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By Wallace Thorneycroft

This paper by Mr. Thorneycroft, Past President of the Institution of Mining Engineers (Great Britain), and chairman of its Subsidence Committee, is a valuable contribution to the assemblage of data on ground movement and subsidence from coal mining. It deals with the effects of advancing longwall, a method almost universal in Europe but as yet little used in the United States outside of Northern Illinois and in a few scattered places elsewhere in thin coal beds, as in the Lexington field, Missouri. Canon City field, Colorado, and the Birmingham field, Alabama. Although by advancing lougwall, a maximum recovery of coal is obtained and it has to be employed where there are weak shale roofs, especially in deep mines, it is a more expensive method of operation unless the mining conditions are suitable, which is unusual in the United States. On the other hand, there is a growing use in this country of what is essentially retreating longwall, with an approximately straight break-line as described by Rayburn.1 With this method, in which the pillars are substantial, it was shown that the ground movement effect is practically identical with that of advancing longwall, hence the value to mining engineers of the precise data given by Mr. Thorneycroft. His study is unusual in several respects; it deals with conditions connected with the mining of a coal bed 20 in. thick, about 490 ft. below the surface, over a mined-out area in a 5-ft. bed about 90 ft. below, which had been mined about 12 years earlier. Both mines passed under Plean House, a building of massive cut stone construction built over a century ago, in which Mr. Thorneycroft resided throughout the under-mining period. Slight cracks opened in the walls as the longwall face approached the house in mining the upper seam, and closed after the face passed and subsidence took place. In the northwest wall, the last wall the face passed under, some stone blocks were broken, which was attributed to a strike period when the advance of face came nearly to a standstill. Other than this there was no perceptible permanent damage, as indicated by the photographs taken by the undersigned in 1923 (Figs. 1 and 2). Mr. Thorneycroft used a novel means of studying the successive positions of the corners of the building: he hung plumb bobs from the eaves and traced the paths of the respective plumb bob points on level surfaces. The angles made by the house walls with the plumb bob lines gave measures of the slope of the subsidence wave at the respective points. A slight upward wave was indicated by the surveys ahead of the subsidence, which would appear to be due to a tilting over of the massive sandstone stratum in the roof measures near the surface, the edge of the coal face acting as the fulcrum.

Jan 1, 1931

By C. A. Siebert, O. S. Duffendack, A. W. Herbenar

IN metallurgical problems involving the study of equilibrium in binary systems, the ,existence of an additional vapor phase, due to the presence of a volatile component in the alloy, has often been neglected. This is well indicated by the modified form of the phase rule, usually accepted in condensed systems in which pressure is not considered as a degree of freedom. In many cases the vapor pressure of the volatile component is exceedingly small and for all purposes can be considered negligible, in which case this form of the phase rule is applicable. However, alloys containing Hg, Cd, Zn, or Mg, tend to show very marked equilibrium vapor pressure, even in the solid state, and therefore present cases where the modified form of the phase rule no longer holds true. A quantitative determination of the vapor pressure of zinc in alpha brasses is not only of practical interest because of the loss of zinc in the processing of these alloys, but also of theoretical interest in that such measurements provide a means of applying the principles of theoretical physics and physical chemistry to problems of applied metallurgy. A number of investigators have reported vapor pressure measurements of zinc in alpha brasses. Hargreaves1 made extensive measurements which were used by Birchenall and Mehl² and Guttman³ for the determination of activity coefficients of zinc in alpha brasses. Hargreaves1 used a differentially heated quartz tube and measured the condensation temperature at one end corresponding to the temperature of the heated brass at the other end. Birchenall and Cheng outlined the condensation method of obtaining vapor pressure of zinc and Cd over some of their silver alloys." The primary object of the present investigation was to increase the range and accuracy of the vapor pressure data for the alpha brasses. Preparation of Alloys: Six alloys were prepared from Bunkerhill zinc and O.F.H.C. copper, both of 99.99 pct purity. The cast ingots were annealed for 24 hr at 550°C, scalped, cold rolled 40 pct and annealed for 50 hr at 550°C. The annealed bars were then surface ground and degasified for 30 min at approximately 550°C in an induction heated vacuum furnace. The surface of the bars was removed before milling the bars into relatively fine chips for chemical analysis and samples for the equilibrium cell. The analyses of the six alloys are given in table I. Experimental Method: The vapor pressure of zinc over the various alloys at a number of temperatures was determined from absorption spectra data. The spark source was produced by means of a high tension discharge between two electrodes of pure zinc. The design of the absorption vessel is shown in fig. 1. The vessel was constructed of transparent quartz which transmits the whole of the visible spectrum and the ultraviolet down to a wave length of 2000 A. The thickness of the vapor space was set at 0.8 mm so as to permit a relatively wide range of measurements without altering the vapor space, and thereby necessitating recalibration of the vessel. The furnace used for heating the absorption vessel consisted of a split wound furnace as shown in fig. 2. The spectrograph used in obtaining the transmitted zinc spectra was a double prism type especially designed for a region of 2500-3500 A. A step diaphragm used in conjunction with a tungsten filament provided the necessary intensity patterns required for calibration of the photographic plates.

