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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 Joseph L. Jernegan

The Whale Lode occurs in the main range of the Rocky Mountains, Park County, Colorado Territory, at Hall Valley. It has been opened up and worked to some extent by the Whale Mine, situated some 11,300 feet above the level of the sea. The mine, with 700 feet of the lode on either side of the discovery shaft, is the property of the Hall Valley Silver-Lead Mining and Smelting Company. The adjacent country rock is a compact, fine-grained gneiss; its general strike is about north and south, dipping steeply to the west. In the immediate vicinity of the mine, the strata are very nearly vertical. The gneiss incloses numberless veins of a reddish granite, in which the feldspar largely predominates over the quartz and mica, the latter oftentimes being scarcely perceptible. As a general rule these granitic veins seem to more frequently follow the lines of stratification of the gneiss than otherwise. They are of varying width, some large, some small; the larger are from 5 to 6 feet wide. Gash veins of feldspar and quartz are also of very frequent occurrence. The general trend of the lode is about northeast. and southwest, intersecting the country rock at about an angle of 45 to its stratification. It dips to the northwest at an angle of 65. I am unable to state accurately how far this lode has been traced upon the surface, but it is at least well known to extend entirely through the mountain upon which the mine is situated, and is traceable over the ridge by a hollow extending for some distance along the surface, in which the lode crops out. This hollow in the surface rock has probably been formed through decomposition of the vein matter by atmospherical influences. The width of the crevice is variable, generally between 5 and 10 feet; the pay vein varies from an inch, or less, to 36 inches. The vein is generally accompanied both on foot and hanging walls by a whitish, semi-decomposed fock, composed of quartz and decomposed feldspar, and in some places—where the process of decomposition has not reached as advanced a stage—a lightgreenish or black mica. This rock, therefore, is in places composed of all the constituents of gneiss, and is undoubtedly nothing more or less than the same in a decomposed condition. It is often very strongly impregnated with iron pyrites, generally crystallized in minute cubes, and it is probably owing to the presence of this min-

By S. Suphi Yavasca, A. M. Gaudin

THIS paper is intended as a contribution to our knowledge of the mechanism of comminution and of the work of crushing. In a previous paper' it was shown that with quartz comminution proceeds as follows I. The size distribution of broken fragments made by a single fracture is such that the new surface on each grade is the same. 2. Multiple fracturing results in a size distribution such that in the fine sizes the surface per grade is the same in every grade; in coarse sizes the surface per grade decreases gradually with increasing size. In that paper it was mentioned that determinations on minerals other than quartz were in course of completion in order to establish the generality of these observations. In this paper, condensed data2 are presented for galena, pyrite and glass. Galena and pyrite are crystalline material and glass is noncrystalline. Galena has excellent cubic cleavage. Pyrite, although cubical, does not have marked cleavage. Quartz, on which the original determinations were made, does not cleave and although crystalline (hexagonal) breaks conchoidally. Glass breaks much like quartz. It is apparent, therefore, that the minerals selected represent some range in character of the solid without covering all possible types. GLASS Fifteen glass marbles were crushed individually in the pendulum crusher described in the preceding paper,1 then subjected to careful screening for 30 min. Six sized fractions were selected and cleaned in a hot 0.12 N solution of hydrochloric acid, washed with distilled water and dried on a hot plate. This was followed by an examination with a binocular microscope, to remove foreign matters not eliminated in cleaning as well as to eliminate "compacts" of fine particles. These compacts are groups of fine iragments that seem to be mechanically stuck together as a result of localized compacting during the comminution operation. The presence and the abundance of these compacts may be related to the amount and direction of the forces applied in different crushing devices. Since, properly, such compacts should be entirely eliminated in the sizing analyses, it is necessary to remove them to the last before making surface determinations on sized fractions. For example, with a - 28 + 35-mesh glass the surface areas of two samples, one cleaned with acid and under the binocular, the other only washed, were 102 and 172 sq. cm. per gram, respectively. Examination of the samples under an Ultropak microscope showed that washing alone failed to remove the compacts and also that it fails to remove certain fine dusts attached to the particles. Cleaning with acid loosens the fine dusts and

