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By F. Hassani, K. Moozar, J. Ouellet, P. Gauthier

"This paper describes a sudden spill of waste rock used for backfilling from a waste pass at an underground mine in Canada, thus causing a major failure/accident. The mine operator immediately launched a detailed investigation to understand the causes of this accident and develop procedures to prevent any recurrence of such events in the future. The authors from McGill University were invited to collaborate with the engineers at the mine to examine this accident. The events leading to the accident were studied, appropriate measurements were taken and samples of the waste material were collected for further testing and analysis.The field visit and the interview of the witnesses allowed the detailed documentation of the events. The sequence of events related to the incident, along with the experimental results obtained in the course of the investigation, are presented. The waste material was characterized in the laboratory with regard to its behaviour in the presence of water. This information is discussed and the failure mechanism involved in the accident is identified. Finally, the full recommendations as well as the immediate operational measures implemented by the mine to prevent the future occurrence of such events are presented and discussed."

Jan 1, 2004

By J. E. Shigley

The gemological properties that allow natural emeralds and blue sapphires to be distinguished from other gemstones are summarized in this paper. A variety of synthetic and laboratory-treated emeralds and blue sapphires are also encountered in the jewelry industry today. Gemologists distinguish these latter materials from their natural counterparts based primarily upon features seen with magnification, such as inclusions and/or growth zoning. In some cases, however, these observations and standard gem-testing methods are insufficient, and the use of non-destructive analytical methods, such as optical spectroscopy and chemical analysis, are required for positive identification. The commercial value of synthetic and treated gems are much less, and can be insignificant in comparison to that of an important untreated natural gemstone. Identification of synthetic and treated gem material is essential to maintaining integrity in the jewelry industry. Loss of consumer confidence in the gemstones sold at the jewelry counter could have a negative impact on the exploration and mining of natural emerald and blue sapphire.

Jan 1, 1998

By R. Grant, C. Bazin

"Brunswick Mining has investigated grinding media optimization for the purpose of improving the flotation feed and regrind product size distributions to enhance metal recoveries. This paper presents the findings of on-going testing of various sizes and shapes of grinding media. Plant observations combined with estimated breakage rates demonstrate the importance of appropriate selection of media sizes on the milling operation.IntroductionBrunswick Mining and Smelting is located near Bathurst, New Brunswick, and operates one of the world's largest lead and zinc mines. The ore mineralogy and processing flowsheet have been described elsewhere (Petruk and Schnarr, 1981; Shannon et 01., 1993). Despite the 25 years' milling experience, there has been considerable disagreement as to the required grind size (Grant et 01., 1991). Since 1964, fineness of the flotation feed ranged from 60% to 80% passing 400 mesh (37 um) and averaged slightly above 71% in 1992. Results from mineralogical analysis (Petruk and Schnarr, 1981), laboratory and pilot plant experiments, as well as plant sampling (Grant et al., 1991; Hendriks and Ounpuu, 1985; Shannon et al., 1993) indicate that improved metal recoveries can be achieved by an increase in the fineness of grind, and more specifically by maximizing the amount of material in the 15 urn to 25 um range.This paper shows the results obtained so far from the evaluation of the effect of grinding media size and shape on grinding mill efficiency. The problem of finding optimum grinding media size, shape and composition has been recogrtized since the early 19405. The main criterion for the selection of media size is the size of the material to be ground (Bond, 1958). Although several relationships have been proposed to assist in the selection of grinding media size, none of them are entirely satisfactory (Wills, 1988). Other approaches using the breakage rates and process simulators were developed to help in the selection of grinding media size (Austin et al., 1976; Lo and Herbst, 1986; Concha et 01., 1992; Samskog et al., 1990; Martinovic et al., 1990). Although considerable effort was put into the analysis of grinding media size, very little information is available on the effect of grinding media shape (Norman and Decker, 1985, p. 3C-4). Norris (1952), Kelsall et al. (1973) and Herbst and Lo (1989) have shown that balls are more efficient than other shapes of grinding media including truncated cones and cubes."

