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By J. W. Harden

AT our meeting in October last we saw in operation at Pittsburgh, the comparatively modern process of the utilization of small coal by washing, by an arrangement similar to that of Bérard or Morrison. The small coal washed was that of an old pile, the refuse of the mining of the Pittsburgh bed, and which had long lain uncared for. Value was thereby restored to it when it was converted into a very good coke. This circumstance led to comments on the mountains of broken coal lying wasted, and in its present condition worse than useless, in the neighborhood of the mines of the Wyoming Valley, though they are not confined to that district. Some things were said condemning the course which produced it, some were left unsaid. Of a system that destroys one-half the coal-bed in producing the other half there can, however, be but one opinion. Schemes have been suggested for the utilization of present accumulations which, if successfully applied, would in so far be beneficial. More than ordinary attention is now being given to the same subject in England; a Mr. Barker has invented a means by which he amalgamates the "dust," too fine to burn in ordinary grates, with a composition he calls "diamond cement," producing blocks of coal said to resist water, both hot and cold, and which a smart blow will only break to pieces, not cause to crumble. But any scheme less than the one which will prevent the wasting of coal, which still goes on, though that involves the abandonment donment of the breaker, will only be one of expediency; and the latter can only be done by the aid of the consumer. But the wasting of coal is not alone with the breaker ; much is made in the mine. The cause is not far to seek ; the remedy is with capitalist and owner. Owners and consumers then are alike interested, and they have it in their power, in the one case, to mitigate, in the other, almost entirely to remove the cause of the evil. Of consumers there is one in every

Jan 1, 1873

By John A. Mathews

It is no longer necessary to explain to an audience like this that there are stainless or non-corrosive steels. It is still necessary to repeat, and to keep on repeating, that no one of them is stainless or non-corrosive under any and all conditions. We do not make railroad axles, springs and rails from the same kinds of steel; nor are shafts, steering-arms, gears and cap-screws made from the same type analysis. By analogy with other fields of endeavor, therefore, it is logical to expect that all the myriad conditions of corrosion due to inorganic and organic acids and salts and their mixtures in all degrees of concentration and at a wide variety of temperatures and pressures will require different materials to withstand them. Possibly stainless steel when first introduced a decade ago was expected to do too much, or suffered from overenthusiasm and lack of positive knowledge and experience on the part of its producers. Its name may have been a bit misleading too, for remarkable as this product is, it has its limitations. There are now so many different ferrous products available and calling for recognition, that we may be justified in an attempt at classification. The first division is very simple. 1. Non-corrosive steels that harden by quenching. 2. Non-corrosive steels which do not harden by quenching. We might make the classification still simpler by saying (1) those that harden by quenching, and (2) those that soften by quenching. Of course there is a border line or fringe of compositions which may possess some of both qualities under limited conditions of treatment. I have seen a steel so perfectly balanced on this border line that in its natural condition, as rolled, the outside of a 1-in. bar was soft and the inside hard, and there was quite a sharp line of demarcation in between. The hardness at the center was more than twice as great as at the surface, as measured by the Rockwell test. This border line of products does not include, however, the commercial products now available to solve the problems of industry. Let us examine the products of these two classes: Hardenable Non-cokkosive Steels This group, practically speaking, includes only the products known as "stainless iron and stainless steel." These names have a special sig-

Jan 1, 1927

By R. M. Caitlin

QUITE a number of years ago in looking for basic facts, it seemed obvious, in view of an unquestion-able supply of raw material and an extensive requirement probable in the near future, that the funda-mental requirement of any shale-oil industry was mass production 'by a continuous process. This decision greatly simplified matters, as it eliminated all considera-tion of externally-heated retorts, and all batch processes, which only utilize a part of the capacity of the interior space because, unless the ashes are removed as rapidly as formed, the space occupied by them is dead, instead of being occupied either by shale in active distillation or in drying out and heating up preparatory thereto. A second imperative and basic necessity soon appeared as a natural sequence, namely, the fixed carbon of the spent shale must be utilized to supply the heat for the eduction of the oil. PRODUCTION OF THE CRUDE As the production of the crude oil is the first and most important step in the utilization of oil-shale, being the only source from which the multitude of possible by-products can come, each by a special treatment of the crude oil, I will devote the time allotted to me to the subject of crude oil production-its cost expressed in terms of tons treated per man per shift. The costs of mining the shale and refining the crude shale oil vary with local conditions and are not specially influenced by the source of the crude. But the cost of distilling the shale in terms of tons per man shift seems to be the basis of any proper comparison of costs. After considerable experimenting, ranging from laboratory tests up to and including quantities of fifteen to twenty tons, it was evident that a plant might be made up of an indefinite number of units operating in concert. The economic size of the units, however, would .have to be determined by experiment. The general theory of our process contemplates a regulated combus-tion of the fixed carbon in the spent shale, in its incan-descent condition after all the oil has been driven out of it; and a transfer of the resultant heat to the mass of raw shale above.

