunnel also has a strong impact on performance, and this impact increases as the power of EMI sources increases. In noisy environments, smaller packet sizes are preferable as they enhance the likelihood of successful transmission. High levels of interference or noise can lead to increased packet loss or error rates, potentially causing communication links to fail completely or become ineffective. The evaluation boards utilized in this study are based on a practical wireless transmission system deployed in a remote controller for a heavy mining machinery used in underground coal mines. The results and findings presented in this paper can aid in the design of wireless systems that are resilient to EMI in underground mining environments.

Feb 1, 2025

By K. K. Bhattacharyya

Vast deposits of lignite occur in the Gulf Coast states and northern plain states. Lignite resources are cited to be over 43 billion tons in the Gulf Coast states. An additional resource of 16 billion tons are reported in North Dakota (Jackson, Smith, 1981). All lignite in the U.S. is mined at present by the open pit method. Draglines and scrapers are primarily used to remove the overburden. Bucket-wheel excavators are also being considered for new mines in the planning stages. Lignite seams are mined using front-end loaders, shovels and trucks, or Easi-miners. The depositional environment of lignite is weak sedimentary soils and rock. Ground water is often encountered within the mining depth. Surface water resulting from heavy rainfall or snow melt contributes to the problems of mining. Mining depths of up to 60 m (200 ft) are under consideration. Draglines exert additional loads on the highwalls and spoil piles. The combination of any number of these factors may cause instability of the slopes. Bearing pressure, trafficability, and settlement can also be a problem for excavation and loading equipment.

Jan 1, 1982

Mr Kapp's paper helps considerably to clarify the subsidence/mine geometry relationships in New South Wales. It is in the best tradition of the presentation of field investigations such as has built up internationalknowledge over the years.The Author has plotted in Fig. 10, the maximum subsidence developed over each of a number of panels of different width/depth ratios and concludes that the maximum possible subsidence over a super critical extractionarea is around 0.65 of the mining height and that this is reached with the critical width/depth ratio of extraction of around 1.5.Although, as Mr. Kapp says, the maximum possible subsidence in the UK can reach 90% of the seam thickness extracted the more usual figure for the first seam is up to 80%. It has also been found in the UK that with shallow workings such as those at Kemiro Coliery the critical width of extraction is 2.0 or more times the depth.

Jan 1, 1981

By D. Mesa, J. Karvonenb, A. López, P. R. Brito-Parada, R. Grau, D. Davoise

The froth zone in flotation cells plays an important role in determining metallurgical performance. This is even more critical as cell sizes increase, since larger bursting surface areas can easily result in poor froth transport and even stagnant froth zones, which are detrimental to recovery. Generating additional overflowing lip length by adding internal launders and reducing surface area (while also directing the froth to the overflow) by adding crowders are well established design strategies to enhance froth mobility. However, comparative experimental studies of froth zone design modifications at industrial scale are scarce and often lack detailed froth characterisation. In this work, we present the results of two experimental campaigns that were carried out at Atalaya’s Riotinto concentrator in order to determine the effect of a new froth zone design on the flotation performance of a TankCell® e300 cell that operates as the first cell of the rougher bank. These campaigns provided a unique opportunity to assess froth phase phenomena and metallurgical performance before and after changes in design. The original cell design had an internal peripherical launder and a froth cone, while the new concentrate launder technology adds a centre launder and an adjustable froth crowder to the existing launder design. The new concentrate launder arrangement reduces significantly the froth area as well as the froth transport requirements, aiming to improve froth recovery and, consequently, enhance flotation performance, allowing copper recoveries in the TankCell® e300 cell to increase dramatically. In addition, radial profiles of froth height and froth velocity at the surface were determined, which provide valuable insight into the effect of design changes on froth stability and mobility. Keywords: Flotation performance, enhanced recovery, launder, crowder, froth stability