Jan 1, 1994

By J. M. Menacho, J. M. Reyes

"Batch and continuous regrind tests were conducted in 3 kW and 15 kW tower mill units, respectively. Single particle size classes of a chilean copper sulphide concentrate were employed in the batch tests, while a fraction of the plant stream was deviated to the continuous unit operated under different conditions.Results are interpreted in terms of the simplified grinding kinetic model energy-based and conveniently adapted to this application. Based on the above figures plus some industrial data supplied by MPSI Inc., a scale-up relationship was developed for the apparent specific rate of breakage siE, as a function of the net power draw P, i.e.siE = siE text (P/P test) 0.089This equation fit very well the available data at the three scales and its application to regrind 4400 t/day of rougher copper concentrate from 70% below 325 Tyler mesh to 95% below same mesh, involves around 30% energy-saving compared to standard ball mill for same grinding task.INTRODUCTIONImpact and abrasion-attrition breakage are two extreme mechanisms present in any grinding system in a proportion defined by specific design and operating conditions. Impact breakage is generally efficient for coarse grinding, while abrasion-attrition is adequate to produce fine particles. Efficiency of conventional tumbling mills decreases as fineness of the product increases, even though distribution of applied stresses is always much stronger than internal force distribution in the particles. On the other hand.in a vertically stirred ball mill like the tower mill, distribution of applied stresses and particle strengths are in the same order of magnitude, making possible nearly ideal abrasion conditions (1).Tower mill configuration includes a cylindrical body vertically mounted and provided with a central screw with flights to produce circulation of balls moved up through the inner region to return down by the external space. Fresh material can be fed into the top , center or bottom in order to assure appropriate agitation of suspended particles. Size reduction and evacuation rates should compensate settling of coarse particles to avoid sanding of the screw. Detailed description of the tower mill and its operation have been given elsewhere (2),(3)."

Jan 1, 1989

By Christopher F. Gleeson, Roger D. Thomas

"Abstract - Wawa has long been a center of mineral exploration activity and diamonds have been reported in the area since the 1930s. However, diamond exploration did not begin in the area in earnest until 1991. In 1993, Sandor Surmacz and Marcelle Hauseux of Saminex began a prospecting program in the area which culminated in their discovery of the "Sandor" diamond occurrence in an outcrop on the east side of the Trans-Canada Highway. They subsequently optioned the property to Spider Resources Inc. who obtained the necessary exploration permits from Algoma Central Corporation and undertook an exploration program. The diamonds at the "Sandor" diamond occurrence are hosted in the matrix of a spessartite dike composed of actinolite, biotite, and albite. Of the 64 similar dikes that have been sampled and analyzed to date, eight have been found to contain a total of 231 diamonds. Most of the diamonds are of high quality, although they are small.The dikes are non-magnetic and do not have any other geophysical characteristic that can be used to differentiate them from the adjacent country rock. All of the dikes discovered to date have been found by prospecting or by geological mapping by the Ontario Geological Survey. The dikes do not contain pyrope garnet or chrome diopside, two of the commonly used kimberlite indicator minerals. Instead, low Mg, high Cr, Zn-rich chromite, and ilmenites of variable composition, some of which lie within the field of kimberlitic Mg-ilmenite compositions, characterize the diamondiferous dikes. A regional-scale till sampling program for heavy minerals, and geochemical analysis of the <0.177 mm fraction, was used to further define the areas of occurrence of the spessartite dikes and to indicate additional areas for diamond prospecting. Heavy minerals in till that were most useful include: actinolite, chromite, and ilmenite. Geochemical analyses of the dikes show them to contain elevated concentrations of Ni and Cr and to be enriched in Ba, Co, V, Ca, Fe, and Mg relative to the surrounding rocks. Elevated concentrations of Ni and Cr in till occur overlying and down-ice of known lamprophyre dikes."