Jan 1, 1951

By Albert W. Giles

The splitting of the coal by partings is a familiar feature of many coal beds. The partings are normally argillaceous, more rarely sandy or calcareous. The material is usually fine-grained, less frequently coarse-grained to conglomeratic. Many partings are wedge-shaped, others are lenticular, and in some coal beds thin partings but one or two inches thick persist as thin sheets throughout areas of regional extent. The origin of the partings differs, and in some cases is obscure and uncertain. Origin of Thick Partings Wedge-shaped Partings Wedge-shaped partings are normally of indefinite linear extent but of short transverse section. They are developed adjacent to the borders of the original peat-forming swamp or around islands formed within the swamp, hence their presence is indicative of the approximate limit of the coal bed or of an interruption in the continuity of the coal bed. Following deposition of the parting gradual reestablishment of swamp conditions is followed by burial of the parting with accumulating peat. Partings developed adjacent to the borders of swamps normally thicken toward the periphery of the swamp and represent either detrital materials carried in from adjacent land areas during floods or materials carried in by advancing waves and currents after a barrier confining the swamp had been breached by the waves. Partings formed in the manner first mentioned should become coarser and more arenaceous toward the source of supply of the detrital materials, and the overlying and underlying coal should gradually grade into carbonaceous shale as the margin of the original swamp is approached. Partings formed by advance of waves across a barrier should be largely or entirely arenaceous, thin wedges of short longitudinal section, possibly with fossils of marine or brackish affinity. The subjacent coal normally should "pinch out" against the barrier, and the overlying coal continue to the barrier, or even extend across it, depending on the geographic conditions established following the breaching of the original barrier. Islands may be formed in swamps in a number of ways. They may represent local uplift of the swamp floor during earthquakes, or

Jan 1, 1934

By William B. Senseman

For reasons well known to mining engineers, wet grinding is quite universal in plants having to do with the extraction of metallic values from crude ores. In the processing of the nonmetallic and industrial minerals, dry grinding is the more common method. The crude materials usually contain less moisture than is required for wet grinding and the products usually are marketed in dry form; most of them as powders. To grind wet, therefore, would entail the addition of water and an expense for drying the product, which is not justified. Furthermore, the material would be a dried cake that would still have to be pulverized or disintegrated before use. For producing fine products, air separators have largely replaced the earlier practice of sizing with screens and bolting reels. Mills in which the air-separating feature is an integral part of the design are now commonplace. Mill designs are many and air systems have developed along various lines, but for the purpose of this discussion, only the fundamental idea need be emphasized— the idea of using air for sizing and removing pulverized material from a grinding mill. About 20 years ago, when the use of mills equipped with air separation had become common practice, heated air or gas was introduced to such a system for the removal of moisture. The purpose of this discussion is to outline the developments and trends that have followed this experiment. It is an important development, for mills equipped with air separation are now universally used for pulverizing not only nonmetallic and industrial minerals, but a great variety of other materials. All such mills are essentially the same. Dried material is pulverized, removed by an air stream, trapped in a cyclone collector, and relatively clean air from the cyclone is returned through a fan to the mill. There is no theoretical need for a vent from the system. The practical need is to vent the air that leaks into the system, and, since the cyclone is not 100 per cent efficient as a dust collector, this vented air carries some dust with it. The initial attempt at drying was made on a system like that described, by the addition of a furnace. The minus pressure within the mill draws hot gas from the furnace. Infiltration air, along with the drying gases and evaporated moisture, is vented as before. The first application was made to a mill used for pulverizing coal. The coal contained very little moisture, so very little drying effect was needed for the success of this experiment. Actually, some calculated efficiencies of over 100 per cent were obtained before due allowance was made for the conversion of mill power into useful heat. When moisture is low, the heat obtained from the conversion of mill power is an appreciable part of that required. That drying can be effected in the short time interval available in a grinding mill of this type is better understood by visual-

Jan 1, 1947

By L. W. Kempf, K. R. Van Horn

Plastic deformation of most commercia1 metals within a sufficiently low temperature range results in profound changes in structure and properties, of which the causes and effects are not completely understood. One of these effects is the presence of internal residual stresses and strains, which ordinarily do not appear to require specific consideration in most structural applications but which may be quite undesirable in particular instances. For example, in heavy sections that require considerable machining before assembly, residual stresses may be undesirable because of the distortion they cause when their balance is disturbed by machining or otherwise. In addition, the distribution of stresses may be such that it acts in the same direction as the applied load, thus bringing about premature failure or reducing the load-carrying capacity of the member. One source of residual stress in metal structures is the plastic deformation that may occur during rapid cooling from relatively elevated temperatures, as in the cooling of a casting in the mold or the quenching of a heavy section from elevated temperatures during heat-treatment. These residual stresses are usually undesirable because their direction of operation and magnitude cannot be controlled well enough to permit utilization of the changes in properties of the metal that they may bring about. The most convenient manner of controlling such residual stress is by proper selection of the cooling rate or by reheating to a temperature at which plastic flow can take place, resulting in relief of the residual stresses and strains. Both of these methods of control, however, may cause a reduction in the optimum properties obtainable from the previous operation. A compromise must be struck, and if it is to result in the best possible combinations of properties, specific information must be available regarding the magnitude of the stresses and the rate at which they are affected by variations in cooling rate or in reheating temperature. The complete quantitative estimation of residual stress in complicated metal shapes is exceedingly difficult, if not impossible. In simple sections, however, relatively quantitative analysis may be applied and useful cstimations of stress distribution may be made. This paper is concerned largely with the rate of relief, upon reheating, of internal residual stress in simple aluminum-alloy structures. Since even with simple structures quantitative estimation of residual stresses is laborious and costly, an attempt was made to find other means of collecting data upon which commercial heat-treatments might be based. Incidentally, a few data were collected bearing on the problem of relaxation of aluminum alloys. Determination of Residual Stresses The magnitude and distribution of residual stresses in simple aluminum-alloy shapes rapidly cooled from elevated temperatures has been discussed in a previous paper.' Fig. I reproduces some of the data

