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By R. E. Ricksecker, W. M. Baldwin, R. McC. Baker

INTRODUCTION THE development of residual stress in strip during rolling has not been systematically studied. A few scattered papers1-3 mention the existence of residual stresses in rolled strip or touch upon some of their consequences,4 but there is no report of experimental studies in the literature describing the effect of roll diameter, strip thickness, reduction per pass, metal or metal temper on the magnitude of residual stresses developed in strip. A knowledge of the effect of these factors is of utmost importance since the present trend in some mills to roll thicker castings brings the rolling operation directly into that set of conditions which, as will be brought out in the present paper, can develop residual stresses of a high order of magnitude. Fundamentally, residual stresses are developed when a metal is inhomogeneously unloaded from a plastic stress state. A quantitative treatment of the problem requires a reasonably complete understanding of both the plastic stress state existing in the metal during deformation and the elastic stress state that would exist in the metal if the metal deformed as a perfectly elastic body. Our knowledge of either state during rolling is so meager that we can make no more than certain limited predictions. The external stress state* operating between the roll and the metal consists of compressive stresses acting almost perpendicularly to the strip surface but vary [ ] ing in intensity both across the width of the strip and along the length of contact between the roll and the strip. An example of such a stress distribution is shown in Fig I. The nature of the internal stress state, produced by this distribution, is not known. Various investigators,5-7 however, have felt that a qualitative similarity must exist between the internal stress state so produced and that produced in a wide strip that is compressed between two flat-nosed punches. In the latter case the external stress state is represented by a uniformly distributed compressive stress acting perpendicularly over the face of the tool. The elastic internal stress state in this case is complex-the principal stresses showing

Jan 1, 1948

By Frank Foote, Eric R. Jette

In a recent article,1 the authors reported the results of an X-ray investigation on the range of solid solutions that occurs in the iron-oxygen system in the vicinity of the compound FeO, which frequently is called "wüstite." The object of that investigation was primarily to study the unusual type of solid solution phenomena involved in this range. Briefly summarized the results were: 1. The NaCl type of lattice found by earlier workers was confirmed. 2. The lattice dimensions decrease rapidly with decrease in iron content. 3. No alloy that was a homogeneous single phase was ever found at compositions beyond 76.80 per cent Fe, while the theoretical iron content of FeO is 77.73 per cent Fe. 4. Measurements of the densities and lattice constants led to the conclusion that the form of substitution was complex, an FeO group being replaced by oxygen. Such a substitution, of course, is equivalent to removing an iron atom (or ion). The ideal unit cell of FeO can be considered as containing four groups of FeO and, thus, when this type of substitution takes place, there remain in the unit cell three FeO groups and an oxygen, or a total of seven atoms with a gross formula of Fe3O4 instead of the original Fe4O4. 5. This was the only interpretation that would fit the experimental results and at the same time be consistent with (a) the previously determined fact that the FeO lattice is ionic (i, e., consists of Fe++ and O? ions) and (b) the chemical fact that as the oxygen content of the substance increases, ferrous iron becomes oxidized to ferric iron. The experimental results of this investigation are included in Fig. 1. The purpose of the present investigation was to determine the limits of this homogeneity range by means of the X-ray structure analysis. This method has been applied frequently to the study of solid solutions by Westgren and his coworkers as well as by other investigators. The principle is simple: if the change in lattice constant with composition is

Jan 1, 1933

By William L. Fink, Dana W. Smith

Many investigators have attempted to determine the true nature of the internal changes taking place during aging. Merica, Waltenberg and Scottlt were the first to propose a theory of age-hardening. They attributed the age-hardening of duralumin to the precipitation of minute particles of the compound CuA12. Later Zay Jeffries and R. S. Archer2 augmented the above theory by suggesting that the small CuAl2 particles acted as "keys" causing "slip interference." Many other investigators3 have devoted much time to the mechanism of age-hardening, some corroborating the "precipitation" and "slip interference" theory, others coming to different conclusions because of effects that to them seemed unexplainable by the early theories; e.g., the increase of electrical resistance upon aging, the fact that no change in lattice parameter could be detected during the early stages of aging even at elevated temperatures, and the fact that the density did not change as would be predicted. In 1932, Merica revised4 his earlier precipitation theory to take care of these presumably anomalous effects. This revised theory, the "knot" theory, assumes that substantial age-hardening occurs before actual precipitation of solute as discrete particles. The assumed mechanism is one of diffusion of solute atoms into groups forming distorted regions which act as "hard" spots and cause slip interference. These "knots" are assumed to have approximately the same lattice arrangement as the solvent. The anomalous behavior of lattice parameter, density, and electrical conductivity, require a modification of the simple precipitation-hardening theory, only if it is assumed that the precipitation of minute particles during aging has the same effects on these properties as the formation of large particles under equilibrium conditions. Data obtained by the authors in the study of the aluminum-magnesium system5 indicated that

