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By Jerome F. Kuzmick

INTRODUCTION THE use of iron powder during the post-war conversion period has been increasing with great rapidity. This is particularly true in regard to the manufacture of molded mechanical parts such as bushings, gears, cams, small wheels, and the like. Many manufacturers have found it possible to replace machined cast iron and carbon steel with molded iron powder parts, and thereby can not only effect a savings in cost, but can produce a better product as well. As the field of application for iron powder parts widens, greater demands are made upon the powder supplier concerning quality and uniformity characteristics. The following are some of the most important properties parts fabricators desire in the iron powder they use: I. The powder should have high compressibility so that good density can be obtained without the use of excessive pressures. At the same time, it should show low die wear so that a large number of pieces can be produced from the die. This means that the powder must be of high purity and good softness or plasticity. 2. The powder should produce compacts of high green strength, so that unsintered parts can be handled without breakage or fraying of the edges. 3. The sintering properties should be good so that satisfactory strength is obtained in the sintered piece. 4. Compacts made from the powder should show small but, above all, uniform dimensional changes during the sintering operation so that accurate parts can be produced, and warping and other such bad effects eliminated. 5. The powder should have satisfactory flow properties for automatic molding. 6. It is very important that the powder be uniform in sieve analysis, compressibility, flow, purity, and other qualities, from container to container in any given lot and from shipment to shipment. 7. Price-The fabricators desire all these good properties, but in many instances still do not wish to pay a premium price. There has been considerable discussion as to the importance of price of the powder in relation to the cost of the finished product. It is true that in cases where certain special properties only procured by powder metallurgy are required, price is not a criterion. On the other hand, there have been a number of applications recently made which would not be commercially practical with a powder which commands a premium in price. Iron powder parts are compressed in automatic presses to definite size, shape, and density. The powder is compressed to a density figure dependent upon the function the part is to perform, as well as upon such important considerations as press capacity and die wear. Such parts can be roughly broken down into the following density ranges:

Jan 1, 1948

MR. Woo's succinct description of the mining and smelting of silver-lead in Mongolia, with the roasting-and-reduction process and cupellation, has much interest as a picture of methods that not only may have been in use, as he suggests, a thousand years ago, long before the existence of mining schools or chemical laboratories, but probably vary little, if at all, from the practice of prehistoric times, when King Priam's handsome silver vases, cups and bowls were formed. For it is highly improbable that such large objects were made from comparatively rare native silver, and the metal must have been smelted from ore, and most likely in great part from galena,, with cupellation of the lead. Dr. W. A. P. Martin, in his excellent book on the Lore of Cathay, points out that Chinese alchemy is over 2000 years old, antedating the European by at least six centuries; and he infers that the Chinese skill in metallurgy and many branches of practical chemistry owes its origin to " those early devotees of the experimental philosophy who passed their lives among the fumes of the alembic." Those alchemists, however, may have more likely derived some of their leading ideas from the mys terious, and at that time wholly unexplainable results observed in already very ancient metallurgical processes; in which, for example, certain stones were transmuted, as it were, into metals widely divergent in character from their ores, and even silver and gold were obtained from the most unlikely-looking mate rials. It is therefore, in any case, not improbable that the Chinese may have preceded western nations in the discovery of metallurgical methods. At all events, it is now evident that the Japanese acquired these arts from China, the former source of all their higher civilization. My own observation of old-fashioned silver-smelt ing at Hosokura, on the main island of Japan, and about 220

Jan 1, 1903

By H. H. Moss

OXYACETYLENE .cutting has experienced rapid development in the last few years and greater advances and expansion and broader application may be expected in the immediate future. Marked changes in cutting practice may be expected as a result of the advances in metallurgical science that have produced special alloy steels with properties requiring different cutting techniques than for ordinary low-carbon steels. Much current attention is being directed to those problems of modified cutting practices. Cutting has thus ceased to be merely a shaping problem. It is rapidly coming to have a predominantly metallurgical aspect. The problem is no longer how to cut a given shape, but how to cut a given steel. The answer

Jan 1, 1936

By E. W. Rouse

THE year 1936 has seen rehabilitation of many plants which had been closed or severely curtailed. The Steptoe smelter of the Nevada Consolidated Copper Co. has been transformed by a rearrangement of the flow of material and utilization of mechanical handling to a maximum. The Phelps Dodge Corp. reports the construction of newer and better reverberatories at the Copper Queen smelter, and of particular interest, a single high-pressure waste-heat boiler placed directly over the uptake. There has also been a complete reconstruction of the smelter at the Laurel Hill plant of the Nichols Copper Co.