Jan 1, 1942

By Karl Fetters, John Chipman

The relationship between the composition of the slag and that of the underlying metal during the refining of a heat of liquid steel may best be studied in the light of the two broad physicochemical concepts of equilibrium and reaction rate. Actual steel-making processes, typified by basic open-hearth practice, involve such complexities of operating variables that it is impossible to distinguish with any degree of certainty between the general limiting conditions imposed by chemical equilibrium and the effects associated with rates of diffusion or of chemical reaction. Further advances in the physical chemistry of steelmaking will depend upon our ability to distinguish clearly between these two kinds of effects, and the experimental work that must be done falls naturally into two classifications. The first is the study of chemical equilibrium that cannot be carried out with assurance under operating conditions but must be done in the laboratory. The second is the -subject of rates of reaction and diffusion and the mechanism of the process as a whole, which can best be studied under operating conditions. The latter is not entirely independent of the former, since its interpretation often requires a knowledge of the equilibrium state. It is the purpose of this and of several papers that will follow to present the results of labora- tory investigations of equilibria involving liquid steel and slag. Open-hearth slag is a complex mixture containing at least eight major components and perhaps twice as many whose influence may be classified as probably minor. It is not surprising that progress toward a complete understanding of such a material at high temperatures has been slow. Attempts to apply the established principles of physical chemistry to the behavior of the individual components of this mixture have been beset by an almost complete lack of data on its chemical properties in the liquid state. This has necessitated the adoption of various methods of approximation based upon such assumptions as, for example, that for a given component the ratio of its mol fraction in the slag to that in the metal is a constant, or that the molecular composition of the liquid slag is the same as its crystalline constitution after solidification. From the thermo-dynamic viewpoint, such assumptions are merely useful dodges, which enable one to hazard a guess as to the magnitude of the more fundamental quantities, the chemical potentials and activities of the components of slag. The problem of determining the activity of each substance in an eight-component svstem seems too complex to be undertaken without the aid of generalizations derived from experimental data on similar systems containing a smaller number of components. Accordingly, it was planned in the present investigation to study the equilibrium of molten iron with the simplest

Jan 1, 1941

By E. N. Cameron

GRAPHITE has been included in U. S. lists of strategic minerals since the problem of mineral deficiencies was revealed during World War I. Since 1918 the domestic graphite industry has led a precarious existence, and there has been much uncertainty as to the amounts of usable graphite of various grades that would be available from domestic sources in time of emergency. In 1950-1951 therefore, the writer, assisted by Paul L. Weis, undertook a review of domestic graphite sources for the U. S. Geological Survey.' The conclusions of this study are presented here, with a discussion of some technologic and politico-economic factors bearing upon the problem. Uses of Graphite: Natural graphite as marketed exhibits a wide range of properties, which determine the uses to which it is put. The most essential uses are in the manufacture of crucibles and related refractory articles, in lubricants and packing materials, and in the manufacture of batteries, foundry facings, pencils, and carbon brushes. Numerous specifications covering the mineral in its various applications must be met by producers and processors of graphite. The problem of supply is therefore not simply one of procuring a sufficient total tonnage, but the more difficult problem of procuring enough of each different grade to meet foreseeable needs. The amount of graphite required by American industry is not large. Ordinarily only a few thousand tons of strategic grades are consumed annually, yet the elimination of this small tonnage would have serious effects in several industries. Strategic Graphite: Since World War I, 60 to 100 pct of the country's annual supply of graphite has been furnished from imports. At present, natural amorphous graphite for use in pencils and batteries is produced largely from American-owned mines in Mexico. Graphite for foundry facings is obtained from a number of sources. Neither grade is a serious problem. High purity graphite for carbon brushes and for pencil leads, however, is imported, largely from Ceylon, in the form of amorphous lump graphite. Most of the flake graphite used for crucibles and related refractory articles is likewise imported, largely from Madagascar, and much of the lubricant and packing grade graphite used by industry is obtained from the same source. The strateg'ic grades of graphite are therefore amorphous lump of the Ceylon type, crucible flake, and flake suitable for lubricants and packing. Ceylon lump and Madagascar flake have for many years been accepted as standard by domestic consumers of graphite, and various essential manufacturing processes are geared to the use of graphite from these sources. Ceylon graphite as marketed is classified into several grades based on particle size and purity. Processing methods are said to be simple, but the products marketed are carefully graded and are consistent in their characteristics, an important matter to the consumer. Nearly all the graphite produced in Ceylon is from veins. Resources are reported to be large, labor is cheap, production costs are low, and world competition is slight—factors accounting for the commercial success of the graphite mining industry in Ceylon. Madagascar is reported to have deposits of the Ceylon type, but its output consists almost entirely of flake. Madagascar graphite as received in the U. S. is further processed by importing organizations, and a large number of grades are produced to meet industry requirements, especially those for crucible flake and for lubricant and packing grade flake. Madagascar crucible flake as marketed is noted for coarseness, uniformity, toughness, clean-

Jan 1, 1957

By B. W. Gandrud

WET-PROCESS coal-washing tables as we know them today have been in use in this country for approximately 25 years. The literature records only a few table installations worthy of note prior to adoption of the present-day differential-motion table. According to Phillip,1 six Campbell bumping tables were being operated by the St. Bernard Coal Co., Earlington, Ky., in 1893. As late as 1923, according to Richardson, 2 such tables were in operation in the Rosedale washery of the Cambria Steel Co., at Johnstown, Pa. Bumping tables probably were not used to any considerable extent except in the plant at Earlington, and at two or three plants in Pennsylvania, but they may be considered as. forerunners of the present-day coal-washing table. The transition from bumping tables to the type of tables now in use signalized a revolutionary change in table design. The advantages of the new design over the old were so outstanding as to make its adoption inevitable. BUMPING TABLES Bumping tables, as the name implies, utilized a bumping action for conveying the refuse and discharging it over the refuse end. The tables were hung from rods attached to overhead supporting beams. A shaft and cam arrangement at one end of the table served as the actuating mechanism and imparted to the table an endwise, back-and-forth, swinging motion. A bumping block was fixed in the proper position at the shaft end, so that the table would strike against it at the end of each backward swing. The hanger rods or stirrups were so adjusted as to give the table a slight uphill slope toward the refuse end; that is, the end next to the driving mechanism. The feed box was near the upper end of the table and designed to spread the mixture of coal and water over the width of the table. Wash water was added a short distance below the feed box. With the table in motion and coal mixed kith water being fed to it through the feed box, a certain amount of stratification took place, depositing heavy refuse at the bottom of the bed in contact with the surface of the table. Constant bumping and a certain amount

