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By H. W. Graham

AS these annual occasions in honor of Henry Marion Howe continue through the years: there is progressively less likelihood that the lecturer will have had personal knowledge of Dr. Howe. The present speaker is one of those who unfortunately had no opportunity to come under the inspiring presence of this great metallurgist. A review of Howe's work shows it to cover a comprehensive range of interests and to evidence an impressive richness of detail. Not only was Howe at home in the laboratory, but he was familiar with the processes of iron and steel making and had a real understanding of them. His writings include much that is descriptive of processes with a wealth of material that is becoming of increasing historical value. He recorded his studies of the theoretical aspects of processes and published at least two process classifications, one in 1890 that was lengthy and somewhat theoretical, and a second in 1906 that was more of a practical listing. Wide as Howe's field of interest was, it is significant of the circumstances of his time that he gave- little consideration to raw materials or to their effect on iron and steel making processes. In 1933, Waterhouse, Howe lecturer for that year, presented a descriptive summary of the major steel making processes, and in 1946 Joseph discussed the blast furnace process. Otherwise Howe lectures have not dealt with processes as major subjects. In today's lecture, with no effort to describe the mechanical arrangements of iron and steel making facilities, it is proposed to examine the essential technological elements of the processes, to explore the inter-relation of these elements, and particularly to seek recognition and understanding of those factors which determine why certain processes are or are not used. The discussion of this lecture will deal with the major well-known large tonnage processes, with only such attention to processes of minor tonnage and special character as may be warranted for explanation by contrast. Subject to the errors of generalization and the shortcomings of condensation involved in presentation limited to a single hour, it is proposed to examine broadly but intensively those operations which convert raw materials into steel. It is an innovation for a Howe lecturer to discuss the raw materials of the iron and steel industry, but the changing circumstances of passing years intensify the influence of raw materials on processes and require the metallurgist to be alert for the process adjustments that may become advisable or mandatory. For a half century the metallurgical processing of iron and steel has followed a surprisingly straight path, but this does not necessarily mean that there are no curves in the road ahead. Ages ago primitive man came to know iron in its metallic form, not only by the

Jan 1, 1948

By B. Fitch

This paper deals with the behavior of sedimenting suspensions. More particularly, it treats, in as organized a manner as possible, the body of knowledge, theoretical or empirical, by which one predicts the behavior of miscellaneous swarms of particles in suspension. Such knowledge is necessary for precise and economical design of equipment. While the behavior of a single spherical particle settling through an infinite sea of quiescent fluid is well understood, practical sedimentation processes are almost always concerned with particles of assorted sizes, densities, and shapes, in such concentration that there is profound particle interaction. Such swarms of particles are observed to settle in any of four markedly different manners. Which one they follow is governed by particle interaction. It is determined largely by the dilution of the suspension, and the relative tendency of the particles to cohere. TYPES OF SEDIMENTATION The relationship between the different modes of sedimentation is shown paragenetically in Fig. 1. The left side of the diagram represents particles having little tendency to cohere; the right side represents particles for which interparticle cohesion is large compared to the settling force. The vertical axis represents dilution. As seen in the diagram, sedimentation is divided into three broad fields or regimes. At high dilutions there exists a regime here named 'clarification.' Particles in clarification may settle either individually, or by collecting into separated floccules. Thus there are two different possible modes of settling in the clarification regime. It is characteristic c~f this regime that there will be no clear line of demarcation between settling suspension and a supernatant. Faster particles settle out ahead of slower ones. In batch tests there develops a gradation of both particle sizes and pulp density due to progressive depletion of the largest particles from any given pulp level.

Jan 1, 1962

By R. P. King

The two-phase distributed-parameter kinetic model for flotation has been wed as the basis for a digital simulation of flotation plants of arbitrary configuration. Ores that contain any number of minerals can be handled. The effects of incomplete liberation and particle-size distribution are specifically allowed for. The simulator allows the investigation of variations in throughput and in the slurry density of the feed, and of variations in stage volumes and aeration rates. It can handle cell behavior even under conditions of hindered flotation. The requirements for data preparation are completely documented so that the computer program is suitable for general-purpose use. The program is written in Fortran. The output from the simulator consists of the complete material flows in the plant, as well as the grade, recovery, and particle-size distribution in each stream.