Jan 1, 1927

The ability of activated charcoal or carbon to adsorb complex metal ions has been recognized for many years, but it wasn't until the late 1940s and early 1950s that attempts were made to employ carbon-In-Pulp or C. I. P. processing to the recovery of gold. Early plants using the process were those at the Golden Cycle in Cripple Creek, Colorado, the Getchell Mine near Golconda, Nevada, and at the Idria Mine in Honduras. Recovery of the carbon from the pulp was done by screening or flotation, and recovery of gold from the carbon was done by burning the carbon (a very difficult task) or by sending it to a smelter. Unfortunately at the time, the price of gold was still fixed at $3-5 per ounce and labor costs were rising to the point where these mines were no longer able to operate. Consequently, C. I. P. treatment was temporarily forgotten. In the early 1970s, however, Homestake Mining Company at Lead, South Dakota, were being forced by environmental regulations to discontinue the use of mercury for amalgamation in their 7,500 ton per day plant, and at the same time were encountering high labor costs in the slime circuit of the plant, where over 2,000 tons of slimes were filtered each day in Merrill plate and frame filter presses. Shortly before that, researchers of the United States Bureau of Mines had developed the caustic -cyanide method of stripping gold from activated carbon and an electrolytic cell (now known as the Zadra cell) to recover gold from the carbon strip liquor. Homestake and the United States Bureau of Mines then jointly operated a C. I. P. pilot plant at Lead. Results were immediately favorable and a 2,400 ton per day C. I. P. plant was then built to treat the slime fraction of the Homestake ore. (See Au and Ag Cyanidation Plant Practice, Volume I, SME of AIME, 1975. Later, Homestake built a second plant at Creede, Colorado, to treat the slime fraction of the tailings from a silver-lead flotation plant. Next was Duval Corporation's 3,000 ton per day C. I. P. plant at Battle Mountain, Nevada. Both of these latter plants are described in this volume. C. I. P. operations under construction at the time of this writing are as follows: Pinson Mining Co. , Nevada Gold Freeport Gold Company, Nevada Gold Compania Minera El Indio, Chile. Silver and Gold

Jan 1, 1981

By Walter Stern

The self-potential or spontaneous polarization method is one of the oldest in the field of electrical exploration. When applied in prospecting for ore bodies, it is one of the most rapid and inexpensive means of locating indications of ore bodies at shallow depth. Usually, the procedure is to survey the equipotential lines of the electrical field that is generated by the electrochemical activity of the ore near the ground-water level, and to localize the so-called negative centers or points of greatest negative anomaly. Another field procedure involves the measurement of potential differences along potential profiles, generally laid out at right angles to the assumed strike. Again, in such survey, the basis for establishing the presence of ore is the location of negative potential anomalies. The earlier writers on the subject, notably Schlumbergerl and R. C. Wells,2 did much to clarify the fundamental electrochemical phenomena involved. Interpretation of the field data, however, remained largely qualitative. In 1925, A. Petrovsky3 analyzed the relation between the shape of the potential anomaly curve and size and depth of an Ore body by assuming the subsurface body to be a polarized sphere.' Along similar lines of approach, Edge and Laby5 considered the ore body a dipping sheet with limited extent in the direction of strike, while Poldini6 based the theory on the assumption of a dipping bar. The following study endeavors to enlarge upon these earlier investigations and attempts, on the basis of the potential distribution of a polarized bar, to indicate certain characteristics of the anomaly curve that make possible the determination of depth, size and dip of a subsurface body. The Spontaneous Polarization Field Set Up by an Ore Body If a sulphide ore body is subjected to oxidation varying in degree in its upper and lower parts according to the difference in the concentration of oxygen within the surrounding medium, an electrical potential field is set up. The form and distribution of this field will be investigated herein with special reference to its components on the earth,s surface. Under the simplifying assumption that the ore body may be considered as a dipole with the point sources Q1 and Q2 situated at its upper and lower ends (Fig. I), the potential of the spontaneous polarization at point P is given by the following equation:

Jan 1, 1946

By R. H. Richards

IN nearly all ore-dressing operations it is a common practice to discharge mixtures of fine ore and water through spigots; for example, from classifier pockets, from jig hutches, from settling tanks, etc. As a, general rule it is desirable to regulate the composition, i.e., the ratio of water to sand, of such discharged products; and this can usually be done by varying the size of the orifice or spigot through which the material is discharged. Thus it is that problems similar to the following are frequently encountered: With a given quantity of solids per unit time, of a given specific gravity, to be discharged with water under a given head, and with a given ratio of water to solid, what must be the size of the spigot opening? If the spigot is to be open continuously, there are, aside from its form, but three factors governing the rate at which it will discharge a mixture of sand and water, namely: the head of water above the spigot; the area of the spigot opening; and the viscosity of the material to be discharged. The term viscosity, as used here, means the ratio of the volume of pure water that will flow through a given orifice under a given head in a given time to the volume of the material under consideration that will flow through the same orifice in the same time under the same conditions. While the actual viscosity of water containing sand in suspension is not increased by the presence of the sand, nevertheless the volume-rate at which such a mixture will flow through an orifice is less than that at which pure water will flow, by reason of the friction of the particles of sand against each other and against the sides of the orifice. In other words, the flow is retarded as it would be by increased viscosity; and therefore, for the purpose in view, we may speak of the viscosity of a mixture of ore grains and water as defined above. The head of water above the spigot is generally fixed by the form and design of the classifier or tank to which the spigot is attached. So, with the head known, in order to determine the size of the spigot required it is necessary to know the viscosity of the desired mixture, and the coefficient of discharge of