Jan 1, 1950

By R. M. Hardgrove

Pulverized coal was first used for firing cement kilns about 45 years ago, with such success that it has continued in general use. Based on cost, pulverized coal is usually the most economical fuel. In some localities natural gas or oil is cheaper, but 85.5 per cent of all cement kilns at present are fired with pulverized coal. The pulverized-coal flame is well suited to kiln conditions. Its soft, luminous nature gives it a high radiating property and the length of the flame can be readily varied to suit conditions in a kiln of any length. Ash and slag cause most of the dificulties incident to the burning of coal. In a. cement kiln, however, the ash, being similar in composition to the raw mix and being deposited uniformly in the mix and clinker, occasions no difficulty as long as it remains constant in quality and quantity. Until 6 years ago almost all cement kilns using pulverized coal employed the bin system. The coal was dried and pulverizeti in a separate plant and delivered into a bin at the kiln. Thus the bin system requires driers, storage-type pulverizers, conveying systems, individual kiln bins, pulverized-coal feeders and primary air fans. The direct-fired system requires only a pulverizer and a blower. Fig. I shows typical plants. The first installations of direct-fired pulverizers were of the impact type but fineness of pulverization was both inadequate and variable. About 1927 a few direct-fired installations employing tube-type pulverizers were made, which were much more satisfactory. As more efficient pulverizers were developed from 1934 on, equipment for direct firing was installed at a large number of plants, until now 196 of about 900 kilns in use in the United States are direct-fired. Most of these replaced antiquated bin systems. Process of Burning Cement Clinkers The process of burning cement clinkers is fundamentally one of heat transfer. In boilers and other heat-exchange apparatus the area of the surface receiving heat from the gases is the best unit for comparing output, This seems to be equally true for kilns. The inside kiln surface is the heat-receiving surface and its area is used as the unit of kiln size in the following comparisons. Heat input is based on British thermal units in the fuel. E. G. Bailey,' in his work on boiler-furnace heat absorption, has used the unit "B.t.u. available." This is the practical calorific power of the fuel, plus the heat in the air used for combustion. In other words, it is the heat available for useful work in the furnace or kiln. The unit of kiln output is barrels per hour. The composition of the raw mix, the percentage of water in the slurry of wet plants and hardness of burning all affect the output. These conditions, however, are hard to evaluate and probably have less effect on the output than irregularities of raw feed and clinker discharge and inexpert control of combustion. Wet vs. Dry Plants The study presented here covers 88 plantsl of which 41 are wet and 47 dry. Of

Jan 1, 1942

By H. Matlock

Beam-columns with continuous or discontinuous transverse and angular loads and elastic restraints are represented mathematically in a manner corresponding to finite-element mechanical models. Solutions for linearly elastic cases are accomplished by direct recursion-equation elimination of unknowns, and for cases involving nonlinear loads and supports, by repeated trial-and-adjustment of complete elastic-type solutions. Five practical applications are presented by which various capabilities of the general method are illustrated. The examples include simulation of a pipeline launching and the bending and collapse of a conductor pipe in deep-water drilling operations. INTRODUCTION The diversified and complex operations being conducted in support of the production of offshore oil have produced a wide variety of new problems in structural mechanics. Many of these problems cannot be solved by conventional analytical or experimental approaches and have therefore stimulated inquiry into new methods of solution. It is the purpose of this paper to give a brief description of an analytical method for solving nonlinear beam-column problems and to illustrate the generality of the method by applying it to several problems related to offshore operations. Although the data for all of the examples are artificial, the cases discussed will be recognized as being based on actual situations. DESCRIPTION OF METHOD The analytical approach which is to be described stems from research on offshore foundations, in particular, the study of lateral-load behavior of foundation piles. The method represents a generalization of a technique which was suggested by Gleser' and extended by Focht and McClelland2 and Reese and Matlock." To maintain generality and therefore versatility in the method, a considerable variety of input data is considered. Fig. 1 illustrates the various types of loads and restraints which might be applied to a short segment of a beam. Each of the terms illustrated in the figure is shown acting in a positive sense. Capital letters are used to designate concentrated quantities whereas the corresponding lower-case symbols indicate effects which are distributed in some way along the length of the beam. The transverse loads and the elastic restraints may be divided into two classes: (1) loads Q and q and springs S and s, which act normal to the axis of the beam, and (2) couples T and t and rotational springs R and r, which act in an angular sense. In addition, there is an axial force P which may be constant or may vary along the length of the beam. The bending stiffness of the beam (the product EI of the modulus of elasticity and the moment of inertia) is designated by the symbol F. The assumptions of conventional elementary beam theory provide the basis for the present method. Among these are the neglect of shearing and axial deformations and the limiting of consideration to straight beams of symmetrical cross-section. Lateral deflections are considered to be small compared to original dimensions. A deformed element of such a beam is shown in Fig. 2a. The curvature of the beam is approximated by the second derivative of the deflection y with respect to distance x along the beam. It is assumed that the material of the beam is linearly elastic and therefore the relation of Eq. 1 between curvature and bending moment M is the ordinary expression from elementary beam theory. A generalized beam element is shown in Fig. 2b. The element has been deflected in a positive direction by an amount y and tilted through a small positive angle dy/dx. The various loads and elastic restraint reactions are detailed in the figure. Temporarily, only distributed effects are considered; provision for concentrated loads and restraints will be made subsequently. Eq. 2 in Fig. 2b is obtained by summing the forces and moments acting on