Jan 1, 1945

By A. E. Back, W. Wyman, K. E. Tame, S. F. Ravitz

In 1940, when it appeared that the United States soon might be cut off from foreign sources of high-grade manganese ore, the Bureau of Mines began an extensive series of investigations on the production of ferro-grade products from low-grade domestic ores by ore-dressing, pyrometal-lurgical, and hydrometallurgical methods. Among the hydrometallurgical processes for oxide ores investigated was a sulphur dioxide process in which the manganese was recovered from solution by precipitation with lime;' this process is essentially as follows: The ground ore is suspended in water and leached with SO2 gas to extract the manganese as manganese sulphate. Calcium chloride is then added to the slurry to precipitate calcium sulphate and form manganous chloride solution, and the resultant slurry is filtered to remove the calcium sulphate together with the insoluble portion of the ore. Calcium hydroxide is added to the filtrate and the mixture is agitated with air to precipitate hydrated oxides of manganese and regenerate calcium chloride. The precipitate is calcined, and the calcium chloride is recycled. To determine manganese extraction, reagent consumption, grade of product, and similar data for this process, a labora- tory investigation was started. Two minor modifications in the process were soon made: (I) the ore was suspended in calcium chloride solution instead of in water in order to extract the manganese and precipitate the calcium sulphate in one step, and (2) the agitation with air after the addition of slaked lime to the filtrate was omitted because manganese hydroxide is readily precipitated without air agitation and can be nodulized or sintered to a satisfactory product. When the process was carried through a series of cyclic tests, it was noted that the concentration of dithionate ion (which is one of the products of oxidation of SO2 by MnO2) in the cycled solution gradually increased; at the same time the chloride content of the solution gradually decreased, owing to soluble losses in the leach residue and in the precipitate. After a number of cycles, the calcium chloride became virtually completely replaced by calcium dithionate, the quantity of dithionate ion formed during the leach being more than enough to make up for the losses of dithionate in filtering. The calcium chloride process thus developed into a calcium dithionate process. Since the latter eliminated the need for make-up calcium chloride, and the dithionate solutions appeared much less corrosive than the chloride solutions, work on the calcium chloride process was dropped in favor of the calcium dithionate process. Acknowledgments The dithionate process was developed by the Bureau of Mines as part of a

Jan 1, 1949

By George M. Rigg, Samuel M. Cassidy

During 1937 a program was begun to mechanize and modernize the then 28-year old Isabella mine of the Weirton Coal Co., which is on the Monongahela River, in Fayette County, Pennsylvania, at one edge of what is generally known as the Coke Region. Weirton Coal Co. is a subsidiary of the National Steel Corporation, and produces metallurgical grade coking coal for the Weirton Steel Co., Weirton, W. Va. Improvements subsequently made included a cleaning plant for washing the entire mine output, shovel-action track-mounted machines for mechanically loading all the coal, universal-type track-mounted cutting and shearing machines, post drills, 8-wheel mine cars of 10 tons capacity, cable-reel gathering locomotives and other auxiliary equipment. This paper presents the factors, reasons and results of decided changes from the mining system generally prevailing in the region, as well as abandonment of selective mining practices in favor of complete seam extraction. Coal-seam Conditions Fig. 1 illustrates the Pittsburgh coal seam on the property. Cover over the seam averages 450 ft., and 675 ft. is the maxi- mum. Main roof varies from very weak to medium strong; usually it disintegrates rapidly on exposure to air. The "wild" coal makes a fairly strong immediate roof if supported by crossbars and if unbroken affords a seal to the main roof. The draw slate is very weak and treacherous. The floor is characterized by numerous irregular bottom rolls, or "horsebacks," protruding from a few inches up to 3 ft. into the coal. Some are soft, but many are hard and flintlike. Although the bottom slate usually is hard, the underlying fire clay causes it to buckle and heave readily with any moderate increase in roof pressure or where damp. As a whole, the bottom is weaker than the main roof. The coal is characterized by numerous closely jointed face and butt cleats and a woody, springy nature when shot, both having a decided influence on face practices. As shown in Fig. I, at both the top and bottom of the main coal seam is a layer of coal of higher ash and sulphur content than the body of coal in the middle. Factors That Influence the Mining System Equipment was bought and organization for mechanical loading was made on the basis of working each mechanical unit as near its full capacity as possible, to lessen investment cost and obtain best operating efficiency. This led to combination double and triple-shift operation at the start, and, very shortly, to all sections being triple shifted.