Jan 1, 2020

By B Ilich, M Brad, R Brandli, E MarT

The Wirtgen surface miner was investigated for application to the Cloud Break iron ore deposit since it can selectively mine thin seams and there is no requirement for drilling and blasting or primary crushing as the surface miner cuts and breaks the rock to secondary cone crusher feed size. A physical metallurgical study of the surface miner run-of-mine (ROM) from Cloud Break was conducted to better understand the product size distribution, amount of -31.5 +6.3 mm lump produced, lump stability and physical metallurgical quality compared to conventional drill and blast techniques. Since the Cloud Break mine was not in production, the lump product from crushing and screening of surface miner ROM was compared with product simulations using traditional premining physical metallurgical processing techniques including drop testing of PQ diamond core. Drop test conditioning is widely used in the iron ore industry to simulate blasting, crushing and screening at the mine and subsequent product degradation during handling from mine to port to predict both the amount of lump product on ship and the size distribution of the fines and lump. The size distributions of surface miner ROM for hard, medium and friable ore types show very tight size distributions with very little above 100 - 150 mm, about 60 per cent of the distribution between 75 and 6.3 mm, with less below 1 mm compared to conventional drill and blast ROM. Crushing, screening and drop test conditioning of the surface miner ROM produced more lump in equivalent ore types compared to drill and blast techniques or their breakage simulation using PQ diamond core. The higher lump yield from the surface miner was also confirmed by pilot scale crushing of some 7400 t of surface miner ROM from the Cloud Break trial pit. The lump produced from surface miner ROM was quite stable and showed similar low degradation characteristics to lump simulated from drill and blasting techniques. Product size distribution simulations using conditioned crushed lump from 1 m diameter Bauer hole samples were found to compare well with processed PQ core samples and surface miner product from trial mining at Cloud Break. The Bauer sample method is therefore considered to be a very useful close simulation to actual lump production, although the lump yield is lower.

Jan 1, 2007

By George S. Rice

The major purpose of this bulletin, as indicated in the preface by Dr. John W. Finch, Director of the Bureau of Mines, is to give a critical review of the coal-mining methods used in the principal producing countries of Europe, to describe the reasons underlying the adoption of these methods, and to contrast them with coal-mining methods employed in the United States. The report includes discussions of various subjects intimately related to coal mining, such as geology of the principal coal fields; production and resources of the several countries; mine safety and health research; Government mining regulations; mine inspection and rescue procedure; safety lamps; fixed lighting methods under-ground; testing electric motors, mining machines, and mining explosives for permissibility; and special mining hazards, such as explosions of gas and coal dust, mine fires, instantaneous gas outbursts, ground movement and surface subsidence, and bumps. Commercial, economic, and labor problems of European coal mining, including miners' output, wages, and social-insurance schemes, as well as cost of mining, prices of coal, etc., are briefly described. It will be noted that data on most subjects are not given for Russia, which has become an important coal-producing country, owing to the lack of reliable published information concerning Russian coal mining.

Jan 1, 1939

By Liaqat Ali, Robert Chapman, Asghar Ali, Mohammad Tahir Shah, Seema AnjumKhattak, Mohammad Farhan

Alluvial gold is abundant in the Quaternary deposits of the Kabul and Indus rivers in District Nowshera, Khyber Pakhtunkhwa, Pakistan. Understanding the provenance of alluvial gold using morphology and elemental composition could be helpful in developing an exploration strategy of regional benefit. Detailed morphological studies of gold grains revealed high flatness index values which are indicative of a distal source. Compositional studies of 58 gold grains using SEM and EMPA showed broadly similar Ag ranges (1– 15 wt%) for each sample and occasional Cu values in individual gold particles to 0.4 wt%.Whilst the Ag profile is not diagnostic, the Cu values are compatible with derivation from either porphyry systems or ultrabasic rocks. The complex geology of the drainage catchments could host gold mineralization of other styles, but larger sample suites would be required to refine the current interpretation to establish whether particles which are simple Au-Ag alloys could be derived fromorogenic or epithermal sources. This scoping study has demonstrated that the compositional and morphological studies of gold grains are useful in providing information regarding the nature and location of the source of placer gold in areas where there is limited information on the nature and location of in situ mineralization.

Oct 6, 2020

By Adeyemi Adesina, Subhabrata Mishra, Syed Mohammed Mustakim, Malaya Kumar Jena, Shaswat Kumar Das

Utilization of low-grade manganese ore adopting the carbothermic reduction roasting process is a proven method to produce high-grade manganese ore. To minimize industrial waste and protect the environment, gas cleaning plant sludge (GCPS), which is a solid waste from steel industries, was employed as a reductant to perform the reduction roasting process. The optimum conditions to carry out reduction roasting of the low-grade manganese ore were found to be: a roasting temperature of 950 °C, a residence time of 2 h, 40% GCPS as reductant, and magnetic separation at 5000 G for a manganese ore size of –10 mm. A lowgrade manganese ore comprising Mn grade 31.27% and Fe grade 19.78% having a Mn/Fe ratio of 1.58 containing a high silica content of 26.48% was used for the carbothermic reduction roasting having mineral phases of pyrolusite (MnO2) and hematite (Fe2O3) as found from XRD. The gangue minerals were separated during the magnetic separation, and the upgraded product was obtained, which reached a maximum value of TMn 49.5% with RMn 76.55% and TFe 62.19% with RFe 42.51%. In the study, activated charcoal (AC) was also taken as a reductant for comparative analysis; the experimental results revealed that GPCS performed better than that of the AC, showing potential to be used as a reductant in metallurgical industries. However, the resultedMn/Fe ratio was very low for the reduced sample; therefore, it can be used for smelting along with high-grade manganese ores as a feed.