Jan 1, 1976

By Thomas W. Gibson

THE Province of Ontario in recent years has come strongly to the front as a producer of metals, especially nickel, copper, silver, and now gold. Of the last named, the output for 1922 was in the neighborhood of $20,000,000. The law governing the mining industry in a community where such develop-ments are taking place will be of interest, therefore, in other places where mining laws are up for revision The first mining of importance done in this province was for copper on the north shore of Lake Huron, where the Bruce mines were opened in 1846. These deposits of copper sulfides, notwithstanding the remoteness from markets and the cost of transportation, were vigorously worked for 12 or 15 years and also intermittently later, but the active career of the mines came to an end in 1875. From first to last, a little less than 10,000 tons of copper was produced, valued at $3,300,000. All the product was shipped to England as dressed ore, contain-ing up to 13 per cent. of the metal. In. 1866, a rich pocket of gold was found on the Richardson farm near Madoc, Hastings County, but was not followed by further discoveries of a like kind and in time the excitement it caused died away. Rich silver ore was found in 1868 on Silver Islet in Lake Superior, a speck of land not larger than a good-sized ball-room. The assemblage of minerals here was practically the same as that at Cobalt, discovered 35 years later, namely, native silver, cobalt, nickel and arsenic; in addition, there was considerable argentite, which has always been scarce at Cobalt. In all, the silver produced amounted to about $3,500,000. The belief persisted that the deposit was not mined out, and in the summer of 1922, some rich ore was extracted from the roof, perilously near the bottom of Lake Superior.

Jan 2, 1923

By E. P. Jennings

Large deposits of titaniferous iron-ore occur at Caribou, an old silver-mining camp in Boulder county, Colo., 17 miles west by south of Boulder, and a few miles northwest of the tungsten-mines. Professor Regis Chauvenet1 published a part analysis of the ore many years ago, but gave no description of the wall-rock. Caribou hill, which contains both the silver-bearing veins and the iron-ore deposits, is a low dome of gabbro surrounded by the Archæan schists and gneisses of the Front range of the Rocky mountains, the peaks of which, a few miles west of Caribou, attain an elevation exceeding 12,000 ft. The gabbro stock is roughly elliptical in outline, with approximate diameters of 1 and 3 miles. The crest of the dome is 10,500 ft. above sea-level, and the town and ore-cleposits are 500 ft. lower. Outcrops of the iron-ore occur in the town and extend NW. for 2,000 ft., where they disappear under the swampy meadows of Caribou park. Portions of the deposit are covered by drift, but one continuous outcrop is 900 ft. long and from 200 to 250 ft. wide. A second deposit is 0.25 mile south of the town along the eastern slope of the hill. It is not as well defined as the north bed, but is approximately 1,000 ft. long and from 100 to 200 ft. wide. The easily disintegrated ore does not form prominent outcrops, but the outlines of the deposits are readily traced by the large amount of ore fragments that cover the ground. Trenches and pits sunk on the outcrop expose a roughly banded magnetic iron-ore, with pyroxene as the principal gangue-mineral. The Gabbro. This rock was classified in the field as a gabbro from the presence of pyroxene and striated feldspars, and for convenience the field-name will be retained.