Jan 1, 1936

By Nicholas J. Grant, Ulf Kalling, John Chipman

THE operation of a blast furnace is dependent to an important extent upon the sulphur content of materials charged and the desired limit of sulphur in the product. It has long been known that the blast furnace is the most efficient tool for desulphurization in common use and that this efficiency is associated with the strongly reducing conditions of the hearth and is enhanced by increased basicity and fluidity of the slag. The chemical reactions of desulphurization may be studied from the viewpoint of the ratio of the process or of the final equilibrium conditions. Both kinds of studies contribute to an understanding of the process and both are included here. A simple measure of the desulphurization power of a slag is given by the ratio: Pct sulphur in slag (Pet S) Pct sulphur in metal [Pct S] This ratio was used by Holbrook and Joseph',' to measure relative desulphurizing powers under controlled laboratory conditions. It was also used by Hatch and Chipman3 as a measure of the equilibrium distribution. For the latter purpose it would be preferable to employ thermodynamic activities rather than percentages, but until very recently this has been impossible for lack of data. Now, thanks to the work of Morris and Williams and Morris and Buehl," the effects of carbon and silicon upon the activity of sulphur in the metal are known. The confirmation of this work and its extension to include the effects of other elements by Sherman and Chipman and by Rosenqvist and Cox' make it possible to calculate the activity of sulphur in pig iron of any composition. Hence it is now possible to use data on the equilibrium distribution of sulphur to find its activity in the liquid slag and to approach an ultimate solution of the thermodynamic aspects of the problem. The rate of transfer of sulphur from metal to slag is the problem of major industrial importance and indeed the principal need for equilibrium data has been as a necessary adjunct to the kinetic studies. The rate of approach to equilibrium under laboratory conditions seems slow compared to the requirements of industrial practice, and it is clear that further laboratory studies of rates are needed. In the research reported below, the items which were investigated were the following: I—The role of mechanical stirring on the approach to equilibrium. 2—The role of MgO in desulphurization as compared to CaO. 3—The role of MnO in desulphurization. 4— The limiting reactions which constitute the slow steps in desulphurization. Experimental Procedure The experimental set-up and procedure previously described by Hatch and Chipman" were essentially followed with several small modifications. The graphite crucible containing the slag and metal charge was altered to provide considerably more active stirring and mixing of the slag and metal in the carbon monoxide atmosphere. For this purpose the crucible was machined to provide two deep cylindrical wells which were interconnected at top and bottom as shown in Fig. 1. A graphite screw with a flat thread and of shallow pitch (4 threads per in.) spinning at 600 to 800 rpm was used to lift the slag and metal over the partition between the two wells and throw them over into the second well, where the metal settled through the slag into the reservoir at the bottom. It was possible to see actual particles of slag and metal being thrown over the partition. In this respect, the stirring was more vigorous than used in the work of Hatch and Chipman. A charge of 400 g of wash metal was first melted, and 20 g of FeS was then added to yield a bath containing 1.65 pct S. Immediately 400 g of slag (as pure mixed oxides) was added and fused. The slag was generally fused in 1 hr * 10 min. Within 30 to 45 min after melting, the temperature was adjusted to 1525"C, and the first slag and metal samples were taken. The slag was picked up on the end of a cold Armco iron rod, whereas the metal was sucked into a silica tube. The wash metal composition was (in percent): 4.29 C; 0.022 S; 0.021 P; 0.38 Si. The slags used were of four fixed starting compositions covering a wide range of acid-base ratios shown in Table I. Deliberate variations in MgO were made in these slags to check the role of MgO in blast-furnace desulphurization. Changes due to additions and reactions were followed by analysis of samples. Additions of Mn and MnO were made to most of the heats to note the role of Mn and MnO on desulphurization. Three heats (62 through 64) were made in an open pot induction crucible (graphite) using a