Jan 1, 1915

By Walter Stern

The self-potential or spontaneous polarization method is one of the oldest in the field of electrical exploration. When applied in prospecting for ore bodies, it is one of the most rapid and inexpensive means of locating indications of ore bodies at shallow depth. Usually, the procedure is to survey the equipotential lines of the electrical field that is generated by the electrochemical activity of the ore near the ground-water level, and to localize the so-called negative centers or points of greatest negative anomaly. Another field procedure involves the measurement of potential differences along potential profiles, generally laid out at right angles to the assumed strike. Again, in such survey, the basis for establishing the presence of ore is the location of negative potential anomalies. The earlier writers on the subject, notably Schlumbergerl and R. C. Wells,2 did much to clarify the fundamental electrochemical phenomena involved. Interpretation of the field data, however, remained largely qualitative. In 1925, A. Petrovsky3 analyzed the relation between the shape of the potential anomaly curve and size and depth of an Ore body by assuming the subsurface body to be a polarized sphere.' Along similar lines of approach, Edge and Laby5 considered the ore body a dipping sheet with limited extent in the direction of strike, while Poldini6 based the theory on the assumption of a dipping bar. The following study endeavors to enlarge upon these earlier investigations and attempts, on the basis of the potential distribution of a polarized bar, to indicate certain characteristics of the anomaly curve that make possible the determination of depth, size and dip of a subsurface body. The Spontaneous Polarization Field Set Up by an Ore Body If a sulphide ore body is subjected to oxidation varying in degree in its upper and lower parts according to the difference in the concentration of oxygen within the surrounding medium, an electrical potential field is set up. The form and distribution of this field will be investigated herein with special reference to its components on the earth,s surface. Under the simplifying assumption that the ore body may be considered as a dipole with the point sources Q1 and Q2 situated at its upper and lower ends (Fig. I), the potential of the spontaneous polarization at point P is given by the following equation:

Jan 1, 1946

By C. E. Arnold

In attacking the problems of mining and treating large disseminated copper orebodies such as those occurring in the Miami or the Ray district of Arizona, one of the vital questions to be decided is, "What is the value of the orebody per ton in place?" The importance of this question lies in the fact that its answer helps to reach a decision concerning the method of mining to be employed. Let it be assumed for the moment that milling and smelting practice, especially the latter, is more or less standardized, and has a cost incapable of much variation, while the cost of mining has a considerable range owing to the large number of mining methods by which a mine may be exploited. For instance, a method may be adopted whereby all the available ore can be extracted perfectly clean (i.e., unmixed with barren material) at a relatively high cost; or a method may be used involving the necessary dilution of a portion of the ore with waste, in order to recover that portion, thus giving a relatively poorer extraction but nevertheless a lower working cost than the former method. Naturally, between these two extremes there lie intermediate methods. In order to arrive at a solution of a mining method problem that is of any value, it is necessary that accurate and complete estimates of mining, milling, and smelting performances and costs shall be established. By way of illustration is given a case of mining, by the system of undercutting and caving, a large orebody with an average content of 1.50 per cent. copper supposedly all in sulphide form, to which case has been applied those results in mining operations which one may fairly assume are to be expected when viewed in the light of G. R. Lehman's ore-drawing experiments, which form the subject of a paper to be presented at this meeting. It is assumed that the total costs will be as shown in the table on page 204. To attain these costs, a daily production and treatment of 14,400 tons has been assumed. Other assumptions are as follows: 15 per cent. of orebody is to be extracted clean by development work and undercutting; 63.8 per cent. (75 per cent. of 85 per cent.) is to be extracted clean by caving, leaving 21.2 per cent. part of which is to be extracted by diluting with waste, and the remainder lost. Dilution and extraction are to

Jan 1, 1917

By J. W. Paul, J. N. Geyer

The measures overlying some coal beds are under stress as the result of geological movements after the measures have been deposited. The removal of the coal in the process of mining induces additional stress in the roof measures. Certain types of deposits have sufficient inherent strength to be self-supporting over definite width of excavations and the stress is adjusted without appreciable movement of the material, to the extent that no part of the material will become detached and fall. The uplifting of the measures in geological time often results in the establishing of cleat planes or planes of weakness in the measures overlying the coal, and these planes generally have a uniform direction. Measures that have not been subject to uplifts are less liable to have noncompensable stresses, although any method of underground mining results in the creation of stress in the roof measures over the excavations and over the coal pillars. The immediate roof measures extending upwards of 10 to 15 ft. above the coal give the greatest concern in maintaining the roof in the advance work in the solid coal. Immediate measures which are inherently weak often may be scaled and supported for indefinite periods by a system of timbering. As an excavation is made, the pillars adjoining must take on the weight previously supported by the coal removed. The roof over the excavations takes on the function of a beam and if too weak to be self-supporting it will fail either through shearing or bending, and the roof cavity may enlarge until a self-supporting arch is formed. As support is removed by taking the coal away, there is a tendency for the roof members to move toward the excavation in an effort to compensate the stress; particularly is this true where there is an overlying bed of clay, which may act as a lubricant on which adjoining members may slide. Unstabilized stresses, plus the force of gravity, plus the inherent strength of the material, govern the tendency of mine roof to fall when not supported by timber. In general, most mine roof depresses when the coal is removed. This depression may be in the nature of a sag as the result of bending, or the edges of the pillar may break away or the floor may come up or heave.