Jan 1, 1913

By Charles M. Rolker

THIS remarkable and well-known district lies about 320 miles south of Salt Lake City, in Washington County, near the Arizona border of the territory. It is now reached by the Utah Southern Railroad and its extension, and the last 100 miles are run by stages. These vehicles are called "jerkies" in the West, which name conveys a good idea of the comfort they afford, and the relief experienced when you alight. Arriving at Silver Reef, the main camp of the district, one sees at once that he stands where once a surging sea had its domain, marked now by heavy sandstone deposits of a red and white color. The town itself, a neat, clean, and orderly mining town, is encircled on the north by traohyte and granite mountains, skirting to the west. They are cut through in places by deep gorges, left us as the only trace of the force of former currents, which drained the adjoining territory to the north; and which when swelled and infuriated by tempests and cloud-bursts, took in their grasp the huge blocks of

Jan 1, 1881

By G. Hasenfus, M. Karmis, G. Goodman

Surf ace subsidence is rapidly becoming an important environmental consideration of active as well as abandoned mining operations. The damages attributed to this phenomenon have been witnessed in both rural and urban areas and include land settlement and fracturing, structural damages to surface buildings or facilities and disruption or contamination of ground water supplies. The problem of mining subsidence has gained considerable emphasis in the Appalachian coalfield. The increased mining activity over the past few years and the particular topographic conditions, lithologic and structural environment, mining methods and hydrological patterns are all factors which have contributed to specific subsidence characteristics in this region. The objective of this paper is to discuss and review the most widely accepted methods of subsidence prediction above longwall as well as partial extraction systems in Appalachia. These include an accurate and easy to apply empirical method, which has been developed entirely from field information pertaining to the Appalachian coalfield and incorporates both geometrical and geological information of the panel in question. The second method is a development of influence functions and is founded on the zone area approach. Both methods, originally derived for longwall mining, have been expanded to include room and pillar applications and have been widely used by the mining industry in the Appalachian coalfield.

Jan 1, 1984

By Michael J. Fiannnaca, Michael M. Easdon

Disseminated epithermal gold metallization occurs within a breccia unit interpreted to be a submarine debris flow. Gold is associated with oxidized pyrite, fluorite, and jasperoidal silica. A minimum of 8 Mt (9 million st) of open-pittable mining reserves will be cyanide heap leached as run-of-mine ore at a rate of 0.9 Mt (1.0 million stpy 1. Careful evaluation of the combined results of successive sampling projects has established the pit plan, minable reserves, and process metallurgy of the operation. The sampling procedure utilized for a given test depended upon geological interpretation as well as the procedures, successes, and failures of previous tests. This paper summarizes the sampling and testing procedures of the development effort in light of the project goals and attendant problems in achieving them.

Jan 1, 1985

Jan 1, 1970

By Philip B. Dettmer

In the last two decades we have witnessed many new developments in the art and science of mineral beneficiation. Competition and the pressures of inflation have caused operating managements to search for every possible way to squeeze out a few more cents savings per ton of product. One illustration of this is the trend toward the use of larger grinding mills. A few years ago a 1000 hp ball mill was considered a giant. Now we have many examples of successful grinding mill installations of 3000 to 4400 hp connected load per mill. The trend toward these larger mills is increasing every year, and we have not seen the upper limit yet. For example, three 6600 hp cement finish mills are presently being built for a plant in Missouri.