Jan 1, 1937

By J. L. Christie, R. H. Leach

SO much has been written recently about the use of silver to replace scarce metals that certain facts about silver and its uses should be of interest. Figures for the production and use of silver, taken from the Handy & Harman annual reviews of the silver market, are given in Table 1. It will be seen that the rate of production has remained fairly constant and has been affected in recent years by the production of base metals, of which silver is a by-product. In each of the years 1937, 1938, and 1939, the U.S. Government acquisitions alone exceeded the entire world production, the difference, of course, being made up by imports of previously accumulated stocks. In 1940 and 1941 the U. S. Government acquisitions plus the United States and Canadian uses in the arts and industries exceeded the Western Hemisphere production. The U.S. Government pays a premium price for silver newly mined in the United States, at present 71.11c. compared with the price of 35'/8c. for foreign silver, with the result that the current U. S. production is not used commercially for the arts and industries. At the time this is written (June 1942) there is much uncertainty as to the future effect of this situation.

Jan 1, 1942

By J. T. Ryan

FIGURES for the first 11 months of 1935 indicate that the total coal production of the United States for 1935 will be approximately 416,000,000 tons, or almost identical with the production figures for 1934. Bituminous production will show a gain of about six million tons, and anthracite production a loss of about the same tonnage, compared with the previous year. This does not take into account so-called "bootleg" anthracite coal amounting to approximately 5,000,000 tons. Twenty-nine years ago, in 1906, the production of coal was almost identical with this year's production. At that time, 626,000 men were employed in producing this tonnage, which took a toll of 2138 lives from accidents. In 1935, approximately 540,000 men were required to produce the same tonnage with an estimated loss of 1155 lives. This shows definite safety advancement in the industry, but even so accidents are still costing an average of 3c. a ton more than they should.

Jan 1, 1936

By TENNEY C. DeSOLLAR

TRADITION tells us that the earliest use of Alabama iron was to make shoes for the horses of General Andrew Jackson and his men during the first part of the nineteenth century. The first recorded incident in the making of iron was the request of U. S. Indian Agent Benjamin Hawkins "that a crew of blacksmiths be sent to the Creek Nation in the lower Mississippi territory." These frontiersmen made up the first body of pioneer iron makers in the territory. The first known blast furnace was built by Joseph Heslip in 1818 at Russellville, named after Major William Russell, who was General Jackson's chief of scouts. The Tannehill furnace was built in 1830 in what is now Tuscaloosa County and its ruins, as shown above, can be seen today.

Jan 1, 1937

By C. E. Williams

THE Iron and Steel Division, A.I.M.E., is unique in this country in that it serves all phases of the iron and steel industries. Through its publications, its meetings, and its sponsorship of new technical developments in the industries, it has proved of great value. The various technical committees of the Division are the nucleus around which this service can be developed. The Blast Furnace and Raw Materials Committee has done excellent work. The need for beneficiation of iron ores is increasing and the economics of this operation are developing more and more in favor of increased activities. Ores that are slightly undergrade should be concentrated up to grade to supplant the present practice of mixing with higher-grade ores to bring up the average composition. Marginal ores that are not now being mined, or that are being mined and piled for future use, should be concentrated. The development of the use of sinter in the blast furnace, because of the elimination of fines, the advantage of better sizing of the charge, the resulting reduction of coke consumption, and increased output of pig iron per furnace, will make concentration and sintering become practical ahead of its natural time.