Jan 1, 1934

By James S. Foster, Paul G. Shewmon, Frank V. Nolfi

Analytical expressions are developed for the kinetics of dissolution or growth of a spheroidized, solute rich stoichiometric Precipitate in the surrounding matrix. There are two limiting cases; in one the rate of dissolution or growth is limited by long range solute diffusion through the matrix and in the other by the transfer of atoms across the mrdrix-precipitate interface. In the former case local interfacial equilibrium exists while in the latter it does not and the rate of dissolution or growth is controlled by an interfacial reaction. The analysis treats both limiting cases as well as mixed control in a single development, where it is found that the thermodynamic state of the interface is completely specified by a single parameter, o, defined by where K is the reaction rate constant, D is the matrix solute diffusivity, and R, is the precipitate radiz~s. If K is infinite then a is zero and local equilibrium prevails; if K deviates infinitesimally from zero, then a is very near unity and an interfacial reaction is rate controlling. Mixed control occurs for intermediate values of o. From the analytical results, numbers are computed which are useful in determining the duration of interfacial reaction or mixed control; following this time period, long range diffusion is rate controlling. THE rate controlling process or processes governing phase boundary migration has been the subject of much speculation and investigation. Traditionally, the most widely assumed boundary condition in quantitative treatments of this problem has been that of local interfacial equilibrium. This condition implies that long range diffusion of one or more elements controls the migration and is referred to as "diffusion controlled migration" (herein DCM). In contrast to the above view is the proposition that local interfacial equilibrium does not exist and that transport of atoms across the interface is rate controlling. Consequently, this mechanism is referred to as "interface controlled migration" (herein ICM). In processes of the latter type, the activity, a, of one or more elements is discontinuous at the phase bound- ary and the flux, J, across the boundary of a given element is some function of its activity discontinuity, a. One of the most comprehensive contributions to a mathematical description of phase boundary migration is due to am.' His analyses are applicable to precipitation in binary systems in which a) the precipitates are spherical* solute rich compounds of constant

Jan 1, 1970

By Stephen Birch

LATOUCHE, or the Beatson plant of the Kennecott Copper Corpn., is located in the Prince William Sound district of Alaska about 80 miles west of Cordova and 60 miles from Seward. Ore was discovered and claims located on Latouche Island in July, 1897. The mines were worked in a desultory manner until 1910, when the property was acquired by the Kennecott Copper interests. The first shipment of ore was made in 1904; only the higher grade ore was mined and no attempt was made to treat the ore until it was taken over by the Kennecott, company. Since that time the mine has been developed to produce 1500 tons a day and a mill has been erected for treating this tonnage, using flotation entirely. The orebody is more or less lenticular in shape with a maximum width of about 280 ft. and a length of about 800 ft. The southern end of the lens is split by a horse of waste for about 400 ft. The hanging-wall limit is a well-defined fault associated with a band of pyrrhotite, having an average dip of 60°. There is no defined foot wall, the value of the ore governing the limits of the mining; in one part of the mine, however, it is defined by a minor fault. The orebody is located in a shear zone of the country rock of graywacke and slate. The principal mineral is chalcopyrite associated with pyrite and quartz. The mine is located a few hundred feet from tidewater; the mill is located on the beach and the ore is hoisted direct from the mine through a vertical shaft into the mill bins. Until the past year practically all the mining had been conducted in open pits. During the past two years, the ore above the 200-ft. level has been developed and a system of stoping devised to recover this ore; however, this system has not been in use long enough to give any definite results as to costs or efficiency. It consists, principally, of dividing the orebody into stopes, across the full width of the orebody, 70 ft. wide with a pillar 30 ft. wide between the stopes. Raises are driven through the stopes at intervals of about 60 ft. and all the ore is broken by drilling from these raises; in other words, similar to a shrinkage stope, doing the drilling from the raises instead of setting up on the broken ore as is customary. The ground is very much broken up by clay slips and seams running in every direction. Shrinkage stoping had been