Jan 4, 1965

By C. R. Sandberg, C. A. Connally, N. Stein

This paper describes the results of volumetric efficiency tests on oil well pumps handling gas oil mixtures. The work was performed in a large scale, above ground unit wherein test conditions could be accurately controlled and measured. The main variables studied were gas/oil ratio (including gas from solution and free gas mixed with oil), pump compression ratio, pump stroke length, pump speed, and clearance volume between the valves at their closest approach. Results are presented for two different pumps and for oils of two viscosities. Relatively small amounts of gas entering the pump resulted in large decreases in volumetric efficiency. Under conditions where the pump was operating at reduced efficiency because of the presence of gas, it was found that variation in the clearance volume between the standing and traveling valves had a considerable effect on pump efficiency level. This effect of the valve clearance volume was found to be significantly altered by the viscosity of the oil used in the tests. The effects on pump efficiency of the other variables studied were found to be relatively small over the range of conditions utilized. INTRODUCTION The production of oil by pumping is often hampered by low volumetric efficiency. A direct increase in lifting costs results from low volumetric efficiency. An indirect increase in lifting costs, probably greater than the direct increase, results from additional wear and tear on pumping equipment and from the down-time necessary for the repairs which can be traced to low-efficiency operation. Both increases in lifting costs tend to reduce economically recoverable oil. A number of different factors can contribute to low pump efficiency. A known basic cause of low efficiency is the presence of free gas in the pumped fluid. Pump volumetric efficiency is calculated only on the basis of liquid pumped and because any free gas pumped is discounted, this volume of free gas would represent a loss of pump efficiency. However, gas also causes a reduction in pump efficiency because it is a highly compressible fluid. It is known that pumps some- times "gas lock" because of excessive gas-to-liquid ratios in the pump barrel. Little is known of the role of gas compressibility in the intermediate case where the pump is operating at low efficiency. The opinion exists, however, that oil-well pumps tend to operate at higher efficiency with long stroke lengths at low speeds, but no quantitative studies of these pumping variables have been reported. It was believed that a much better understanding of the variables which control pump volumetric efficiency could be obtained and that possibly some suggestions as to the methods for increasing efficiency might be found from a study of the operation of pumps handling gas under closely controlled conditions. Previous investigators have studied the effects on pump efficiency of such factors as oil viscosity, oil temperature, slippage of oil. past pump plungers, pump submergence, valve size and spacing, pressure above pump plunger and fluid vapor pressure. However, none of these published investigations were conducted with pumps being subjected to large amounts of gas such as might be the case in a pumping well, nor did any of the investigations study the effect of variation in stroke length or pump speed. A large-scale teat unit was therefore constructed for studying the operation of pumps handling gas and for evaluating effects of such variables as pump stroke length and pump speed. PROCEDURE AND EQUIPMENT A schematic diagram of the pump testing equipment is given in Fig. 1. A 45-ft length of 6-in. casing is mounted vertically in a 65-ft tower. Sight ports are mounted in the casing at intervals near the location of the pump intake and the liquid level in the casing. These sight ports are fitted with Lucite windows sealed by neoprene "0" rings. The Lucite windows are machined to conform to the I.D. of the casing so that no obstruction to flow is present along the casing wall. The casing is fitted with a tubing head and 2-in. tubing is hung inside the casing. Pumps are seated in a shoe attached to the 2-in. tubing. A 1-in. polish rod is attacked directly to the pump without any intervening sucker rods. The top of the polish rod is attached to the weight carrier, which contains a number of weights to be used to force the polish rod in against tubing pressure on the down-stroke. This is necessary because a long string of sucker

Jan 1, 1953

By Bruce A. Kennedy, Richard M. Stewart

Slope stability has now become a practical tool in the design and operation of open pits. The selection of slope angles is a critical decision that can have far-reaching effects on the accumulated cash flow and the overall profitability of a mining project. Slope failures can now be dealt with in a number of ways. Two methods - the total removal and the partial unloading of a failing zone-have been practiced for many years. However, with the refinement of monitoring techniques, open pits can now learn to live with a slide and even turn a potential loss into a gain. There are various techniques, such as presplit blasting, drainage systems, and artificial stabilization, which can be applied immediately in an existing open pit to improve the stability of the pit slopes. The technology of slope stability will play an important part in the future mining of low grade, previously marginal orebodies, which will have to be exploited if the mineral needs of the world are to be met.

Jan 1, 1971

HENRY M. HOWE, Bedford Hills, N. Y. (communication to the Secretary *).-Dr. Burgess would add to the value of this important paper if he would give us the carbon content of the steel made in the several charges, or, if this cannot be done, if he would indicate whether, as might he inferred from his paper, the teeming temperature is approximately constant and independent of the carbon content of the steel, or whether as would be expected, it varies with the content and is materially higher for low- than for high-carbon steel. If he could add to Table 3 the time of the several tests, that would be welcome. His Table 3 leads one to infer that, once the bath is melted somewhat more than flat, the temperature of the roof is nearly constant and is approximately the highest compatible with reasonable longevity. That is to say, the metal is heated by means of a roof and flame at nearly constant temperature. The temperature of the observed upper surface of the slag should reflect that of the roof approximately, and in Table 3 this seems to be true, the temperature of both rising toward the middle of the record, and again falling. The slag as the medium through which the heat passes from roof to metal, should be intermediate in temperature between the two, as it is here. But the temperature of the metal ought to rise continuously, unless when cold additions are charged, and this too seems to be. true, allowing for slight observational errors, the total rise from the first to the last spoon-test being 89°. The temperature drop of from 85° to 135° from the last spoon-test to the teeming is surprisingly great, suggesting that the spoon-tests represent the metal immediately beneath the slag, and therefore appre-