By S. T. Wlodek, John Wulff

Dense, adherent, and ductile coatings of chromium can be applied to Molybdenum by selectively freezing out the chromium solute from a supersaturated copper-or tin-rich liquid alloy. The successful exploitation of this technique depends on the control of variables common to any freezing process. Under the most favorable combimtion of supersaturation, nucleation, and mass-transfey, coatings as thick as 0.004 in. can be obtained. In exploratory experiments it was found that a coating of chromium may be applied to molybdenum by immersing the molybdenum body in a supercooled copper-chromium or tin-chromium melt and selectively freezing out the contained chromium onto the molybdenum body. Supercooling of the liquid metal plating bath can be achieved by cooling, or the maintenance of thermal or concentration gradients in the melt. The technique is similar to conventional dip-plating procedures where the sample is immersed in a molten bath of the pure plating medium, except that in these studies, the plating medium consisted of a dilute solution of chromium in liquid tin or copper. The success of this method requires that the base material to be plated be isomorphous with the coating and insoluble in the plating bath. In addition, the plating bath, while having an appreciable solubility for the coating component, must have negligible solid solubility in the solid plate. Such relationships exist in the molybdenum-chromium, chromium-tin, and chromium-copper systems. Liquid tin and copper are satisfactory as the plating solvent, because although chromium is appreciably soluble in both of these liquid metals, solid inter-solubility is almost negligible, and no compound formation occurs. The same relationships exist between molybdenum and copper or tin except that the solubility of molybdenum in liquid tin or copper is insignificant. It is this combination of solubility relationships, as well as the completely isomorphous nature of the molybdenum-chromium system, which allows the formation of a chromium coating on molybdenum by the selective freezing mechanism. Since the main deterrent to the widespread use of molybdenum for high-temperature structural applications is its poor oxidation resistance, the formation of a dense and ductile chromium coating on molybdenum may well be of commercial significance. In addition, the basic principle of coating formation by selective freezing should be applicable to other metallic or even nonmetallic systems. The precipitation of the solute from a liquid metallic solution, for the formation of a protective coating, has not been previously considered in the literature. Frequently, however, a similar phenomenon has been described in the corrosion of metallic heat exchangers by liquid metals1 wherein temperature gradients in the liquid metal heat-transfer medium result in the formation of layers or deposits of metallic residue2 in the cooler portions of the system. Impregnating techniques using liquid baths have been tried as a plating process. Semchyshen and Barr, for instance, have successfully diffused chromium into molybdenum by immersing the molybdenum specimen in a liquid tin-chromium or copper-chromium alloy. This simple holding technique fails to produce a layer of pure chromium and requires prolonged immersion to allow for the diffusion-activated enrichment of the molybdenum. During the course of this investigation, most of the phase relations published for the copper-chromium4 and molybdenum-chromium4 systems, were found reliable. It was necessary, however, to investigate the solubilities of chromium and molybdenum in liquid tin as well as the solubility of molybdenum in liquid copper. These determinations were made by a simpie weight loss technique on materials of the same purity as used in the plating studies. The results of these solubility studies are given in Tables I and I1 and indicate that although the solubility of molybdenum in liquid

Jan 1, 1961

By E. Miller, N. Chou, K. Komarek

The solid solubilities of the compounds PbS, PbSe, and PbTe have been determined by equilibrating single crystals with two phase alloys. The solubilities were determined by measuring the Hall coefficient of the equilibrated samples. The observed maximum deviations from stoichiometry on the lead rich and the chalcogen-rich side of the phase fields were: at. pct excess Pb at pct excess S at 850°C; PbSe--4 x 10'" at. pct excess Pb at at. pct excess at 800°C; and PbTe-2.8 x 10 4 at. pct excess Pb at 780°C, 10"1 at. pct excess Te at 720°C. The previously developed theory of retrograde solubility has been expanded to include intrinsic disorder in the compounds, and the experimental results are in agreement with the theory. THE solid solubility limits of intermetallic semiconducting compounds are of considerable interest, since many of these compounds have potential use as thermoelements in thermoelectric devices, as infrared detectors, or in semiconductor devices. The solidus curves of a significant number of these compounds have been reported to be retrograde with the maximum solid solubility occurring between the eu-tectic and the maximum melting temperatures. In a previous paper,' equations were derived which permit calculation of the maximum solid solubility of an AB compound exhibiting retrograde solubility. Derivation of these equations was based on the assumption that the compound is a nondegenerate semiconductor at the temperature under consideration, that the defects were unassociated, and that the vibrational contribution to the entropy of the compound could be evaluated by the Einstein approximation. It was shown that at the temperature of the maximum solid solubility The entropy term ASS is composed of the entropy of formation of the solid stoichiometric compound (AS$)*, and the entropy due to deviations from stoichiometric composition which is the sum of a con-figurational term (aS*), a vibrational term (AS,), and an electronic term (AS,). In the previous paper the positional entropy was evaluated considering the con- N. CHOU, Member AIME, formerly Graduate Student, New York University, N. Y., is with IBM, Yorktown Heights, N. Y. K. L. KOMAREK, Member AIME, formerly with New York University, is Professor, Department of Inorganic Chemistry, University of Vienna, Vienna, Austria. E. MI LLER, Member AIME, formerly with New York University, is Associate Professor of Mechanical Engineering, California State College at Long Beach, Calif. The paper is based on a thesis submitted by N. CHOU to the Graduate Division, School of Engineering and Science, New York University, in partial fulfillment of the requirements for the degree of Doctor of Philosophy in Materials Science. tributions from defects arising from deviations from stoichiometric composition. The derivation is generalized in the appendix to include intrinsic disorder. The electronic entropy term is also recalculated in the appendix. Of the various semiconducting compounds, the solidus curves of Pbs,' and ~b~e,~ have been most extensively studied. The solidus of PbSe has also been determined, but the temperature of maximum solubility has not been accurately established.5129 The present investigation was undertaken to compare the experimental solid solubility data for these systems with the values predicted theoretically. Since the temperature and composition of the maximum solubility of PbSe has not been accurately determined, experimental emphasis was placed on determining the solidus curves for PbSe in the region of maximum solubility, although experiments were also performed on PbS and PbTe at several temperatures. X-ray diffraction studies were also made on carefully prepared powder samples of PbSe to determine the variation of lattice parameter with composition. EXPERIMENTAL PROCEDURE The procedure of Brebrick and Allgaier was employed for determining the solidus data. Monocrystal-