Jan 1, 1924

By J. B. Macelwane

Geophysics differs from geology and physics in in many respects. In the first place, geophysics is a complex science embracing the fields of seismology, geomagnetism, geoelectricity, geodesy, meteorology, vol-canology, physical oceanography, physical hydrology, tectonophysics and exploration geophysics. Geology is also a complex science and so extensive in its various fields that no one can master them all, and no part of geology deals in any sense with several of these fields of geophysics. In the second place, geophysics makes use of methods and instruments that are derived primarily from the science of physics. Geology, on the other hand, has methods of its own and it draws its borrowed techniques and its instrumental equipment not only from physics but also and perhaps primarily from chemistry and biology. The difference, therefore, between the geophysicist and the geologist lies partly in the phenomena that are observed, partly in the methods and instruments with which each carries on his exploration; but partly also, and perhaps principally, in the habitual attitude of mind and in the background of specialized training with which each approaches the problems presented by this planet of ours. The geologist as such, therefore, is no geophysicist. On the other hand, the physicist is not a geophysicist either. Isolation of each problem in a closed laboratow system under complete control is fundamental to the methods of the physicist. The geophysicist must apply physical instruments and physicomathematical reasoning to the study of physical quantities in their undisturbed natural environment. What, then, is a geophysicist? In the sense that he is a trained expert in all of the geophysical sciences, I do not believe that such a person ever existed. It would be beyond the possibilities of a single lifetime. I think there is confusion in our ideas and in our use of terms. We are not all thinking of the same thing when we say geophysics or geophysicist; yet we seem to talk as though we were. It is as absurd to say that the whole of geophysics belongs to geology because the field of a particular type of geophysicist—the exploration geophysicist —calls for some knowledge of geology as it would be to say that the whole of biology belongs to geology because a particular type of biologist—the paleontologist— needs some knowledge of geology. Development of a Geophysicist Since it is impossible to become an expert in all the fields of geophysics, and since students entering college seldom know the field they will choose as a career, what would we suggest as the best general preparation for work in geophysics, whether as a meteorologist, an oceanographer, a seismologist, a geodesist, a geomagneticist, a volcanologist, a tectonophysicist, a hydro1 ogist, or an exploration geophysicistp we may distinguish five phases in the development of a geophysicist: (I) his mathematical and scientific studies in high school; (2) the general mathematical and scientific

Jan 1, 1946

By J. B. Macelwane

Geophysics differs from geology and physics in in many respects. In the first place, geophysics is a complex science embracing the fields of seismology, geomagnetism, geoelectricity, geodesy, meteorology, vol-canology, physical oceanography, physical hydrology, tectonophysics and exploration geophysics. Geology is also a complex science and so extensive in its various fields that no one can master them all, and no part of geology deals in any sense with several of these fields of geophysics. In the second place, geophysics makes use of methods and instruments that are derived primarily from the science of physics. Geology, on the other hand, has methods of its own and it draws its borrowed techniques and its instrumental equipment not only from physics but also and perhaps primarily from chemistry and biology. The difference, therefore, between the geophysicist and the geologist lies partly in the phenomena that are observed, partly in the methods and instruments with which each carries on his exploration; but partly also, and perhaps principally, in the habitual attitude of mind and in the background of specialized training with which each approaches the problems presented by this planet of ours. The geologist as such, therefore, is no geophysicist. On the other hand, the physicist is not a geophysicist either. Isolation of each problem in a closed laboratow system under complete control is fundamental to the methods of the physicist. The geophysicist must apply physical instruments and physicomathematical reasoning to the study of physical quantities in their undisturbed natural environment. What, then, is a geophysicist? In the sense that he is a trained expert in all of the geophysical sciences, I do not believe that such a person ever existed. It would be beyond the possibilities of a single lifetime. I think there is confusion in our ideas and in our use of terms. We are not all thinking of the same thing when we say geophysics or geophysicist; yet we seem to talk as though we were. It is as absurd to say that the whole of geophysics belongs to geology because the field of a particular type of geophysicist—the exploration geophysicist —calls for some knowledge of geology as it would be to say that the whole of biology belongs to geology because a particular type of biologist—the paleontologist— needs some knowledge of geology. Development of a Geophysicist Since it is impossible to become an expert in all the fields of geophysics, and since students entering college seldom know the field they will choose as a career, what would we suggest as the best general preparation for work in geophysics, whether as a meteorologist, an oceanographer, a seismologist, a geodesist, a geomagneticist, a volcanologist, a tectonophysicist, a hydro1 ogist, or an exploration geophysicistp we may distinguish five phases in the development of a geophysicist: (I) his mathematical and scientific studies in high school; (2) the general mathematical and scientific