Jan 1, 2000

By Jacques Deraisme

The technology of percussion drilling is well mastered. The lower cost of percussion drilling allows more holes to be drilled for the same budget. However significant differences are often observed between percussion and diamond drill assay data. This is due to the increased level of contamination associated with the percussion drilling process. Statistical studies on twinned drillholes show that diamond and percussion assays cannot simply be merged in a traditional kriging approach. The question then arises on how to use both types of data to produce reliable resource estimates. To take into account the lower reliability of the percussion assays, a noise characterized by a variance is added to these data. The methodology consists of two steps: 1. Cokriging of the equivalent diamond value at the percussion assay locations. 2. Block kriging using diamond assays and equivalent diamond values, calculated previously, adding to these data a noise, whose variance is the cokriging variance of step 1. This particular way of achieving kriging is called kriging with variance of measurement error. The paper illustrates this innovative methodology with an application on an iron deposit. The results of this method is compared to block kriging using only diamond assays and the gain in precision is quantified. An extension of that approach to multi-element cokriging is also presented.

Oct 1, 2009

By A. H. C. A. Zimmerman

WE have just heard what must be regarded as a thoughtful, constructive and somewhat painful analysis of the financial function of our industry. While thinking about this, it is interesting to reflect on the conditions which have stunted the growth of the financial side of our affairs. Mining must be regarded as a wealthy business. •while immeasurable grub takes and development budgets have been lost, there can be little argument that a productive ore-body nearly always produces the type of wealth that breeds some extravagance. I recognize that this statement can be attacked from many sides, but an historical comparison with a commercial enterprise involving similar investment will demonstrate what I mean. However, these old times are be-ginning to disappear for a variety of reasons. High amongst these are: ( l) Increased costs of exploration. (2) Remoteness of many new finds. (3) Fixed or declining metal prices (particularly when expressed in constant dollars). ( 4) Constant demands for higher wages.

Jan 1, 1962

By Donald Leroux, Colin Hardie

"New or improved mathematical models of mineral processing machines are published almost on a monthly basis. Often, these models can be calibrated from bench-scale test results and programmed using spreadsheet software to simulate different designs and operating conditions in open-circuit configuration. However, since mineral processing plants frequently operate comminution, separation and/or extraction machines in closed-circuit configurations, open-circuit simulations often have limited applicability.The simulation of closed-circuit configurations necessitates the programming of an iterative loop to bring the circuit to equilibrium. This can be done by using spreadsheet software but often requires advanced programming skills. As an alternative, LIMN® software, which simplifies the programming of closed-circuit configurations within spreadsheets can be used. This software was specifically designed to turn a Microsoft EXCEL® spreadsheet into a closed-circuit modeling and simulation platform with minimal programming.During the past few years, the Mineral Processing Group at the Noranda Technology Centre, has used this software for numerous projects which include the simulation of multi-stage cyclone circuits, closed-circuit regrinding and locked-cycle flotation tests. Using these projects as examples, the flexibility and the easy to use nature of the LIMN® software is demonstrated.INTRODUCTIONMineral processing engineers routinely have to make predictions regarding comminution and separation processes. Predicting the appropriate dimensions of equipment and the process response to changes in operating mode are probably the most common situations that they face. In all cases these predictions are expected to be rapid and accurate.Predictions made by engineers are frequently based on mathematical models. Many first principles, empirical, semi-empirical, steady state and dynamic models of mineral processes can be found in the literature. In fact, new or improved mineral processing models are continuously being proposed and in spite of this variety, process engineers often have to either develop their own or tailor existing models to suit their particular needs."