Jan 1, 1947

By J. E. Hilliard

A procedure is described for determining, from measurements on a section, the moments of any degree n (i.e., the mean value of Dn, where D is a linear dimension) of the size distribution of particles (or grains) in an opaque sarnple. The analysis is applicable to particles of alnzost any shape and to any mixture of shapes. However, if absolute values of the wloments are required, it is necessary to know what shapes are present and the relative frequency of their occurrence. In addition, certain shape-dependent parameters have to be evaluated before the formulas can be used. The measurement required is the distribution of intercept lengths. This can be determined either visually or with an automatic scanning instrument. Corrections me derived for the bias due to instrumental end effects. The proposed analysis has the following advantages over existing ones: 1) Confidence limits are easily estimated for the measured properties or, conversely, the number of counts required to achieve a given accuracy can be determined. 2) The analysis is not restricted to particles of a special shape. 3) The error resulting from any known degree of departure of the actual from the assumed particle shape can be estimated. 4) The computations are simple and, apart from a change in constants, are independent of particle shape. 5) The number of particles per unit volume can be determined by a simple counting procedure. MANY procedures have been described for determining the size distribution of particles from measurements on a section (or plane of polish). They differ from one another in the property measured on the section (radius, intercept length, profile area) and in the method used for the numerical solution of the integral equation relating the property to the particle size distribution. However, all existing analyses share at least two of the following disadvantages. 1) They are limited to a particular shape of particle (usually spherical). 2) It is very difficult to determine how the statistical sampling error is propagated into the computed size distribution. The investigator thus has no means of knowing the reliability of his result and, what is of equal concern, he is unable to estimate how many measurements are required to obtain a result of the required accuracy. 3) It is also difficult to assess the error resulting from any deviation between the actual and assumed particle shape. The foregoing limitations stem from the complex relationship between the particle size distribution and the distribution of the property measured on the section. As will be shown, they can be avoided by defining the size distribution in terms of discrete parameters

Jan 1, 1969

By John R. Lewis

DURING the past few years there has been considerable interest in the sizing and the preparation of the iron ore fed into blast furnaces. Furnacemen know that proper sizing of ore tends to increase the efficiency of the furnace. It has been shown by Joseph1 and his associates that there is a direct relationship between the porosity of an ore particle and the time required for its reduction in the blast furnace. This relationship may be stated as follows: All other factors remaining constant, the time for reduction of a given sample of ore is inversely proportional to its porosity. As a consequence, large pieces of very porous ore, say 3 or 4 in. in cross section, will be completely reduced by the time they reach the hot zone just above the tuyeres, while large pieces of dense, nonporous ore may reach the hot zone with their centers unreduced. This means that for the latter complete reduction will be accomplished by the so-called "direct method;" i.e., where carbon reacts directly with the ore. Some recent work by Philbrook2 seems to contradict this rule. He found that of two unlike ores he studied, the one with the lower porosity reduced more readily. He explained his results as "possibly due to an apparently greater tendency of the `A' ore (lower porosity) to crack during preliminary dehydration and during reduction." This brings his results in line with the rule stated above. It is not the author's intention to enter into a discussion of the merits of "direct" versus "indirect" reduction. It is enough to say that, in general, indirect reduction is desirable. For the greatest efficiency, Gruner's theorem3 requires that all reduction in the blast furnace be indirect. Joseph seems to believe this also, because in his recent article on Some Comparisons between Iron Ore, Sinter and Nodules as Blast Furnace Feed' he concludes that: "In general, the carbon in blast-furnace coke is used most efficiently when the largest amount of the carbon charged reaches the tuyeres." However, P. V. Martin,' in an excellent paper, has shown that some direct reduction may actually increase the efficiency of the furnace; that is, increase its rate of production while maintaining maximum fuel economy. For nonporous ores there is more opportunity to have an excess of direct reduction unless the factors that make for indirect reduction are favored; for instance; the proper sizing of the ore particles. Another factor that has an important bearing on the reduction rate, as it is affected by particle size, is the flow of heat into the particle. The ore particle