Jan 1, 1946

By K. R. Van Horn

RESIDUAL stresses in metals operate under a cloak of mystery, as they have neither been seen in the laboratory nor detected by means of the microscope. In spite of their phantom-like nature, they frequently exert metallurgical effects that cannot be ignored. In some cases the results have been detrimental, causing rejections or premature failures, but frequently the effects have been highly beneficial to the producer or consumer of metal products. First, however, what is a residual stress? When a metal is plastically deformed by bending, rolling, pressing, or by a phase transformation or precipitation from solid solution, or by a sharp temperature gradient resulting from nonuniform cooling, quenching, or welding, it remains in a state of strain. The strains or strain gradients produced by such operations and retained after all external forces are released are known as residual strains, and the accompanying stresses as internal or residual stresses. Many defects or failures in metal products have been ascribed to residual stresses, sometimes erroneously, because there was no other apparent explanation after the usual metallurgical tools of diagnosis had been applied. For example, during World War 11, the forged aluminum alloy aircraft cylinder head in the reciprocating engine began to replace the cast head with the familiar cooling fins. The fins were machined in the solid forged head by an ingenious milling operation. One plant reported an epidemic of excessive distortion during the delicate high-speed milling. A thorough examination revealed that the composition, heat treatment, mechanical properties, and metallurgical quality of these heads were comparable to those of forgings that machined satisfactorily. It was then claimed that the cause of the machining difficulties was connected with residual stresses resulting from the quenching during the solution heat treatment. An elaborate stress analysis actually demonstrated, however, that the magnitude of residual cooling stresses was lower in the cylinder heads which machined poorly than in those which were satisfactory in this respect. Subsequent tests proved that the machining problems in this case originated from variations in the tools and tool design. Sources of Residual Stresses in Metals Residual stresses are of two origins—mechanical and thermal. Thus, stresses may be produced in a metal by any cold-working process. The distribution and magnitude of these mechanically produced stresses can be calculated in a satisfactory, although approximate, manner for such simple cases as bending, torsion, and expanding of tubes. However, most manufacturing processes are too complex, and the original stress-strain relations in the products are not sufficiently known to permit calculation of the resulting residual stresses. Also, a specific process, such as wire drawing, may vary in complexity or uniformity of working, and large or small residual stresses may result, depending on the conformation of the dies and other features of the working process. Neither substantially unidirectional deformation, such as can be imparted by stretching a metal product having essentially the same mechanical properties throughout the cross section, nor deformation

Jan 1, 1954

By L. G. Graper, E. L. Ramsey

The present program of increased production of armament and lend-lease material for mechanized war has created a problem for the shops that must do the machining. They have naturally turned to the steel producers to provide them with a steel that can be accurately machined with the greatest possible speed. The adding of sulphur to steel as an aid to machinability has long been practiced; however, it may cause red shortness in rolling and may result in billets with seams and cracks, which must be removed before rolling can be continued. This conditioning of billets slows down production and adds to the cost of making steel. Experience with various grades of sulphur steel made to different specifications has shown that Bessemer sulphur steels roll better than similar grades made in the open hearth, and also that low-carbon steels that are open or semikilled as tapped roll better than completely deoxidized or killed steels. This has led to the belief that oxygen plays an important part in the rolling qualities of sulphur-bearing steels. It is generally held that the red shortness of sulphur steels is due to the low melting point of the sulphide compounds that separate out at the grain boundaries when the steel solidifies. At the rolling temperature of steel these sulphide compounds melt and cause cracking. Adding Sulphur as a Sulphite These difficulties can be avoided if sulphur is introduced into the stecl by means of an anhydrous sulphite, such as sodium sulphite or sodium bisulphite, which—upon decomposition—forms sulphur dioxide. It is assumed that, in this case, the oxygen of the sulphur dioxide forms part of the sulphide inclusions in the steel, and raises their solidification temperature enough so that the formation in the steel of a low-melting eutectic is prevented. The result is the prevention of hot shortness and a more uniform distribution of inclusions. Fig. I shows photomicrographs of steels made with sulphur, while Fig. 2 illustrates the structure of steels made with sodium bisulphite. These samples were cut from the steels as cast—that is, before rolling— and were polished and lightly etched to bring out the grain boundaries. Fig. I shows that sulphide inclusions segregate more or less at the grain boundaries, and it can be seen how the continuity of these low-melting inclusions would cause red shortness. Fig. 2 shows that the sulphide inclusions arc more or less uniformly distributed throughout the matrix. This arrangement of inclusions has no apparent effect on the rolling qualities of a steel. This statement has been substantiated by the observation of the rolling of over 6000 tons of steel made with a sulphite addition. Results As stated before, the sulphur dioxide is added to steel by means of the decomposi- 27

Jan 1, 1942

By George L. Reiter, George B. Clark

Commercial strip mining of coal was first begun in the state of Illinois in 1911.l The annual tonnage of coal produced from coal strip mines in the state was very small until 1924, when the strip mines shipped 1.68 pct of the total state shipping mine tonnage. Since then, strip mines have gradually come into their own by producing a sizable percentage of the coal produced in the state. Table 1 shows the coal tonnage shipped from both underground and strip coal mines in the state of Illinois for selected years. The table illustrates the major role that strip mines play in the state's coal industry. Today, strip mining is generally conducted in areas where the coal seams lie so close to the surface of earth that a stripping method of mining the coal seam is cheaper than an underground method. Strip mining not only recovers 100 pct of the coal deposit, but may also be used as a method of mining large acreages of coal abandoned by the closing of underground mines. Open cut or strip mining is a very highly mechanized method of producing coal and is carried on in three distinct and separate operations. The first of these is uncovering or exposing the coal seam so that the coal is made available for mining. The second operation is that of actually mining the coal. The third operation is the washing, crushing and grading of the coal according to the producer's market. Description of Shovel The Marion 5560 power shovel is used in the first of these three operations. The large electric-powered shovel works forward and back across the coal deposits, removing the overburden of dirt, rock, and clay in successive cuts of 30 to 60 ft deep and 40 to 80 ft wide. The shovel has a maximum cutting height of 95 ft, but around 60 ft is considered to be the maximum economical cutting height by the operators. The smaller the depth of cut, the more economically the shovel will operate until a minimum cut of 15 ft is reached, below which the efficiency decreases rapidly. The Marion shovel may be used in tandem stripping in excessive depths of overburden. The other type of excavating equipment used in the tandem team is generally a dragline with a long boom of about 180 ft. In tandem stripping, the dragline is used to remove the upper portion of the cut and to place it at a maximum dumping radius from the place of removal. The Marion 5560 power shovel is then used to remove the overburden left above the coal seam and to deposit it at the shovel's maximum dumping radius. The Marion 5560 power shovel is of gigantic proportions. It has a 102 ft 6 in. boom and 32 cu yd dipper and is