Jan 1, 1936

By Lawrence H. Van Vlack, Alfred S. Keh

The distribution of sulfur in iron was found to be dependent upon the time and temperature of the treatment as well as the chemical composition of the sulfide. With higher temperatures, the sulfide phase spreads more extensively between the iron grains. A complete network, however, does not form until approximately 1300°C (2372°F), ot which temperature the dihedral angle approaches zero. Silicon has little effect on this change. Aluminum, oxygen, and manganese all modify the temperature of sulfide network formation to a higher value. The microstructures which result and have significance in relation to hot-shortness are discussed. SULFIDE inclusions in steel were recognized by metallurgists before the turn of the century. Considerable attention has been paid to them, and numerous studies have been made on the working properties of steel as affected by them. It has been suggested that ho t-shortness of steel is due to the presence of an enveloping liquid sulfide film at the grain boundaries of the steel in the range of the hot-working temperatures. However, several facts have been observed in commercial steels which do not seem to be completely consistent with this explanation: 1) the frequent absence of continuous films of sulfide as observed under the microscope, 2) the absence of hot-shortness in some high sulfur and resulfurized steels, and 3) the limitation of hot-shortness to a definite temperature range. The role that manganese plays in steel to eliminate hot-shortness is well known, but the theory behind it is still under question. Moreover, the effect of de-oxidizers such as aluminum and silicon, and the effect of oxygen are still not clearly known. In this study, the effect of heat treatments and of additions of manganese, aluminum, silicon, and oxygen upon the distribution of sulfide inclusions in iron was investigated. Both the as-cast and the heat treated structures were studied, using microscopic and autoradiographic techniques. Part of the results were interpreted in terms of Smith's' concept of microstructure. Review of Literature Metallurgists used to consider sulfide inclusions as suspended particles. It was Wohrman' who first pointed out that sulfide inclusions are soluble in liquid iron. Many observed facts may be understood on the basis of this concept of solubility. Wohrman found that small castings contain small inclusions. and larger castings contain larger ones. Also, inclusion sizes are smaller near the chilled surface. For the same size ingot, the average inclusion size in a given heat of steel depends upon the rate of solidification. That is, with slow solidification, enough time for precipitation and agglomeration of these

Jan 1, 1957

By FREDERICK MCAKCCOY

THE production of tin from Mexico has never reached the point of being considered a national industry, but the distribution of tin ores is so widespread that there are possibilities that one day it may become of importance. Of the twenty-seven states of the Republic, tin claims have been taken up in sixteen. In all there had been taken up to the end of 1926, two hundred and twenty-five claims, of a total area of about 7400 acres. The first historical mention of tin in the Americas is found in a letter of Cortez to the Emperor, Charles the Fifth, of Spain, which is as follows: Speaking of his manufacture of some small cannon, he says: "For these reasons I took considerable pains to get copper from some provinces of this country, and bought it at a high price in order to get it quicker.

Jan 1, 1929

THE solid nonmetallic inclusions that are present to some extent in all commercial steels have been variously designated. In early references they were usually called slag inclusions, and. this terminology is still retained to some extent. On the premise that all nonmetallic matter produced in a metallurgical process is slag, this can be justified. We have come to think of slag, however, in a more restricted sense, and calling these particles slag inclusions is further objectionable because it fosters the erroneous concept that they are actually incorporated portions of furnace slag. Rarely is this true. The term sonims (coined from solid nonmetallic impurities) was proposed many years ago but never came into common use. In general the term "nonmetallic inclusions" seems to be satisfactory and adequate. NATURE AND CONSTITUTION OF NONMETALLIC INCLUSIONS From the standpoint of origin, inclusions fall naturally into two classes: (1) those that occur as a result of reactions taking place in the body of the molten or solidifying metal and (2) those that result from the mechanical incorporation of refractories or other materials with which the steel comes in contact. The former are by far the more numerous and have been called indigenous, natural, or native inclusions. The latter are by their very nature sporadic in occurrence and have been called exogenous, accidental, adventitious, or foreign inclusions. They are often referred to as the "slag stringer" type, though here also the material is not likely to be furnace slag. Substances Found in Inclusions. Nonmetallic inclusions are composed principally of oxides and sulphidea but carbides and nitrides sometimes play an important role. In the case of indigenous inclusions the reactions by which these particles are precipitated from the molten or solidifying steel may be caused by (1) oxidation such as may occur during refining or during tapping and teeming, (2) deoxidation by added alloys, (3) change in equilibrium constants as the steel cools to the freezing temperature, (4) decreased solubility with lower