Jan 1, 1947

By Samuel M. Cassidy, George M. Rigg

During 1937 a program was begun to mechanize and modernize the then 28-year old Isabella mine of the Weirton Coal Co., which is on the Monongahela River, in Fayette County, Pennsylvania, at one edge of what is generally known as the Coke Region. Weirton Coal Co. is a subsidiary of the National Steel Corporation, and produces metallurgical grade coking coal for the Weirton Steel Co., Weirton, W. Va. Improvements subsequently made included a cleaning plant for washing the entire mine output, shovel-action track-mounted machines for mechanically loading all the coal, universal-type track-mounted cutting and shearing machines, post drills, 8-wheel mine cars of 10 tons capacity, cable-reel gathering locomotives and other auxiliary equipment. This paper presents the factors, reasons and results of decided changes from the mining system generally prevailing in the region, as well as abandonment of selective mining practices in favor of complete seam extraction. Coal-seam Conditions Fig. 1 illustrates the Pittsburgh coal seam on the property. Cover over the seam averages 450 ft., and 675 ft. is the maxi- mum. Main roof varies from very weak to medium strong; usually it disintegrates rapidly on exposure to air. The "wild" coal makes a fairly strong immediate roof if supported by crossbars and if unbroken affords a seal to the main roof. The draw slate is very weak and treacherous. The floor is characterized by numerous irregular bottom rolls, or "horsebacks," protruding from a few inches up to 3 ft. into the coal. Some are soft, but many are hard and flintlike. Although the bottom slate usually is hard, the underlying fire clay causes it to buckle and heave readily with any moderate increase in roof pressure or where damp. As a whole, the bottom is weaker than the main roof. The coal is characterized by numerous closely jointed face and butt cleats and a woody, springy nature when shot, both having a decided influence on face practices. As shown in Fig. I, at both the top and bottom of the main coal seam is a layer of coal of higher ash and sulphur content than the body of coal in the middle. Factors That Influence the Mining System Equipment was bought and organization for mechanical loading was made on the basis of working each mechanical unit as near its full capacity as possible, to lessen investment cost and obtain best operating efficiency. This led to combination double and triple-shift operation at the start, and, very shortly, to all sections being triple shifted.

Jan 1, 1947

By W. P. Blake

FORGING under the hydraulic press, which was introduced by Haswell in the year 1861, at the machine shops of the Imperial State Railway Company of Austria, has since been greatly improved, so that at the present time there are very few parts of machines which cannot be produced in this way, and at no greater cost than iron castings. The process is now used at Vienna chiefly for such parts of locomotives as cross-heads, link-bars, axle-box frames, etc., especially where the form is intricate, and there are many angles and projections. These objects weigh from 50 to 150 lb. or more, and it is claimed for them that they are not only much cheaper than ordinary forgings, but are much more regular in form and stronger. The results which Mr. Haswell has attained, after years of patient experimenting, were well shown in the Austrian Department of the Vienna Exhibition by a collection of the pressed objects in iron and steel, just as they left the moulds, with some of them cut asunder longitudinally and the surfaces etched, so as to show the internal structure or direction of the grain. Through the courtesy of Mr. Haswell and his son I saw the hydraulic presses in full operation at the works, drawing down large Bessemer ingots, cutting them up into blocks of convenient size, and forming various parts of locomotives. They have two large hydraulic presses in use; the largest, with a piston 24 inches diameter, gives 1200 tons pressure, and the second, with an 18-inch piston, gives 600 tons pressure. The pressure in the pumps is 600 atmospheres. The action is vertical ; the piston descends upon the work, and for forging ingots is armed with a hammer-like head. An ingot of No. 7 soft Bessemer steel, which was forged in my presence, weighed 2030 lbs. One end being placed upon the anvil, the piston is brought slowly down and crowded into the mass as if it were putty or dough, forcing it each way, but chiefly in the direction of the length of the ingot, this being the narrowest section of the anvil and hammer. The piston is then raised and the ingot is moved forward for a second squeeze, and so on, until the first half of the ingot has been reduced in thickness, when it is turned on edge and the operation is repeated. The ingot is then turned end for end and forged until the whole length has been re-