Jan 1, 1952

By Wm. I. Weisman, Sid McIlveen

Sodium sulfate is an important industrial chemical, being one of perhaps a dozen or so chemical commodities produced and consumed in the United States in quantities exceeding 1 Mt/a. In recent years approximately half that production has come from natural sources, whereas 27 years ago only 25% was derived from these sources. Table 1 illustrates the history of production of natural sodium sulfate in the United States. Production of natural sodium sulfate from various types of deposits is the main source of this chemical in Canada and Mexico, and probably in Argentina, Chile, Spain, and the USSR. Mineralogy and Physical Properties Sodium sulfate is widespread in occurrence and is a common constituent of many mineral waters, as well as seawater. Atmospheric precipitation contains sulfate; it is one of the major dissolved constituents of rain and snow (Davis and DeWiest, 1966). Many of the saline lakes throughout the world contain varying amounts of sodium sulfate. Because sodium is usually the dominant cation, some workers make an anionic distinction, referring to lakes containing predominately sulfate as bitter lakes and those containing predominately carbonate as alkali, or soda lakes (Bateman, 1950). Sodium sulfate in its natural form is found as the hydrous salt mirabilite (commonly called Glauber's salt), and as thenardite, the anhydrous variety. The largest quantities occur in the form of mirabilite. Sodium sulfate is found in varying degrees of purity, from theoretically pure efflorescent crystals of mirabilite to combinations and admixtures of other salts and impurities. It is a common constituent of some brines; from this source much is extracted commercially. [ ]

Jan 1, 1983

By W. F. Netezband, E. H. Crabtree

The productive area of asphalt-bearing sandstone in Missouri is near the Missouri-Kansas state line near Nevada, the county seat of Vernon County about 100 miles south of Kansas City. While production thus far has been confined to Vernon and Barton counties, there are known deposits in adjacent counties. The area is served by four railroads: the Missouri Pacific, the Kansas City Southern, the Missouri-Kansas & Texas, and the St. Louis & San Francisco. The plant of the Reliance Rock Asphalt Corporation is in Vernon County, about 5 miles west of Nevada, at Ellis, a flag station on the Missouri, Kansas & Texas Railroad. A siding has been built to the plant SO that the finished product can be loaded directly into railroad cars. The property consists of a lease of 240 acres in one block. All portions of the property not required for quarrying or processing the asphalt-bearing sandstone are used for farming by the fee owner. The entire tract is very flat so that there are no transportation difficulties from quarry to plant. Geology The commercial asphalt-bearing sandstones are all of Pennsylvanian age, the major portion of the production coming from the Cherokee formation, the basal member of the Des Moines group. The Cherokee formation includes all beds between the base of the overlying Fort Scott limestone and the Mississippian limestones below. It underlies most of the area, but in the west and northwest townships of Vernon County, and elsewhere in local outliers, the Henrietta limestone, forming mounds, escarpments and high ridges, covers the Cherokee, and is in turn covered by the Pleasanton shale. In the eastern portion of the counties, the Mississippian limestones are exposed. The thickness of the Cherokee varies according to the amount that has been removed by surface erosion. Where fully present under the Henrietta; it is approximately 375 ft. thick, but over most of the county it ranges from 100 to 200 ft. thick.