Jan 1, 1970

By J. Marin, H. A. B. Wiseman

This paper presents results of an experimental study dealing with the plastic stress-strain relations of aluminum alloy 14s-T6 subjected to combined biaxial tension and compression stresses. Plastic stress-strain relations for both constant and various types of variable stress ratios were determined and a comparison made with the simple flow theory of plasticity. THIS investigation was undertaken for two main purposes: 1—to obtain plastic stress-strain relations for Alcoa 14s-T6 when subjected to various combinations of biaxial stresses, and 2—to determine the validity of the flow theory in predicting plastic stress-strain relations for combined stresses. The biaxial stresses used were tension combined with compression. These stresses were produced by subjecting a thin-walled tube to axial tension and torsion. Various types of combined stress conditions were investigated. To provide control test data and information on the influence of biaxial stresses on the strength, the usual constant stress ratio type tests were made. These tests showed that the biaxial yield strength agrees approximately with the distortion energy theory. However, the Prager semi-empirical theory agrees best with the test results. For these constant stress ratio tests the plastic stress-strain relations were found to agree approximately with the flow theory. (For constant stress ratio the flow and deformation type theories are identical.) In view of the fact that the constant stress ratio tests cannot distinguish between the flow and deformation theories, a number of variable and special biaxial stress tests were made. These tests showed that the flow theory is inadequate, since large differences exist between the experimental and theoretical results. Special tests were also conducted to check the validity of the isotropic yielding assumption. This assumption is made in the linear-type flow theory. In these tests specimens were loaded in tension to predetermined values beyond the proportional limit stress. The tension load was removed from the specimen and the specimen was subsequently loaded in torsion to fracture. Other tests were applied with the order of torque and tension loading reversed. The nominal stress-strain curves for these two tests approximately coincide indicating that the assumption of isotropic yielding is valid. In addition, these tests verified the requirement by the slip theory of plasticity that prestraining below 140 pct of the proportioned limit stress in either torsion or tension did not influence the subsequent plastic stress-strain relations in tension or torsion. Another type of test was conducted to check the assumption that the axes of principal stress and strain coincide during plastic flow and variable stress conditions. These tests were conducted by applying combinations of axial tension, internal pressure, and torsional loads such that the axes of maximum principal stress could be rotated through 90" during the loading path. The results of those tests showed that the angle between the axes of principal stress and strain varied greatly and that the assumption of coincidence between axes of principal stress and strain is not valid. Introduction In various metal processes including forming of sheets, rolling of bars, and extrusion of rods, metals are subjected to stresses beyond the yield strength of the material. Often these stresses are not simple stresses acting in one direction, but are combined stresses acting in more than one direction. Structural and machine members are often subjected to combined stresses. To adequately determine the factors of safety for these members, it is necessary to know the plastic stress-strain relations of the material used for various combined stress conditions. Various theories have been proposed for predicting the plastic stress-strain relations for combined stress in terms of the simple tension plastic stress-strain relation for the material. To determine which theory might be adequate, test results must be obtained for various combined stress conditions, in order to compare the actual with the assumed theoretical behavior. Although there is considerable test data available for combined stress conditions in which the principal stress ratios are constant, relatively little test information is available for vari-

Jan 1, 1954

By R. M. Hardgrove

Pulverized coal was first used for firing cement kilns about 45 years ago, with such success that it has continued in general use. Based on cost, pulverized coal is usually the most economical fuel. In some localities natural gas or oil is cheaper, but 85.5 per cent of all cement kilns at present are fired with pulverized coal. The pulverized-coal flame is well suited to kiln conditions. Its soft, luminous nature gives it a high radiating property and the length of the flame can be readily varied to suit conditions in a kiln of any length. Ash and slag cause most of the dificulties incident to the burning of coal. In a. cement kiln, however, the ash, being similar in composition to the raw mix and being deposited uniformly in the mix and clinker, occasions no difficulty as long as it remains constant in quality and quantity. Until 6 years ago almost all cement kilns using pulverized coal employed the bin system. The coal was dried and pulverizeti in a separate plant and delivered into a bin at the kiln. Thus the bin system requires driers, storage-type pulverizers, conveying systems, individual kiln bins, pulverized-coal feeders and primary air fans. The direct-fired system requires only a pulverizer and a blower. Fig. I shows typical plants. The first installations of direct-fired pulverizers were of the impact type but fineness of pulverization was both inadequate and variable. About 1927 a few direct-fired installations employing tube-type pulverizers were made, which were much more satisfactory. As more efficient pulverizers were developed from 1934 on, equipment for direct firing was installed at a large number of plants, until now 196 of about 900 kilns in use in the United States are direct-fired. Most of these replaced antiquated bin systems. Process of Burning Cement Clinkers The process of burning cement clinkers is fundamentally one of heat transfer. In boilers and other heat-exchange apparatus the area of the surface receiving heat from the gases is the best unit for comparing output, This seems to be equally true for kilns. The inside kiln surface is the heat-receiving surface and its area is used as the unit of kiln size in the following comparisons. Heat input is based on British thermal units in the fuel. E. G. Bailey,' in his work on boiler-furnace heat absorption, has used the unit "B.t.u. available." This is the practical calorific power of the fuel, plus the heat in the air used for combustion. In other words, it is the heat available for useful work in the furnace or kiln. The unit of kiln output is barrels per hour. The composition of the raw mix, the percentage of water in the slurry of wet plants and hardness of burning all affect the output. These conditions, however, are hard to evaluate and probably have less effect on the output than irregularities of raw feed and clinker discharge and inexpert control of combustion. Wet vs. Dry Plants The study presented here covers 88 plantsl of which 41 are wet and 47 dry. Of