Jan 1, 2003

By R. Jolicoeur, J. F. Jackson, M. A. Green

"The design, construction and commissioning of Kiena Gold Mines Limited's new mill was completed in 15 months ending in September 1984. Rated at 1250 tonnes per day the mill incorporates the latest innovative technology such as semi-autogenous grinding, carbon in pulp, pressure stripping and induction furnace refining. The mill is housed in a pre-engineered building with the leach tanks and thickeners located outdoors in spite of the intense winter cold. 1.0 INTRODUCTION AND HISTORYThe operations or Kiena Gold Mines Limited are located in Dubw1sson Township, approximately 10 Km west of Val d'Or, in the Abitibi region northwestern Quebec. Comprised of 59 mining claims covering 1214 hectares, a large portion of the mining property is overlain by the waters of Lac de Montigny. Sometime between 1911 and 1914 Barney Parker discovered gold in a shear zone on an island in Lac de Montigny that now bears his name. The first shaft the Parker Shaft, was sunk in 1936 from the island to a depth of 136 meters but owing to the known veins being of limited extent and the onset of the Second World War operations were terminated in 1940. In the early l960 1 s exploration drilling indicated an orebody of 4,500.000 tonnes at 6.3 grams of gold per tonne. A causeway was built to link the island to the mainland in 1963 and a new 3 compartment shaft was sunk to 403 metres. The orebody was further delineated and the ground conditions within the orebody and surrounds were evaluated.At the end of 1965 the property was placed on a care and maintenance basis as a mining operation would be marginal with gold selling at $35 per ounce."

Jan 1, 1986

By J. Ran

There are challenges in mining deep tabular ore deposits using the open stoping method, particularly mining remnant panels towards the end of mine life. The remnant panels have experienced stress concentration and are in the failing or post failure state causing drilling and loading difficulties, ground movement, induced seismicity and ground instability problems. As more mines are going deep, without effective ground control management, the mine production will be interrupted and equipment damage and personnel injury are likely to occur. Mining at Falconbridge Lockerby Mine located in the Sudbury Basin was concentrated in the deep zone from late 1990s to 2004. The remnant panels situated approximately from 1800m to 1920m below surface were mined in 2004 before the mine closure. These panels were in the central section of the orebody along strike. The orebody was relatively narrow ranging from 5m to 15m and steep dipping at 70o to 80o. Because of the retreat mining sequence and the mining depth, stress concentration, wall closure and seismicity had caused a number of mining difficulties. Managing these challenges was critical in achieving the mine production target without compromising personnel safety and excavation stability. A comprehensive ground control management approach was adopted to mine the remnant panels at depth. The measures taken included ground movement monitoring, understanding the movement pattern of the footwall rock and selecting appropriate support systems, analyzing seismic monitoring data and defining re-entry protocol, brow support design and restricting access. This paper presents these ground control measures and the experience gained in successfully mining the deep remnant panels at Lockerby Mine.

Apr 1, 2005

By Andy Fortin, André Vien, Christophe Bouché, Jeff McKay

"The technology and equipment design of the Twenty-first Century permit us to exploit low-grade ore bodies with milled tonnages reaching 300,000 tpd. Because of their substantial operational costs (energy, wear parts, etc) and precarious economic situations, the operations of today must maximize their metallurgical performance.The implementation of an Expert System becomes a logical avenue to pursue in view of increasing plant performance.Many operations, following the implementation of an Expert System, meet the objectives they determined before its integration; such as increased tonnage, stability, decreased costs, etc. However, they often cannot develop the full potential of the system due to certain factors that have been neglected or omitted during the implementation of the system.Three main elements have been identified during the implementation phase at INMET Mining Troilus Concentrator: 1- Instrumentation & Control 2- Software 3- Integration. Even though they have been clearly identified, these elements are often neglected due to lack of resources or lack of comprehension on the part of the operations personnel. This document will demonstrate, based upon our experience at Troilus and that of Metso Minerals, that we can identify and handle many factors which influence the profitability of the Expert System, for both short and long-term process control improvements.INTRODUCTIONThe Inmet Troilus Mine is an open pit mine, situated 175 km north of Chibougamau in the province of Québec, Canada. The mill, which started production in November of 1996, was originally designed to treat a gold – copper ore at a rate of 10,000 tpd.In early 1998, the mine plan called for a pit pushback and decreasing head grades for the following two years. With the price of gold nearing decade lows, the Troilus project was facing a major economical setback. There was a sense of urgency to reduce operating costs below the market price of gold. The mill team presented a project to management calling for an increase in mill throughput while minimizing capital expenditures and operating costs. This idea was supported by the existing mine plan, which called for a mine cut-off of 0.7 g/t Au and stockpiling low grade 0.5 g/t material for future milling."