Jan 1, 1944

By D. H. NETLAND

DURING the year 1907 an investigation of the Clinton formation in New York has been carried out under the direction of the State Geologist, and a full account of the results has been prepared for publication.1 The more important economic features of the report are summarized in the present paper. Previous knowledge of this, the type, section of the Clinton has been contributed mostly by Hall and Vanuxem in their reports for the Natural History Survey of New York, which were issued in their final form in 1842-43. Brief accounts of the ore-occurrences have been given by B. T. Putnam,2 J. C. Smock,3 A. H. Chester,4 and E. C. Eckel.5 Prof. C. H. Smyth, Jr.,6has discussed the origin of the Clinton ores in two papers, which, so far as the local occurrences are concerned, have removed all doubt that may have existed on that subject. Distribution of the Clinton Formation. The Clinton strata in New York State are restricted to a single belt, Which extends from the eastern central part to the Niagara river, which it crosses, and thence continues for some distance into the province of Ontario. The New York

Mar 1, 1909

By Felix Edgar Wormser

JUST as the ancients used the products of their crude mining endeavors to fashion tools with which to make digging easier, so today mining enterprises are dependent upon the very metals they mine for the efficient conduct of mining and metallurgical operations. In fact, the outlet afforded by the production of minerals in the United States is no mean market for the nonferrous metals. I believe that mine managers frequently lose sight of the opportunity they have to select from competitive products those which will help the market for their own metal output. For example, some years ago a large lead mine used storage-battery locomotives for its haulage, common practice, of course, throughout the United States. These particular locomotives, however, were powered not with the ordinary lead storage battery but by a competitive battery product made from an imported metal. After studying this situation, the manager saw how he could help himself by purchasing a product made from his own mineral output, and in his next order turned tip the use of the lead storage battery.

Jan 1, 1935

By Claus G. Goetzel

POWDER metallurgy is known as the art of producing metal powders and fabricating them in a nonfusion process by a simultaneous or consecutive application of pressure and heat under controlled operating conditions. Before the advent of powder metallurgy, the high melting points of the refractory metals and nonmetals made their manufacture and use practically impossible. Today, however, the uses of refractory materials in high-speed cutting tools, surgical instruments, brake linings, electrical contact switches, and filaments in incandescent lamps are commonplace in industry. Lately designers have even been turning to powder metallurgists to develop new techniques of fabricating refractory materials for extreme-service use in high-temperature zones of such modern products as gas turbines and jet engines. The new techniques being born will undoubtedly provide industry with a great number of new alloys and materials for future designing.

Jan 1, 1948

By M. J. R. Morris

THE year 1939 has seen the iron and steel industry driving for efficiency with unabated zeal. "Efficiency" is here used in the sense of enabling the customer to do more with less, either supplying him with more economically priced steels or with higher priced steels that will do a job more economically. The plain carbon steels have been improved tremendously in quality be- cause of recent control tests. All steel companies have been urged to hold to .closer chemical control, closer standards, soundness, and more control on grain size, and now attention is being directed to closer control of hardening properties. Better control of open- hearth operations undoubtedly will result in an increase in the application of special carbon steel. Further, with a better understanding of quenching, the present trend to study the quenching of this class of steels will be ex- tended. These steels will then be used for purposes to which they are best suited. Utilization of special carbon bars and large shapes seems to be developing less slowly than special car- bon in the form of strip. There are many reasons for this and the future development of this trend will be important. Continued development of the manufacture of parts from strip and sheet to replace forgings, and of formed; structural members such as channels or welded pipe, is notable. Special carbon sheets with nonaging properties have been produced during the year; they maintain a higher degree of ductility over a longer time and are less sensitive to the changes which took place in the former product when stocked.