Jan 1, 1942

By A. L. Foell

THE development of the modern blast furnace began more than one hundred years ago, with the abandonment of the small hillside furnaces. Its development, especially during the past 50 years, has been accomplished through a rapid succession of enlargements and improvements. The remarkable growth in furnace output during this period is a tribute to the engineers and operators who have constantly endeavored to build larger and more efficient blast furnaces. The blast-furnace operators and their mechanical and electrical maintenance staffs have originated most of the furnace improvements as a result of their practical operating experience. FURNACE LINES About 50 years ago furnaces consisted of hearths about 11 ft. in diameter, which merged into rather high flat boshes, with no cylindrical section between the bosh and inwall and no cylindrical section at the stock line. Since then the lines of the furnace invariably have included a cylindrical section above the bosh and a cylindrical section at the stock line. Notable increases have been made in both hearth diameters and furnace heights. During the past 10 years hearth diameters in new and replaced furnace stacks have rather consistently fallen within the range of 25 to 28 ft. while their heights have varied between 100 and 106 ft. The lines of most large furnaces using Mesabi ores have followed a fairly uniform pattern (Fig. I) in which the principal dimensions for 25-ft. hearth furnaces are as follows: [Hearth diameter 25 ft. o in. Height of bosh 10 ft. o in. Bosh angle 8 1 ½° Diameter top of bosh 28 ft. o in. Inwall batter per foot 15/16 Stock-line diameter 19 ft. 6 in. Large-bell diameter 14 ft. 6 in. Height from iron notch to top ring casting 100 ft. o in.] In determining the size of a new furnace for the replacement of an existing stack or for an addition to productive capacity, it is not possible to formulate a procedure that can always be followed. Local conditions, requirements as to capacity, available raw materials and prospects for future expansion dictate the size of such proposed improvements or additions. However, where the immediate requirements indicate a stack or furnace of a certain productive capacity, and the future prospects indicate that more capacity can be utilized, it is well to consider building the furnace for the ultimate capacity rather than to install a smaller hearth with provision for future enlargement. The decision to build the larger hearth and stack for the ultimate capacity probably will require no greater initial investment, since the saving in the cost of brickwork will about offset the greater cost of the hearth jacket, tuyere breast and bosh bands. In the meantime, the furnace of larger hearth dimensions, while operating below its ultimate output, will yield a better coke rate and

Jan 1, 1942

By Louis A. Rosales, Kanji Ono

The anomalous behavior of hydrogen in iron is examined and a new model is proposed It is postulated that hydrogen single and di-interstitials are in equilibrium with each other. When the binding enthalpy of the di-interstitial, B, is assumed to be about 10 kcal per mole, the predicted temperature dependence of the solubility agrees reasonably well with the reported data. Effective diffusiuity is calculated assuming the di-interstitials to be immobile. Since the number of mobile single interstitials is greatly reduced at lower temperatures, the effective diffusivity is decreased. A good agreement in the temperature dependence of diffusivity between theory and experiment is provided with B - 10 kcal per mole. The predicted diffusivity is also a function of total concentration of hydrogen and this appears to be Partly responsible for the large scatter in the reported data. HYDROGEN is known to form an interstitial solid solution with iron.''' At elevated temperatures, it has been well-established that hydrogen enters iron in the dissociated form and occupies the interstices, and that diffusion of hydrogen in iron is via the interstitial mechanism. The concentration, c, permeability, P, and diffusivity, D, of hydrogen in iron have been separately determined and are consistent with each other under the steady-state condition for temperatures above approximately 400°C; that is, the relationship P = c-D holds. At lower temperatures, however, anomalous behavior of hydrogen in iron has been observed by many investigators. The results of experimental studies4-'' of the diffusion of hydrogen in iron are summarized in Fig. 1, in which the values of D are plotted against the reciprocal temperature. Although there is an increasing divergence in observed values of D with decreasing temperature, the values of D at temperatures below approximately 200°C are definitely small as compared with the extrapolation from high-temperature data. The lines shown bracket the region containing the most probable data. The observed values of c6," are plotted against the reciprocal temperature in Fig. 2, where the dashed lines represent Geller and sun's'' most probable isobars at 1 and 100 atm. At high external hydrogen pressure and low temperatures, the values of c observed are higher than those expected from high temperature data. It is generally accepted that certain trapping mechanism is responsible for the anomalies, but the nature of the trapping mechanism has not been clarified. Various types of hydrogen traps were suggested in the literature, such as "rifts" in the lattice dislocations, voids, microcracks, and so forth. However, no quantitative account of the observed behavior has been given in terms of these trapping mechanisms. Formation of methane in hydrogen-charged steel was found by ~odgurski." This appears to explain the existence of the so-called "residual" hydrogen,4 but not the observed anomalies of hydrogen in iron. McNabb and Foster' proposed a mathematical analysis in terms of a trapping mechanism. However, the physical significance of the traps was not clarified. The necessity of evaluating five parameters in their theory made comparison with experiment difficult. In the present paper, a model is proposed in which the anomalous behavior of hydrogen is attributed to the formation of hydrogen di-interstitials at lower temperatures. In this model, it is postulated that single and di-interstitials are in equilibrium with each other. (The hydrogen di-interstitial is to be distinguished from a hydrogen molecule which may exist in voids.) It can then be shown that most of the anomalies can be explained by assuming that the di-interstitials are virtually immobile and that the binding enthalpy of the di-interstitial, B, is approximately 10 kcal per mole. Predictions of the theory agree with the available experimental data reasonably well. THEORY The basic postulate of the present analysis is that single and di-interstitials are in equilibrium with each