Jan 1, 1950

By L. G. Graper, E. L. Ramsey

The present program of increased production of armament and lend-lease material for mechanized war has created a problem for the shops that must do the machining. They have naturally turned to the steel producers to provide them with a steel that can be accurately machined with the greatest possible speed. The adding of sulphur to steel as an aid to machinability has long been practiced; however, it may cause red shortness in rolling and may result in billets with seams and cracks, which must be removed before rolling can be continued. This conditioning of billets slows down production and adds to the cost of making steel. Experience with various grades of sulphur steel made to different specifications has shown that Bessemer sulphur steels roll better than similar grades made in the open hearth, and also that low-carbon steels that are open or semikilled as tapped roll better than completely deoxidized or killed steels. This has led to the belief that oxygen plays an important part in the rolling qualities of sulphur-bearing steels. It is generally held that the red shortness of sulphur steels is due to the low melting point of the sulphide compounds that separate out at the grain boundaries when the steel solidifies. At the rolling temperature of steel these sulphide compounds melt and cause cracking. Adding Sulphur as a Sulphite These difficulties can be avoided if sulphur is introduced into the stecl by means of an anhydrous sulphite, such as sodium sulphite or sodium bisulphite, which—upon decomposition—forms sulphur dioxide. It is assumed that, in this case, the oxygen of the sulphur dioxide forms part of the sulphide inclusions in the steel, and raises their solidification temperature enough so that the formation in the steel of a low-melting eutectic is prevented. The result is the prevention of hot shortness and a more uniform distribution of inclusions. Fig. I shows photomicrographs of steels made with sulphur, while Fig. 2 illustrates the structure of steels made with sodium bisulphite. These samples were cut from the steels as cast—that is, before rolling— and were polished and lightly etched to bring out the grain boundaries. Fig. I shows that sulphide inclusions segregate more or less at the grain boundaries, and it can be seen how the continuity of these low-melting inclusions would cause red shortness. Fig. 2 shows that the sulphide inclusions arc more or less uniformly distributed throughout the matrix. This arrangement of inclusions has no apparent effect on the rolling qualities of a steel. This statement has been substantiated by the observation of the rolling of over 6000 tons of steel made with a sulphite addition. Results As stated before, the sulphur dioxide is added to steel by means of the decomposi- 27

Jan 1, 1942

By G. Ansell, J. Weertman

G. Ansell and J. Weertman (Rensselaer Polytechnic Institute and Northwestern University, respectively) —The great increase in creep strength that you found in your indium-glass composites is quite striking. You ruled out a decrease in the dislocation source density as an explanation of the reduced creep rates. Could you tell in greater detail why you feel this is an inadequate explanation of the phenomenon. It appears to us that it is a reasonable one. Consider the spacing between the glass spheres in your composites. It is of the order of 10-3 cm. The spacing between dislocations in a (single-phase) annealed metal with a dislocation density of the order of 106 to 107 cm per cm3 also is of the order of 10-3 cm. Therefore it is not reasonable to expect that the arrangement of the dislocation lines is the same in the composite material as it is in pure indium. If the dislocation arrangements are different the density of the dislocation sources likewise will be different. Another way of saying the same thing is the following. The presence of the glass spheres reduces one of the dimensions of the metal phase to 10-3 cm. Thus the metal phase, in effect, is equivalent to a metal whisker or a thin metal film. These are strong because they have so few dislocation sources within them. T. D. Gulden and J. C. Shyne (authors' reply)—It is to be expected that the arrangement of dislocations in the indium-glass composites would be quite different than that observed in annealed pure metals. The dislocations probably exist primarily as segments connecting the dispersed particles. These segments and discontinuities at the very large area of particle-metal interface could act as dislocation sources. For this reason it was considered unlikely that the very high observed creep strengths were due to a low density of dislocation sources. A more likely explanation is that the distance a dislocation can glide is limited by the interparticle spacing. The particles averaged about twenty in diam and were less than 10 µ apart in the 40 pet composite. It seems reasonable to assume that a dislocation loop in a volume of metal surrounded by these relatively large particles would not bow out around them but would be restricted to the region between particles. A general expression for creep rate is given by the product of the dislocation source density, the average rate at which loops are generated from a source, and the average area swept out by a loop times the Burgers vector magnitude. Assuming that the area swept out is limited by the interparticle spacing and the rate of generation of loops is controlled by the rate of climb of loops over second-phase particles, as suggested by Ansel and Weert-men,9 a calculation of the dislocation source density may be made from the experimentally observed creep rates. The result comes out 10" to 10" per cm3 which seems reasonable in view of the assumptions involved. Thus it is concluded that the anomalously low creep rates that were observed were due not to a low dislocation source density but rather to a limitation on the area swept out by each dislocation loop.