Jan 6, 1917

By D. M. Wyslouzil

Standard testing methods are described that are presently used for the selection of grinding equipment. Correlation between laboratory batch grinding tests and pilot plant continuous tests are established by means of particle size distributions and flotation results. Conventional and autogenous grinding circuits are discussed showing the relationships of the controllable circuit parameters.

Jan 1, 1982

By R. S. Busk, E. G. Bobalek

The relation between gases and metals has been a subject of increasingly active investigation during the past years, principally devoted to the study of metal-hydrogen systems. It has been found that hydrogen is soluble in most molten metals to an appreciable extent and somewhat soluble in most solid metals.l,2 In every known case there is a sudden decrease in solubility at the melting point. Thus a freezing mass of metal containing hydrogen in excess of the solid solubility must in some way expel that excess during the freezing process. This leads to internal blowholes, and such effects as pinhole porosity. Gas trapped in metal that is to be fabricated by a working process such as extrusion or rolling may be the cause of blisters. For some cases, notably in copper and iron alloys, the presence of hydrogen can lead to extreme embrittle-ment of the metal. The aluminum-casting industry has long recognized the importance of hydrogen in its techniques. Excess gas in molten aluminum alloys often leads to the formation of "pinhole porosity" in the solid casting.= To prevent this hydrogen pickup it is necessary to avoid overheating the melt and to protect it from such sources of hydrogen as water. In spite of all precautions, it is sometimes necessary to extract hydrogen from the melt just before pouring by bubbling with a gas such as chlorine or nitrogen. Reccntly it has been found that somewhat similar effects are possible with magnesium alloys, in that the presence of hydrogen can induce or aggravate micro-p~rosity.4-6 This paper is primarily concerned with a presentation of some facts concerning the solubility of hydrogen in magnesium and its alloys, with some discussion of the significance of these facts in a practical sense. In any study of gas-metal systems it is important to bear in mind a clear distinction between adsorption on surfaces and absorption within the lattice.' Considerable attention has been directed toward determining whether hydrogen is truly soluble in any solid metal, or whether the gas extracted from a sample was present at surfaces (external and internal) only.7 Most present day evidence supports the idea of true solution in addition to adsorption. A second important factor when dealing with gas solubility is the dependence of such solubility on external pressure. For diatomic gases such as H², solubility in both liquid and solid metals apparently is proportional to the square root of the pressure, indicating a breakdown to a monatomic gas before diffusion into the lattice.= For true equilibrium values of solubility, therefore, the pressure at the the surface must be constant and, preferably, known. Very little has been published concerning the hydrogen-magnesium system. Winterhager has presented the most