Jan 1, 1969

By C. H. Li, R. J. Stokes, T. S. Liu

Poly crystalline silver chloride specimens having different micro structures were prepared by extruding monocrystals or precompressed powder at varying temperatures. Extrusion at high temperature (370°C) produced a Fully recrystallized equi-axed material which was brittle and fractured by simple cleavage below its transition temperature (60°C for notched specimens). Extrusion at low temperatures (down to -196°C) produced an extremely tough cold-worked material with grains elongated in the extrusion direction. This material fractured below its transition temperature (which varied from —20" to —200°C) by an intergranular mode. It is concluded that cold work increases the resistance to transgranular cleavage. Fracture is then de-flected to propagate intergranularly ouer surfaces making an angle with the tensile axis with a corresponding improvement in notch toughness. This deflection is greater for extruded powder than for extruded monocrystals because of the extremely elongated grain shape. PREVIOUS work1,' on the fracture properties of fully recrystallized silver chloride under notch impact conditions has indicated that the fracture behavior is rather invariant. Thus polycrystalline materials originating from a number of sources ranging from relatively pure Harshaw single crystals to commercial-purity powder and prepared by hot extrusion at 370°C all fracture by simple cleavage with a ductile-brittle transition at 60°C, see Fig. 1. This behavior is also typical for fully annealed single crystals and appears to be fundamental to silver chloride for the particular loading conditions and notch configuration adopted. One way in which this characteristic fracture behavior can be modified is by the dispersion of alumina particles in the silver chloride matrix.' Then, particularly when the alumina particles are in the shape of spheres, the duc tile-brittle transition is much less sharply defined and occurs over a range of temperature, the transition temperature is lowered considerably and the fracture mode changes from simple cleavage to a fibrous or shear mode. The reason for this change is believed to be partly due to the nucleation of cavities in the region of the dispersed alumina particles which influences the state of stress locally and the distribution of plastic constraint at the root of the notch. It is emphasized however that this is not the sole factor responsible for the increase in toughness. In extruded materials it is reasonable to expect that the resultant grain size, texture, and the residual cold work will be influenced by the presence of a dispersed phase. The present experiments were initially designed to determine the extent to which cold work influenced the fundamental ductile-brittle transition temperature and fracture mode of silver chloride. They were stimulated by the discovery that silver chloride could be extruded at temperatures as low as -25°C when commercial-purity powder was used and as low as -196°C when single crystals were used. This working temperature was far below that previously used (370°C) and it was found that such extruded material was exceedingly tough. The reasons for the enhanced toughness and its relation to the previous work on silver chloride-alumina compacts will be discussed. EXPERIMENTAL PROCEDURE Materials Used. Two forms of silver chloride were used in this study: i) silver chloride powder

Jan 1, 1964

By D. B. Gillies

IN 1938 the Republic Steel Corp. announced that it had leased the ore mines and other property of the Witherbee Sherman Corp. at Port Henry, N. Y. The announcement brought forth an interesting reaction. Two questions were asked repeatedly: (1) Is the iron product high grade? (2) Is there a substantial reserve? The answer to both questions was and is a decided and emphatic "Yes."

Jan 1, 1943

By William R. Rumbold

WHEN I was in South Africa during the latter part of 1904, there were three known tin-fields, which may be called the Cape Town, the Bushveld and the Swaziland fields. THE. CAPE TOWN TIN-FIELD. This district is situated near Kuils river, 20 miles west of Cape Town, and 5 miles from Kuils River station on the Cape Town & Stellenbosch Railway. The deposits are in granite, intrusive in the Malmesbury beds, which are supposed to be of Silurian or Cambrian age. The granite, resisting denudation better than the surrounding shales,, has formed low-lying hills, the highest of which, the Bottlelary Berg, is 1,510 ft. above sea-level. , The rock consists of quartz, orthoclase feldspar and biotite mica; tourmaline is also present. The feldspar occurs in large crystals. The rock is generally decomposed on the surface, and the decomposition sometimes extends as deep as 100 ft. This formation-granite intrusive in Silurian shales-extends for many miles to the northeast, but so far as I know the Kuils River deposits are the only ones now known to occur in it, though probably further prospecting will reveal other deposits. This particular discovery was accidental;. alluvial tin being found in the course of boring for oil. The Kuils River Deposit. This comprises both lode and alluvial tin. The lode strikes N. and S., and dips about 30° E. into the hill. It is 5 ft. wide, and composed of dense white quartz, in which pinkish-gray cassiterite is distributed in large crystals. The vein also contains considerable quantities of wolfram. Fig. 1 is a rough plan of the relative positions of the lode and the alluvial deposit, the latter, as shown, following the course of a stream, while the lode crops out on the hillside

Jan 7, 1908

By Joseph A. Holmes

Iv all new movements unavoidable misapprehensions arise, which should be cleared away, lest they retard the progress of the movement itself. An impression has gone abroad that the movement for conservation of resources is a new movement. No one knows better than the engineer that this is not the case. Men like Douglas and Raymond and John Fritz and Edison and McDonald, and hosts of others, have preached and practiced conservation as applied to mineral resources throughout a long and useful life-time; and, in general, the work of the engineer and the chemist, both in this and in other countries, has been along the line of continually greater efficiency in the use of all available materials. And the results already accomplished through the efforts of these experts are now saving annually many millions of dollars to the people of the United States in materials and labor. It is true, however, that the need for conservation, that is, for a wiser and more efficient use of the natural resources, has taken on a new life, and is being brought home to the people of the United States in a manner which is awakening public interest and even the public conscience. It is, therefore, both appropriate and fortunate that the engineers, the chemists, and the thinking men of all classes are availing themselves of the present impetus to the movement to emphasize anew the lessons which heretofore they have found it more difficult to impress upon the American public or even upon the captains of industry. Still another of these misapprehensions is to the effect that many of the leaders in the present movement hope to bring about conservation of resources through legislation or execu-

May 1, 1909