Mar 5, 2021

By T Isaksson, J Anderson

The procurement process for underground construction contracts, in particular those contacts involving tunnel boring machines (TBMs), is subject to many complex and inter-related variables, including national and local politics, public policy, community involvement and media attention û as well as strict environmental and legal requirements. Other restrictions include the time available to adequately investigate geotechnical conditions and viable technical options to determine the best construction methodologies û including selection of tunnel boring machine characteristics and, those construction means and methods suitable for the specific geotechnical and environmental conditions. The latter are, most often, quite imperfectly understood. æGetting it rightÆ implies that an optimal configuration û of machine type, characteristics and associated methodologies û can be found and successfully implemented for a particular project. æFrom the beginningÆ implies that the lack of time issue can be successfully resolved. Within an international context this paper highlights a number of issues of concern which relate to tunnel procurement systems and the ways in which certain key processes are managed during planning, design and construction. The authors argue that there is considerable room for improvement in the way tunnelling projects are undertaken and an approach is discussed which has the potential for substantial gains in cost and schedule and reduction of risk. Savings, however, may only be fully realised if the new methods can be fully implemented by all parties involved. This, we believe, will require the rejection of ætraditionalÆ forms of management and procurement with associated changes in the roles and responsibilities of owner, engineer and contractor. Additionally, risk identification, assessment and mitigation are essential cost and schedule control process which have, to this point, been underutilised by the underground construction industry.

Jan 1, 1999

By Y. R. Murthy, S. Angadi, A. K. Bhatnagar, S. K. Tripathy, L. O. Filippov

Dolomite is an essential raw material for the refractory industry, a flux in the iron and steel industry and also for the extraction of magnesium metal. Generally, particle size reduction, screening and classification are used for the preparation of the high-grade sized material for different applications, whereas low-grade fine fractions are not utilised. These fines or low-grade overburdens are dumped at the mine site for future utilisation, which creates environmental issues along with inadequate space management. In the present investigation, a detailed study was carried out to decrease the silica content of the low-grade dolomite fines from Gomardih , India, containing 28.6% CaO and 20.1% MgO along with 8.3% silica. Different process flow sheet options were evaluated with a combination of dry classifier, wet classifier, gravity concentrators as well as flotation. Different process variables were assessed along with mineralogical characterisation to optimise the process for efficient rejection of siliceous gangue minerals. Results indicated that dolomite, calcite and quartz are the major mineral phases present in the ore along with other minor minerals. It was concluded that two-stage flotation was an effective process for the reduction of silica up to below 1% after grinding to a particle size below 212 μm. A process flow sheet with a combination of gravitation air classifier and flotation can produce a concentrate with silica content below 4.5%. Keywords: Dolomite, flux, dry classification, flotation, characterisation, beneficiation

Jan 1, 2020

By J. A. Bakken

Thermal plasmas are interesting for a wide range of metallurgical and chemical processing applications. The 300 kW experimental reactor PRESS, which has been in use since 1987, is operated in the transferred arc mode with three or one plasma torches . Tests include remelting of silicon fines and production of ultrafine silica. Work on a novel three stage process for production of silicon metal is under way. A 1:1 model of the plasma reactor is used to measure the wall heat flux distribution calorimetrically. The cold walls of this model are divided into several water-cooled sections. The same plasma torches as in the real hot-wall reactor are used. In parallel to the experiments and calorimetric measurements theoretical work is done on numerical modelling of one and three transferred arcs. A modified version of the flow simulation program FLUENT from Creare Ltd. is used.

Jan 1, 1991

By B. Loveday, G. W. Delaney, S. Cummins

"Applying DEM to prediction of tumbling mill performance is challenging because several different modes of breakage are active in the process. As our knowledge of breakage and computational capacity improve, it is worth revisiting previous simulation tasks which did not produce a satisfactorily realistic description of a measured process. At SAG 2006, we reported the simulated and measured outcomes of treating a well characterised ore in a 1.2 m diameter mill. This well instrumented, pilot scale mill at the University of KwaZulu-Natal has been combined with some new approaches to ore testing to allow different modes of breakage to be tested. The mill design allows the rate of generation of fine material to be measured in close to real time for autogenous and SAG mill charges. The updated simulation model estimates mass loss with particle evolution and embeds the cumulative damage and breakage.The simulated results are compared with the measured results. Issues such as relating modelling inputs to particle breakage characterisation data and the accuracy of the predictions of the models are discussed."