Jan 1, 1947

By R. S. Busk, E. G. Bobalek

The relation between gases and metals has been a subject of increasingly active investigation during the past years, principally devoted to the study of metal-hydrogen systems. It has been found that hydrogen is soluble in most molten metals to an appreciable extent and somewhat soluble in most solid metals.l,2 In every known case there is a sudden decrease in solubility at the melting point. Thus a freezing mass of metal containing hydrogen in excess of the solid solubility must in some way expel that excess during the freezing process. This leads to internal blowholes, and such effects as pinhole porosity. Gas trapped in metal that is to be fabricated by a working process such as extrusion or rolling may be the cause of blisters. For some cases, notably in copper and iron alloys, the presence of hydrogen can lead to extreme embrittle-ment of the metal. The aluminum-casting industry has long recognized the importance of hydrogen in its techniques. Excess gas in molten aluminum alloys often leads to the formation of "pinhole porosity" in the solid casting.= To prevent this hydrogen pickup it is necessary to avoid overheating the melt and to protect it from such sources of hydrogen as water. In spite of all precautions, it is sometimes necessary to extract hydrogen from the melt just before pouring by bubbling with a gas such as chlorine or nitrogen. Reccntly it has been found that somewhat similar effects are possible with magnesium alloys, in that the presence of hydrogen can induce or aggravate micro-p~rosity.4-6 This paper is primarily concerned with a presentation of some facts concerning the solubility of hydrogen in magnesium and its alloys, with some discussion of the significance of these facts in a practical sense. In any study of gas-metal systems it is important to bear in mind a clear distinction between adsorption on surfaces and absorption within the lattice.' Considerable attention has been directed toward determining whether hydrogen is truly soluble in any solid metal, or whether the gas extracted from a sample was present at surfaces (external and internal) only.7 Most present day evidence supports the idea of true solution in addition to adsorption. A second important factor when dealing with gas solubility is the dependence of such solubility on external pressure. For diatomic gases such as H², solubility in both liquid and solid metals apparently is proportional to the square root of the pressure, indicating a breakdown to a monatomic gas before diffusion into the lattice.= For true equilibrium values of solubility, therefore, the pressure at the the surface must be constant and, preferably, known. Very little has been published concerning the hydrogen-magnesium system. Winterhager has presented the most

Jan 1, 1947

By J. F. Wolff

EXPLORATION of Lake Superior iron ores is done principally by drilling. The soft iron ores are churn drilled and the harder ores are diamond drilled. In exploratory work in the harder formations, where the diamond drill is used, the sample comprises both core and cuttings. The care given in handling and preserving the core depends on the im-portance that may be attached to certain characteris-tic strata in different formations. The following instructions for the care of core samples are issued by the Oglebay Norton Co. for diamond drill work done for them on the Gogebic Range of Michigan: The driller shall be careful upon removing the core from the core-barrel to keep the core in exact order. Not only should the pieces of core be kept in exact relation to each other, but care should be used not to turn them end for end. Core should be placed in the core-box from left to right in each row. Each drill should be furnished with small, hinged cover core-boxes, and each drill should be well supplied with empty boxes. Core remaining at the drill when the drillers are not working should be locked up. The practice of picking sample pieces of core and carrying them away from the drill to be examined in better light, or shown to someone else, is unnecessary and prohibited. The reason for this is that these pieces are seldom returned to the core-boxes and valuable information or "markers" may be lost. If the inspector suspects that a critical point is reached in the drilling and he cannot determine at the drill, he should remove the entire core-box and see that the drill is immediately furnished with an empty core-box. It is customary to split the core longitudinally so that one-half may be ground to a pulp for analysis and the other half may be kept for future inspection. The core should be filed in permanent core-boxes, properly labelled, if the core is to be kept in exact order as taken from the core-barrel. Otherwise, it is often filed in tin boxes inn the way that sludge samples are filed. To obtain the average analysis, the core and cutting samples obtained in the same run are analyzed separately and the analyses are combined in the proper ratio.

Jan 9, 1922

By C. R. Hayward, H. O. Hofman

The aim of instruction in a metallurgical laboratory is to make real the principles on which metallurgical processes and operations are based, and to foster the spirit of investigation. The materials with which experiments are carried out are ores, metals, and metallic compounds. The method varies with the end sought. A class may work as a whole, each member contributing his share to the solution of a problem, or the students may carry on investigations independently; the former exemplifies class-research; the latter, individual research. It is with a branch of the former, with special reference to ore-treatment, that the present paper deals. In smelting an ore by a well-established process, the result is shown by analyzing the products to see whether their compositions correspond to those calculated in making up the charge; by taking account of stock to show the distribution of metal in the different products made and the losses from dust and volatilization; by casting a thermal balance to find the distribution and losses of heat; and by making a cost-sheet to ascertain, as far as possible, the necessary outlay of money. In lixiviation and amalgamation, the mode of operating has to be varied to adapt a process to the individual ore. Here a number of tests become necessary. Each will consist of a series of experiments with one variable, in order to find the conditions under which the variable gives the best result; a summary of several tests will give the best method of operating. Working a number of charges with the best method will furnish the data desired for ascertaining the recovery of metal,