Jan 1, 1940

By W. C. Winegard, A. Galibois, C. J. Beingessner

The effects of solutes on the distribution of two-dimensional configurations of grains in zone-refined tin have been studied. When solutes with partition coefficients (ko) greater than unity are added, three-sided pains become more prevalent and the growth law changes. It is shown by electron-Probe micro-analysis that a solute buildup occurs ahead of a moving grain boundary when ko > 1. It has been found recently1, 2 that solutes with partition coefficients greater than unity have a larger retarding effect on grain growth than solutes with k, less than unity. ko is defined as the ratio of the concentration of solute in the solid to the concentration of solute in the liquid with which the solid is in equilibrium. Niessen and winegard2 have suggested that this effect is probably due to the complex shape changes which occur during the process of grain growth and that no theory based on single boundary motion3-5 can explain the results. They suggested that the dissociation of the unstable fourfold junction was delayed in alloys where ko was greater than 1 because the boundaries at the junction had to move into a region of high solute concentration. If indeed this mechanism were correct, it was felt that not only would the dissociation of fourfold junctions be affected by the solute buildup ahead of the boundaries, but the collapse of three-sided grains would be impaired. These combined effects would naturally lead to a modification in the distribution of the number of sides per grain seen on a two-dimensional section. The present investigation was undertaken to test these hypotheses by examining the grain-growth process in detail. EXPERIMENTS The Distribution of Grain Configurations in Zone-Refined Tin as Seen on a Two-Dimensional Section. Following the method of Bolling and Winegard,6 zone-refined tin was cast into button-shaped specimens and, subsequently, plastically deformed under a drop hammer at room temperature. The resulting flat coin-shaped samples were annealed at 200°C, some for 50 sec and others for 100 sec. The specimens were then examined to determine the distribution of the number of sides per grain, i.e., the num- ber of crystals adjacent to any particular grain in the section. For simplicity, the grains were classified as three-sided, four-sided, and so forth; this concept is schematically illustrated in Fig. 1. As indicated by smith,' it was necessary to examine every grain within an enclosed area to obtain a proper distribution of the relative frequency of each type. The distributions for the two annealing times are illustrated in Fig. 2. The total number of grains examined is also indicated on the figure. It is evi-

Jan 1, 1965

By D. W. Breck

Zeolites were first recognized as a new group of minerals by Cronstedt with the discovery of stilbite in 1756. The word zeolite was coined from the two Greek words meaning "to boil" and "a stone" because of the loss of water when heated in the mineralogist's blowpipe (Breck, 1974). In 1845 it was discovered that certain soils lave the power of retaining ammonium salts Way, 1850). These were the first ion exchange experiments. Later it was discovered that it was the hydrated silicates in the soil that produced this phenomenon. Several years later a paper was published dealing with the action of dilute salt solutions on silicates which showed that this base-exchange principle, which we now call cation exchange, is reversible. The quantitative cation exchange behavior of zeolite minerals, such as chabazite, was studied. As a result any aluminosilicate which exhibited the property of ion exchange was referred to as a "zeolite," even today the term has been applied to clay minerals as well as synthetic organic ion exchange resins.

Jan 1, 1975

By William E. Greenawalt

IN these days of special legislation for the benefit of various industries one might well consider one branch of human endeavor intimately associated with engineering-that of patents and patent litigation. It is estimated that 85 per cent of all industries in the United States are based directly or indirectly on patents. Most inventors are engineers, and most patent litigation pertains to the engineering industries. It is fitting, therefore, that engineers should be vitally interested in discussing patent affairs, particularly as inventors are not a professional group, and invention is mostly a transitory phase incident to the development of specific industrial problems.

Jan 1, 1937

The growth and influence of Sherritt Gordon Mines Ltd. in the nickel producing industry has been quite phenomenal. Although the company's Lynn Lake deposit in Manitoba was actually dis- covered in 1941, it was not until 1945, when men and materials were more readily available as a result of the end of World War II, that the area was staked and news of the discovery leaked out. As a result of the discovery, Professor Frank Forward of the University of British Columbia was commissioned by Eldon Brown, then President and Man- aging Director of Sherritt, to develop a new nickel refining process. A pilot plant, based on the results of Professor Forward's research, was constructed in Ottawa, and after the successful testing of the Lynn Lake ore, Chemical Construction Co. was given a con- tract in 1952 for construction of a producing plant. By 1954, the Fort Saskatchewan refinery was operating at an annual production of 15 million lb of nickel metal in the form of briquetts or powder. Capacity has since been increased to 30 million lb.

Jan 10, 1968

By AIME AIME

EVERETTE LEE DEGOLYER, past President of the Institute and Anthony F. Lucas Medalist, was presented with the John Fritz Medal at a dinner at the Wal-dorf-Astoria Hotel in New York, Jan. 14. Dr. DeGolyer is the third representative of the Institute in recent years to receive the John Fritz Medal which is awarded jointly by the four Founder Engineering Societies through a board composed of sixteen past presidents. In 1938 Paul D. Merica was given the award "for important contributions to the development of alloys for industrial uses" and in 1933 the distinction was given to D. C. Jackling "for notable industrial achievement in initiating mass production of copper from low-grade ores through application of engineering principles."

Jan 1, 1942