Jan 1, 2012

By Renee Royer, Allan Punkkinen

As mines progress to ever increasing depth, new challenges are encountered with serious concerns for rock excavations in highly stressed conditions. New procedures have been undertaken or are under way to remove workers from the workface, mitigating risk and exposure to hazardous conditions. Rockbolting crews are at particular risk as they are the first line of defense in the installation of the ground support systems. One such initiative for removal of workers from danger has been with remote bolting. Equipment manufacturers have had the ability to remotely inject resin pneumatically into boreholes for several years, but it has not been recognized as a very effective method due to a variety of complications. This makes the installation of dynamic support system components such as the D-Bolt® increasingly difficult. More recently, hollow-core bolts have become popular providing far more effective installation when installed with pumpable, two component urea-silicate injection resins. Normet has developed high energy dissipation self-drilling dynamic bolts (SDDB®) to meet these challenges. Following several inquiries as to the effectiveness of pumpable resins for use with dynamic support components, Normet Canada performed comprehensive testing of the bolt and resin system at CanmetMINING in Ottawa to dispel or substantiate any preconceived beliefs. Several dynamic and static tests in direct and indirect loading were carried out. Results include tests in shear and early strength UCS of the resin to measure the performance of the SDDB compared with the established D Bolt as an effective dynamic ground support component. Underground field observations, installation methodology and in-situ testing are investigated.

Apr 26, 2022

By Fernando Nunes da Silva

Wear mechanisms of materials that constitute the equipments and operating parts in the pre-salt area during the production of petroleum and gas can include corrosion, corrosion-cavitation and corrosion-cavitation-erosion. In the laboratory, it is realizable, but at times it is inaccurate to reproduce or visualize some of these mechanisms due to the real complexities caused by hydrodynamic flows, and the physico-chemical and mechanical non-linearities. The main objective of this work was to study coupons of low carbon steel under laboratory conditions, such as corrosive, cavitative-corrosive (CO2) and corrosive-erosive (CO2 + SiO2), in a stirring aqueous saline solution (0 and 5.0 m/s) at two levels of temperature, with bubbling of gas (5.0 L/min) and contaminated with or without (2.5 % mass), by solids particles of SiO2. The surface of the coupons subjected to upstream flow (0° in a cylindrical generatrix of coupon), and downstream flows (180º) were analyzed by profilometry. The measurements of roughness and waviness of all coupons were statistically analysed using Statgraphics® Centurion XVI, at a confidence level of 95% and significant differences observed in some matrices were discussed.

Jul 31, 2018

By Fred P. Peters

At first glance this paper may seem unique among those comprising this symposium on designing for powder metallurgy, since it is evidently concerned with everything but Powder metallurgy. This paradox mill be at once resolved, however, when the real Purpose of the symposium meeting is understood—to present factually and objectively the things that can and cannot he done with powder-metallurgy methods, and especially to set forth with brutal frankness the limitations of Powder metallurgy, so that costly over-enthusiasm and misapplication may be prevented. Since much of powder metallurgy's future development (and many of its present disappointments) has been in competition with other and long-established methods of fabricating parts, it is easy to see that its true competitive possibilities in any given case cannot be accurately appraised without rudimentary knowledge of what the competition can do. This paper, therefore, presents a few reminders of things you all know—a background to be kept in mind as you examine the data on each of their specialties given by the authors of the papers that follow. From the standpoint of the design engineer powder metallurgy is often in Competition with one or more of the following: sand casting, die casting, permanent-mold casting, precision investment casting, ma- chined bar stock, screw-machine parts, cold-heading, drop-forging, and stamping and drawing. We will here briefly discuss each of these individually, and set forth so, rough (and therefore dangerous) generalizations about its competitive position, especially with respect to powder metallurgy. Sand Casting Sand-casting of small parts is sometimes an inexpensive method of manufacture, for its raw-material costs (i,e., for gray iron) are the lowest of the various methods and it involves the use of no tools and dies of jewelry quality. its design flexibility— that is, the ability to make complicated, cored and undercut parts in one piece—is about the highest of the competing processes and in this respect it can do many things that are impossible by powder metallurgy. For small castings its production rates may be higher, by using multi-impression molds, than can be achieved with parts of the same size by powder metallurgy. But its labor charges for melting, pouring, patternmaking and molding are comparatively high and the waste it entails in gates and risers is always considerable. Tolerances of sand castings are wide (+1/6 to 1/32 in- per in.) and where precision approaching that of powder metallurgy is required sand castings must be machined to final size, thus increasing their cost. Steel sand castings are more expensive and less precise than iron, and nonferrous the most costly of all.

Jan 1, 1945