Jan 1, 1938

By E. H. Crabtree, W. F. Netezband

The productive area of asphalt-bearing sandstone in Missouri is near the Missouri-Kansas state line near Nevada, the county seat of Vernon County about 100 miles south of Kansas City. While production thus far has been confined to Vernon and Barton counties, there are known deposits in adjacent counties. The area is served by four railroads: the Missouri Pacific, the Kansas City Southern, the Missouri-Kansas & Texas, and the St. Louis & San Francisco. The plant of the Reliance Rock Asphalt Corporation is in Vernon County, about 5 miles west of Nevada, at Ellis, a flag station on the Missouri, Kansas & Texas Railroad. A siding has been built to the plant SO that the finished product can be loaded directly into railroad cars. The property consists of a lease of 240 acres in one block. All portions of the property not required for quarrying or processing the asphalt-bearing sandstone are used for farming by the fee owner. The entire tract is very flat so that there are no transportation difficulties from quarry to plant. Geology The commercial asphalt-bearing sandstones are all of Pennsylvanian age, the major portion of the production coming from the Cherokee formation, the basal member of the Des Moines group. The Cherokee formation includes all beds between the base of the overlying Fort Scott limestone and the Mississippian limestones below. It underlies most of the area, but in the west and northwest townships of Vernon County, and elsewhere in local outliers, the Henrietta limestone, forming mounds, escarpments and high ridges, covers the Cherokee, and is in turn covered by the Pleasanton shale. In the eastern portion of the counties, the Mississippian limestones are exposed. The thickness of the Cherokee varies according to the amount that has been removed by surface erosion. Where fully present under the Henrietta; it is approximately 375 ft. thick, but over most of the county it ranges from 100 to 200 ft. thick.

Jan 1, 1938

By H. L. Washburn, G. L. Judy

DURING recent years thermal drying of fine coal has increased at a tremendous rate, but very little discussion of the several excellent units has found its way into print. This is particularly true for operating and maintenance costs, and the operator who is faced with his first fine coal drying installation must depend chiefly on hearsay when trying to determine what his drying costs will be. This article presents the maintenance and operating costs for the seven drying units now installed in preparation plants of Pittsburgh Consolidation Coal Co. and lists other cost information that should be obtained before any particular drying unit is selected. Plant Description: The fine coal drying section of Plant A consists of four Flash driers operating on two furnaces equipped with spreader stokers. Plant B has one Flash drier operating (together with a screen-type coarse coal drier) on one furnace equipped with a spreader stoker. Plant C has two Cascade-type driers operating on a single furnace with a spreader stoker. Plant Costs: Tables I, 11, and III present the cost of operating these units as reported by the individ- ual plants. As can be seen, the labor rates vary, depending on the amount of overtime paid and the time interval the cost figures cover. There is considerable variation in thermal units used and in the value given to the thermal units at the particular mine. There is some difference in power costs at a given location and, finally, the power costs of conveyors leading to the drying plants were included in some cases. Maintenance supply costs are simply a tabulation of the cost of all supplies used on the driers, furnaces, and stokers. Depreciation is not included, and the tables omit items such as supervision, plant cleanup, oiling, general maintenance, taxes, and insurance. These tables in themselves do not offer a true comparison of costs. This information must be reduced to some common basis. But what is this common basis to be? A mine operator must calculate his overall mine and preparation plant costs in terms of tons of clean coal sold. Unit costs on pieces of equipment within a given plant are correctly calculated on the same basis. However, when unit costs are compared between one plant and another, some thought must be given to unit design. This reasoning is similar to the old argument concerning i solid bowl vs basket-type centrifuges—the units themselves are not directly comparable without their supporting equipment. So it is with thermal driers. Except in rare cases of low entering moisture i content, driers are sized on the basis of water that must be evaporated, while the wear each unit gets de-