Jan 1, 1964

By AIME AIME

Few men in the coal-mining industry have had experience in metal mining as well, as has Carroll A. Garner. He went to the Arizona copper country immediately after graduating from Penn State in mining engineering in 1910, and worked in the engineering departments of the Miami and Inspiration companies for two years. Then he came back to Penn State far a year as an instructor in mining engineering before embarking in the coal industry. He was born in Ashland, Pa., July 6, 1889, and reared there, in the heart of the anthracite district, which undoubtedly influenced his choice of a professional career. The green Pennsylvania hills were preferred to the Arizona cactus country. His first coal-mining job was with the Lehigh Valley Coal Co., of which he was division engineer at Hazleton when he joined the Institute in 1917. He gave that up to go to Ohio as head of the Fernwood Mining Co. in 1921, but even that was too far west and after two months he was back in Pennsylvania as assistant general manager of the company that has since monopolized his services the Jeddo Highland Coal Co. Since 1927 he has been vice-president in charge of operations of both the Jeddo-Highland and the Hazle Brook Coal Companies, Jeddo, Pa. Between them they normally produce about 1,500,000 tons of what Mr. Garner will readily admit is the very highest grade of anthracite, utilizing the services of some 2600 men.

Jan 1, 1942

By W. B. Mather

Of the 61 dikes examined some yielded cassiterite, tantalite, and beryl; eight contained spodumene; and six carried amblygonite. Two mines stockpiled spodumene as a byproduct. Only zoned pegmatite dikes carried lithium minerals. GEOLOGICAL studies have revealed the occurrence of hundreds of pegmatite dikes in northeast Brazil, Fig. I, in the three states of Rio Grande do Norte, Paraiba, and Ceara. Heretofore data have not been available on the possible production of lithium minerals from these areas, and in March, April, and May 1953 the author undertook a reconnaissance survey covering a cross-section of the pegmatite~. Sixty-one pegmatites were examined. The pegmatites of Rio Grande do Norte and Paraiba are located in an arid region (Seratao), and except in the most southerly portion there is a minimum of vegetation and overburden. The region is easily prospected and relatively accessible by jeep or truck. The pegmatites examined in Ceara are in an area of lush vegetation along the flanks of the Jaqueribe River valley. It is therefore more difficult to prospect, and the dirt roads, as a means of access, leave much to be desired. For all practical purposes rail transportation, except in Ceara, is not available. The rocks of the area are composed of Pre-Cambrian schist, gneiss, quartzite, and marbles. They have been intruded by granites, monzonites, and diorites and cut by quartz veins and pegmatites. Pre-Cretaceous erosion reduced the area to a peneplain upon which Cretaceous or younger sandstones were deposited. Recent erosion has left only a few remnants of these younger rocks. In most of the Rio Grande do Norte-Paraiba area the pegmatites were more resistant to erosion than the enclosing schists and therefore stand out in relief. This is not true in the rolling country of Ceara, where the pegmatites lack topographic expression. With regard to structure and lithology, the pegmatite~ of northeast Brazil are divided into two types, uniform and zoned. Of the 61 examined, 19 belong to the uniform and 42 to the zoned type. Uniform pegmatites are normally long, narrow, and tabular, with sharp contacts. They are composed of an intimate mixture of feldspar (microcline or ortho-clase), mica (biotite, phlogopite, or muscovite), and quartz. The grain size5 varies from fine at the contact to coarser in the interior. They are not considered a commercial source of pegmatite minerals, although efforts have been made to produce green beryl of gem variety. This type of dike is often abundant in schists and gneisses close to granite intrusives. The productive dikes — lenticular, pod-shaped, or irregular in outline, with sharp contacts — are of the zoned variety. Zone contacts are gradational, except for those with the quartz core. Zones re identified as follows, see also Fig. 3. Border Zone: This outer zone, in contact with the country rock, is composed chiefly of fine-grained muscovite and biotite, with lesser quantities of finegrained microline and quartz. It is the narrowest zone, usually measurable in inches. Wall Zone: Lying between the border and intermediate zones, the wall zone is composed of medium-grained feldspar (often microcline), muscovite, and quartz. Usually it is the widest zone. Widths of 50 ft were noted. Intermediate Zone: Lying between the wall zone and core, the intermediate zone is composed principally of coarse-grained microcline (occasionally with some orthoclase and albite). It may also carry minor amounts of coarse-grained quartz and fine to medium-grained mica. The width varies from less than 3 ft to more than 30 ft. Core: The center of the dike is composed almost entirely of massive quartz, occasionally with minor amounts of fine-grained muscovite. The width reaches 30 ft. Lithium and other minerals of potential economic value are found in the following zones:

Jan 1, 1955