Jan 1, 2003

Background Chronology 2008 Positions May 8, 2010 Summit Going Forward Say one thing and do another ??Genuine passion to see our customers succeed?, ?A passion for exceeding our customer?s expectations? Self serving actions to gain competitive advantage at the expense of the customer No single supplier or technology can manage the overall mine and its integrated operation - April 2005: Informal meeting at Toronto CIM 2004 -Unanimous interest - July 2005: Formal Calgary Meeting, developed: - Scope and vision statement , - OEM/OTM communication plan, - industry communication plan - Aug?Nov 2005: Aligned with SMART - Nov 2005?May 2006: Direct OEM, OTM communication - May ?Sept 2006: Developed baseline standards - Sept -April 2007: Developed SMART document - Sept 2007: Document distribution and request OEM OTM response - Jan ?May 2008: Acquired OEM OTM feedback and positions May 2008: Results presented to SMART and discussions on next steps

May 1, 2010

By M. D. Vance, G. R. Corbett, S. D. Butt

Surface wave imaging is a relatively new seismic technique that generates subsurface depth images without having to drill boreholes into the ground, and is rapidly becoming a standard tool in non-destructive geotechnical characterization. This paper presents a case study of the application of these surface wave techniques to image shallow abandoned mine workings at the Montague Gold Mines district near Dartmouth, Nova Scotia. This district has numerous steeply dipping narrow vein workings from historical mining activity, and has actively subsiding and collapsing crown pillars. Due to the rugged conditions at the site and the relative narrowness of the openings (often less than 1 m), a surface seismic system was developed that had improved portability and lateral resolution over other available seismic imaging systems. Seismic surveys were conducted over two sites where independent evidence indicated the presence of shallow mine workings. At one site, a comparative gravity survey was also conducted. The seismic data was processed to generate velocity vs depth images. Overall, the velocity images show vertical zones of zero velocity in the same lateral positions where historical mapping, current subsidence and gravity surveys indicate the presence of steeply dipping workings. Further, the velocity sections are consistent with the thickness of the till cover at each site and the possible weakening of crown pillars at one of the sites.

Jan 1, 2005

By Herbert D. Drechsler, James B. Stephenson

"AbstractThe paper identifies the major components of price change which affect the determination of the internal rate of return of a mining project. It illustrates several price indexes which may be used to measure general price increases, identifying techniques which might incorporate them into mine valuation procedures. The ""hurdle rate"" for new investment is discussed.IntroductionDECISIONS regarding the value of an orebody and whether or when to mine an orebody are based on an estimate of the cash flows which would be associated with its exploitation. These pro-forma cash flows represent cash in or out of a possible mineable deposit and include exploration and construction costs, sales revenues, operating expenses, taxes, debt borrowings, interest and debt repayment. It has long been recognized that when combining the cash flows occurring over the life of the mine, dollars received or paid out early have greater value than those received or paid out later. This time value of money has been incorporated into mine evaluation calculations through the use of present-value or discounting techniques. Another factor affecting mine valuation, inflation, is not accounted for by valuation techniques now in use. In recent years, price changes have become more volatile. In the past, price change could easily be ignored when evaluating potential mines. Today, the combination of larger investments and greater price volatility leads to great concern about the effects of price change on mine valuation."