Jan 1, 1958

History of Reverberatory Smelting in Montana, 1879-1933. By FREDERICK LAIST (Trans, vol 106 31,800 words ) The development of the art of reverbera¬tory smelting from 1879, when smelting first started in Butte, up to the present time is described. The paper traces the development of the reverberatory furnace, as regards both constructing and operating, from the initial 10-ton furnaces to the present-day 600-ton furnaces and the changes in operating practice which accom¬panied the gradual enlargement of the furnaces and the reasons therefor are described and explained The results obtained from an investigation (made in the course of the Carson litigation) into the various methods of charging reverberatory furnaces are given These investigations proved that the method of charging a reverberatory had very little to do with its performance It was also found, at the same time, that the depth and extent of the bath maintained in the furnace had very little to do with its performance Numerous operating results are included and the article is illustrated Development of Copper Converting at Butte and Anaconda. BY WILLIAM KELLY AND FREDERICK LAIST (Trans , vol 106 4400 words.) This paper is based on recollections of one of the authors, W M Kelly, who has been identified with the development of smelting and converting at Butte and Anaconda since early times The article starts with a description of the circumstances surrounding the first intro¬duction of copper converting at the Parrot Works in Butte under the Manhes patents It briefly recounts the difficulties which were encountered and the steps taken to overcome them Among these were the absence of means for punching tuyeres in the original converter This difficulty was overcome crudely by drilling holes in the windbox opposite the tuyeres, said holes being closed by wooden plugs Later these plugs were replaced by steel slides and still later by the Dibblie ball valve, which has remained standard ever since The development of the converter from both struc¬tural and operating standpoints is traced from the early beginning to the present day Developments in Lead and Copper Converting at Tooele. BY B L SACKETT (Trans, vol 106. 3900 words) This paper shows the development at this Utah lead and copper smelter from separate converting of the two kinds of matte produced to a more efficient and economical treatment of the combined mattes This was accompanied by the use of relatively large amounts of silicious ore in the converting of lead matte as well as copper matte, which greatly improved the quality of converter slag produced, both from the standpoint of its copper content and its desirability for

Jan 1, 1935

By V. N. Mackiw, D. E. Weir, D. J. I. Evans

The world's largest reserves of nickel are found in lateritic ores. Commercial exploitation has been carried out for almost one hundred years; however, none of the plants currently in operation produce pure nickel but rather ferronickel, matte, impure nickel oxide or mixed sulphide precipitate. Over the past decade Sherritt has studied various processes, including the modified reduction roast-ammonia-ammonium carbonate leach process, for the production of pure nickel powder and briquettes from laterites. Nickel can be reduced to the pure elemental form at elevated temperatures and pressures from impure basic nickel carbonate slurries. Several methods were studied in the development of the process for working up the pregnant leach liquor and basic nickel carbonate to produce feed for the aqueous hydrogen reduction step in which pure nickel powder is produced. This paper is concerned only with the laboratory studies using the basic nickel carbonate slurry reduction procedures.

Jan 1, 1973

By H. C. H. Darley

The influence of particle size and concentration on the development of chip hold-down pressure (CHDP) was studied in an apparatus designed to measure the change of filtration rate during the first second of the filtration process. CHDP is controlled by the "bridging" particles (i.e., particles in the 50 to 0.2 micron range), whereas filter loss is controlled by the colloid fraction. The results indicated that a fast drilling fluid with a low filter loss could be obtained if the concentration of bridging solids and the viscosity were kept very low. A novel group of drilling fluids, which we have named colloid emulsions, was developed to meet the above requirements. These colloid emulsions are made by dispersing art oleophilic colloid in oil and emulsifying about 5 per cent of this dispersion in water or a dense brine. Good results have been obtained in field trials with emulsions which use asphalt as the oleophilic colloid. INTRODUCTION In recent years it has been found that fast rates of penetration can be maintained in hard formations by using "clear" water as a drilling fluid. In some cases, however, water cannot be used because the very high down-hole filter loss creates various difficulties in drilling, in logging, or in producing the well. It then becomes necessary to "mud up", which results in a decrease in drilling rate. The reason that mud decreases drilling rates is a complex subject which has been well covered by such authors as Garnier and van Lingen, Cunningham and Eenink,' and van Lingen.3 One of the principal factors involved is the tendency of the drilling fluid to develop a filter cake on the bottom of the hole. The pressure differential which develops across this filter cake opposes the action of the bit in dislodging chips from the rock. This pressure differential is referred to by Garnier and van Lingen' as the chip hold-down pressure, which is denoted by the initials CHDP in this paper. The work described in this paper was undertaken to develop a drilling fluid which would minimize CHDP but which would still have a low filter loss—in other words, a fluid which would deposit a filter cake on the sides but would lay little or no filter cake on the bottom of the hole. EVALUATION OF CHDP EXPERIMENTAL Conditions governing the growth of filter cake on the sides of the hole are obviously different from those on the bottom of the hole. On the sides of the hole, cake will form continuously but at a decreasing rate, until eventually the rate of growth will equal the rate of cake erosion by the mud stream.' On the bottom of the hole, each time a bit tooth dislodges a chip the cake is removed, a fresh rock surface is exposed, and the filtration process must start over again. Thus the CHDP is determined by the amount of cake which can form in the interval between successive tooth strikes at a particular spot, normally a fraction of a second. Our first step therefore was to study filtration rates over the first second or so of the filtration process. These tests were conducted in the simple type of dynamic filter cell shown in Figs. 1 and 2. In this cell the mud was filtered through a train of rock cores while rotating blades kept the mud flowing over the surface of the core. The procedure was to evacuate the cores to 0.05 mm of mercury, saturate with brine, and assemble in the holder under brine. The permeability of the core train was then determined. A plastic seal was placed on the face of the core train, and a rip cord was attached from the seal to one of the blades. At the start of the test, 500 psi was applied to the mud, and the meniscus in the capillary measuring tube was adjusted to zero. When the blades were started, t,he seal was ripped from the face of the core, and filtration began. The filtration rate was at first measured by photographing the advance of the meniscus in the capillary tube. Using