Jan 1, 1910

By N. B. Pilling

THE development of a proper treatment for shells in connection with war contracts has brought to our attention the fact that the temperature of the liquid bath in which steel is quenched has a decided influence on the speed of cooling in the case of some liquids and very little in the case of others. Widely different physical results have been obtained by the use of water spray, water immersion, and oil immersion and further experiment has shown that the quenching effect of water used as a spray or an immersion varies greatly with the temperature of the water. The present experiments were undertaken with the idea of obtaining information of a quantitative nature regarding the quenching properties of a number of liquids used commercially in hardening steel. The general features of such cooling media are common knowledge and in the literature may be found records of numerous attempts to evaluate the cooling power of a liquid when used as a quenching bath. Much, if not most, of the data given on this subject is in the form of a simple statement of the time required for a certain heated mass to cool between two arbitrary temperatures when immersed in the liquid, quite regardless of the path of the temperature change. Our own purpose has been somewhat different. We have attempted to isolate that property of these. liquids having to do with their ability to absorb heat rapidly, as distinct from the behavior of a considerable mass when exposed to different thermal environments. More specifically, from the data obtained through autographically recorded cooling curves of a small standard mass quenched under various conditions, we have tried to analyze the mechanism of heat absorption by the several liquids, measure the changes in its rate as a function of the temperature of the surface of transference, and ascertain the influence of the temperature of -the liquid itself upon both.

Jan 9, 1919

By C. D. Ramsden

During the war years of 1941 to 1945, maintenance of mine locomotives and other mine equipment took the form of rebuilding rather than of renewing. Purchase of new parts became increasingly difficult and mine operators found it necessary to maintain equipment by salvaging old parts. Mine-locomotive wheels, although not representing a high cost per pound of material, contain a considerable amount of steel and without rebuilding would have to be scrapped long before even a moderate percentage of the steel in the wheel is actually consumed. Many mine operators have been rebuilding locomotive wheels for several years with automatic open are-welding equipment. In 1927, the Pittsburgh Coal Co. started such a program, using a single Westinghouse automatic welding head. Since that time, many refinements have been added, until in 1944 the setup was operating very efficiently. A desire to increase wheel life and to hold down rising costs led the company in 1944 to investigate the possibilities of the under-flux are-welding process for wheel rebuilding, although at that time, little or no work had been done on multiple pass or "build-up" welding with the underflux arc. Work with this process had been confined largely to welding together flat plates in a "down hand" position. Possibilities for savings were intensified by the fact that the company has 300 locomotives in operation, using actively or as spares 1200 sets of wheels. During 1942 and 1943, about 500 sets of wheels were sent each year to the company's maintenance shop at Library, Pa., for rebuilding. Based on having 800 sets in service (many of the company's heavy locomotives have three sets of trucks), the average life of a set of wheels was approximately 19 months. Anything that could be done to increase wheel life promised sizable annual savings. Open Arc Welding With the open arc process, a set of wheels could be rebuilt for about 40 pet of the cost' of new wheels. Underflux arc welding gave promise of greatly increased welding speeds, more homogeneous, dense deposits and the chance for use of a wider range in welding-wire compositions. Against this was ranged the higher cost of materials and the cost of developing the process from the theory to a practical reality. Since 1927, when a single open arc head was placed in operation, fixed welding procedures had been gradually developed, a positioner for handling a set of wheels was built, and a second head was placed in operation in order to weld two wheels simultaneously. The fixture, or positioner, which was built to position and turn the wheels under the two welding heads, included a motor drive, controlled by a rheostat, which rotated the wheels through a double set of speed reducers and a removable jaw coupling attached to one end of the axle of the wheel truck.

Jan 1, 1947