Jan 1, 1977

By Douglas M. Smith, G. A. Maki

"The initial development of the massive potash deposits of the prairie evaporite formation took place over a decade ending in 1970. The potash mining and refining facility near Rocanvi11e, Saskatchewan was the 1ast of ten mines to come into production during that era. This operation, known as Sylvite of Canada Ltd., was designed to produce 1. 2 million short tons per year of KCl product in granular, coarse, standard and special standard grades.In 1977 the parent company, Hudson Bay Mining and Smelting, sold the Sylvite property to the Potash Corporation of Saskatchewan. Shortly thereafter PCS slated its new Rocanville Division for a two phase program of expansion. The first phase, completed in the spring of 1979, was relatively small, involving mill debottlenecking and additional equipment in the compaction circuit and the product and ore storage areas. The second phase was a major undertaking which included additional mining equipment and a new 300 STPH milling circuit. This work was completed during the fall of 1981 and has increased the Rocanville Division's nameplate capacity to two million STPY.Thickening equipment operating in the Saskatchewan potash industry is generally situated within the main refinery building or a separate insulated and heated structure due to the harsh winter climate and the need to closely control plant brine temperatures to ensure good flotation circuit performance. Since these thickeners process large volumes of slurries, conventional basin type designs tend to be large, ranging up to 150 feet in diameter or more. As part of the general effort to minimize capital costs, the potash industry has begun investigating the use of alternate high capacity, compact thickener designs. In this regard, PCS Rocanville undertook a program in 1978 to evaluate a Lamella™ Thickener and one other type of 'High Rate' thickener* as alternatives to a conventional design for the phase two expansion project."

Jan 1, 1983

"INTRODUCTIONGold tailings retreatment plants have been operated for many years throughout the world. Several large tailings retreatment facilities have been operated profitably in South Africa since 1976 and there are tailings retreatment operations in Canada currently in production with more in the feasibility stages.The Timmins Gold Tailings Project of ERG Resources Inc. was designed to treat 8,000,000 tonnes per annum of gold tailings for an eight month operating season, and commissioning of the operation began in July 1988. The payback period for this project is about 3 years which corresponds to an IRR of 30%.This report summarizes the metallurgical characteristics of the reclaim tailings, describes the process flowsheet which was developed to enable ERG to economically recover gold from the Timmins area tailings, and reviews commissioning activities."

Jan 1, 1989

By Christopher W. Corti

A major aim of the GOLD 2003 conference, is to promote new gold related science and technology with a view to developing new useful industrial applications for gold. Current industrial uses have provided a steady annual industrial demand for gold of around 350-400 tonnes in recent years, the bulk of which is centred on electronics applications, with dental uses constituting the second largest application. However, there is good reason to believe that whilst gold will continue to play a major role in these sectors in the future, substantial growth of demand is not anticipated. Increased industrial demand for gold is only likely to come through the emergence of new applications, probably most significantly in five broad market sectors: ? Pollution and emission control technologies, including fuel cells. ? New uses for gold in advanced electronics, electrical systems and devices. ? Chemical processing of a range of bulk and speciality chemicals, using gold based catalysts ? Advanced coatings exploiting the novel properties of gold, particularly in nanoparticulate form. ? New biomedical uses for gold including medical treatments, drugs, implants, sensors and devices. There is cause for optimism that many new applications for gold could emerge in these sectors over the next decade and that this will lead to a substantial growth in demand for gold. It is clear that many of these new opportunities will be based on a chemical approach to synthesis of useful products rather than what has historically been a materials or mechanical approach. To turn this expectation into reality requires sustained support of R & D and a determination to exploit this new science and technology into viable commercial applications.