Jan 1, 1966

By Joseph J. Yancik

From previous work, it was learned that relative strengths of blasting agents can be reasonably predicted from heats of detonation modified by their (D/D*)2 ratio.(1) Bulk Strength = Q x d x (D/D*)2 x K (1) In this equation Q is the ideal heat released during detonation, d is density, D represents actual detonation velocity while D* is ideal velocity. An energy transfer coefficient, K, was used to account for differences among rock strata in response to explosive loading. This equation gave reasonable, field supported strength values for oxygen balanced blasting agents. For aluminized nitrocarbonitrates and slurries which have high Q's the rating system predicted better strengths than were shown in the field. This discrepancy was felt to be related primarily to problems in calculating Q and D*. Theoretical calculations cannot take into account varying energy contributions from particulated aluminums whose reactivities vary substantially with physical properties. One approach to circumventing this problem would be to use a characteristic Q that is dependent on mass reactivity of ingredients as components in explosive formulations. Since the underwater testing method is capable of measuring a functional, relative energy release, it was chosen for study.

Jan 1, 1971

Jan 1, 1881

By John L. Ryon

Experimentation with ammonium nitrate fuel oil mixtures at three under-ground salt mines revealed its excellent applications at those properties. The author relates the present blasting practice used at these mines by the International Salt Co.

Jan 4, 1961

By R. L. Thayer, D. L. Auer

A review of bentonite production and quality control methods, is presented along with an update on techniques employed by the bentonite industry. This paper also includes an overview of bentonite market demands and long-range supply with resulting emphasis on changes in bentonite testing methods required to utilize existing reserves.

Jan 10, 1979

By H. B. Emerick

An effort has been made to evaluate the individual influence of various factors in steel making and rolling operations upon the surface quality of semi-finished steel products. The thoughts expressed are not entirely theoretical, but rather are based upon several years critical observation of mill yields and rejec-tions and are supported by actual data wherever this has been possible.

Jan 1, 1940

Jan 1, 1892

Jan 1, 1913

Jan 1, 1938

By Victor F. Hollister

North American ophiolite complexes are known to contain significant volcanogenic sulfide only in the following five areas: Newfoundland; Quebec; Applegate, Oregon; Rogue, Oregon; and Orca, Alaska. Most North American ophiolites, including the Baltimore, Kings-Sierra Nevada, and Del Puerto complexes, and those associated with the Franciscan, Trinity, eastern Oregon, and Cache Creek groups lack significant volcanogenic sulfide. The characteristics of sulfide-bearing ophiolites are: (1) manganozls cherts, and (2) fine, carbonaceous clastics inter- calated with pillow basalt and chert. It is suggested that sulfide- bearing ophiolite complexes developed in a restricted basin environment, such as is now present in the Gulf of California; whereas sulfide-poor ophiolites, formed in midocean, rises distant from land masses. Sea floor oxidation makes the typical midocean ridge configuration not conducive to sulfde preservation, whereas spreading centers bounded by land masses are more likely to produce anoxic physiographic lows favorable to sulfide accumulation.

Jan 1, 1982