Oct 1, 2003

By Kjell Winther

"Hydralift Scanmec introduced early in the eighties a new and different mill design for very large grinding mills. The design described has actually no size limitation upwards and is so far suggested with motor power up to 40 MW. The mill is furnished with gearless ring motor drive transmission. It is totally fabricated, without heavy castings. The first installation, an 8, 1 MW ball mill dia. 6,5 m x 9,65 m length, has been in continous operation in 13 years without problems. Total grinding costs has been reduced with 3 0% compared to traditional smaller mills. Reductions has been achieved in maintenance cost, power consumption, liner wear and grinding media consumption.So far 3 ball mills of the described design are delivered and in operation, one grinding Iron ore and two grinding Nickel ore.IntroductionThe design of mills for mineral ore dressing has basically been unchanged since grinding in mills started some I 00 years ago, in spite of the fact that mills have grown larger and larger. This has resulted in structural and mechanical problems, causing expensive failures and loss of production.Hydralift Scanmec engineers were designing mills for more than 20 years according to the old «rules». As they experienced interest for an increase in the mill size at the time when reports about failing mills were published, they started analyzing the different mill parts to find new solutions. One goal was to only use elements from proven technology in the new design. Two key items were ring motor (wrap around motor)(Isch et al. 1977, Meintrup and Klein 1982, Ranze 1983) and large diameter pad bearings (wrap around bearings)(Fuller 1984), both acknowledged from other industries."

Jan 1, 1995

By R. Kwiatkowski

Agenda ? Health Canada Protocol _ Screening Level Risk Assessments (SLRAs) Contaminants Foods Exposure Pathways COPCs _ Site Specific Risk Assessments (SSRAs) In-depth, quantitative Monitoring Exposure estimates Food Issues in Environmental Impact Assessments ?Country Foods? ? Foods gathered from the project area and consumed by local residents.

Apr 1, 2005

By D. M. Maijer, S. L. Cockcroft, A. B. Phillion, P. Fan, C. Reilly

"A numerical model has been developed to study macrosegregation associated with liquid feeding in the Low Pressure Die Casting of A356 aluminum alloy wheels. The model of the wheel casting process has been implemented within the commercial CFD software package, FLUENT, using a User Defined Function (subroutine) to account for Si rejection based on the Scheil approximation. The model has been validated against temperature and microstructural data taken from a commercially cast wheel. The amount of segregation in the wheel has been shown to be significant in a couple of key areas. The implications of accounting for segregation include an improved ability to predict shrinkage porosity, fatigue performance and potentially also hydrogen porosity.INTRODUCTION The aluminum alloy A356 is widely used in the automotive and aerospace industries for various components. Examples include automotive wheels, automotive suspension components and airframe castings. Focusing on automotive wheels, Low-Pressure Die Cast (LPDC) A356 wheels offer significant design freedom and are far more aesthetically appealing to consumers than conventional stamped steel wheels. A356 wheels now dominate the market, appearing in all but the entry level offerings of the OEM manufacturers. However, they are typically over-designed to allow for the various casting related defects that degrade their mechanical performance. Thus, their potential to save weight has not been fully realized. Wheel manufacturers are under constant pressure to ensure their products meet strict mechanical requirements (ductility, fatigue, vibration), tight geometric tolerances and high aesthetic quality. The mechanical properties of the final product are determined by the microstructure – e.g. SDAS – and the defect population (porosity and oxides). Depending on their size and location, both porosity and oxides, can act as crack initiation sites reducing fatigue life (Caton, 2001; Jordan, 2010; Wu, 2015). There are a number of examples appearing in the literature (Atwood, 2000; Carlson, 2007; Lee, 2001; Yao, 2011) of numerical models that have focused on hydrogen-based pore formation that have demonstrated an ability to predict porosity formation and pore size distributions in geometrically simple castings. These models assume that the local gas species diffusion through the liquid metal to the pores is the rate-controlling factor of pore growth. Another common source of porosity is liquid encapsulation (Dantzig, 2009). As the pressure within the isolated liquid drops, pores form first due to the pressure dropping below the equilibrium partial pressure of hydrogen in solution and then second grow substantially as the pressure continues to drop falling below the vapour pressure of Al. One factor that can affect both mechanisms of pore formation is species macrosegregation, which has received comparatively little attention in die-casting."

Jan 1, 2017