Jan 1, 1874

By W. McA. Johnson

The object of this paper is to describe the several necessary characteristics of the zinc-retorting charge and to show how by certain improved methods, the large excess of coal, over that theoretically required, can be reduced, thereby effecting an increase in the smelting capacity of a retort plant as well as other economies. In the southwestern zinc works a charge of roasted zinc ore with a side mixture of carbonates and silicates, analyzing on the average 50 per cent. Zn, is mixed with 55 or more per cent. of its weight of a mixture of coal and coke analyzing 60 to 70 per cent. fixed carbon. The ore is of varying fineness and the coal and coke are usually crushed in a semi-moist condition through a 3/8-in. screen. With ores of a slaggy nature, this coal proportion is increased, sometimes to as much as 100 per cent. of the weight of the ore. With carbonate ores, or where anthracite screenings with higher carbon content are cheap enough, the percentage of reducing agent is cut to 45 per cent. or even somewhat lower. The average charge per retort for a monthly run of a plant on ore, as distinguished from retorts on blue-powder, ladle-skimmings and other between-products, runs from 60 to 66 lb., with a mean of 63 lb. for the Southwest with standard retorts of 8 1/2-in. inside diameter and 50 in. long inside, using roasted sulphide ores. Conditions will change these figures, but 40 lb. of ore per cubic foot of retort space is, I believe,'an average in the better-operated plants. Since the rise in the price of spelter, the tendency has been to overcharge. To remove the slag that is formed when retorts are overcharged, extra men are put on to "gum-chisel" the retorts to prevent "set" furnaces and "butchered retorts." Taking the above conditions as premises, we find that from four to six times the amount of coal necessary for the reduction is used, as is evidenced by the fact that the residues analype as high as 35 per cent, fixed carbon. There are good reasons why this excess of fixed carbon must be used and perhaps these can be best explained by a description of the metallurgical requisites of a zinc charge. We may enumerate these as follows: 1. High reducing power, especially at the end of the shift, to reduce any carbon dioxide to monoxide and bring about a good condensation

Jan 1, 1918

By Edward Saibel

THE object of this study is to investigate the effect of prior tensile strain on the fracture stress of a metal. This is done in a theoretical manner starting from the point of view developed by the author in his thermodynamic theory of the fracture of metals. The results are compared with experimental findings and a rational interpretation is given to work that shows the variation of fracture stress with prior tensile strain. THEORY OF FRACTURE In the thermodynamic theory of the fracture of metals developed earlier,1 it was shown that a critical strain energy per unit volume exists. This is characteristic of the material and may be calculated from basic thermodynamic data. When the area under the flow curve reaches this characteristic value, fracture occurs. The general criterion for fracture is expressed in the form u ± uo = JLm?AV/V [1] where Lm, is the latent heat of melting of the unit volume, ?V/V is the ratio of the change in volume of the unit volume to the original unit volume on passing from the solid to the liquid state, [uo] is an initial energy density, and J is a conversion factor, which changes energy from heat to mechanical units. As a first approximation, it will be assumed that the stress-strain curve is the straight line that extends from the point of maximum load onward, extrapolated back to the axis of zero strain, for example, line AC of Fig. 1. If the point of intersection of the straight line with the axis of zero strain is represented by so, and the slope of the straight line is p, the analytic form of the flow curve is [s = s + pd [2]] and the strain energy per unit volume evaluated from [JvdS] becomes (vsod + pd2/ 2). When this latter term reaches the critical value JLm?V/V (designated hereafter by M), it is assumed that fracture occurs. This leads to the following expression for the fracture stress: [s1 = \/C r.2 + 2Mp [31] The strain at fracture may be calculated from Eqs 2 and 3. It is assumed in this paper that the initial energy density is either zero or that it may be neglected. Furthermore, the complicated states of stress and of strain existing in the necked region of the tensile specimen after "necking" has occurred will also be neglected for the present, so that average conditions will be assumed to prevail. FLOW AND FRACTURE CURVES Ludwig2 attributed to materials two fundamental properties: (I) a resistance to flow and (2) a resistance to fracture. He reasoned that at each instant the

Jan 1, 1947

By William J. McCaughey, Richard L. Barrett

For sixty years—in fact, ever since the inception of the basic steelmaking process —basic slags have been the subject of study by chemists, metallurgists and petrog-raphers! with the purpose of providing a better understanding of the reactions between the slag and the metal during the refining process. The result of this work and of the researches of mineralogists and physical chemists into the chemistry of oxide systems is a considerable body of literature dealing not only with slags themselves but with equilibrium relationships in systems synthesized from pure components. Since any actual slag is a multicom-ponent system more complex than any yet worked out in the laboratory, a complete solution to the problem is still far away. The writers have recently published a paper1 which they believe sheds light on the role of the slag in the elimination of phosphorus and it is the purpose of the present paper to discuss the metallurgical applications of that work. Since the pioneer investigations on the constitution of basic slags carried on by Stead and Risdale, Carnot and Richards, Hilgenstock and others in the I88o's, a considerable body of literature on this subject has appeared. Many of the more important of these papers were summarized in the previous paper,l therefore they will not be reviewed here. PetRographic Study The present writers have had occasion, over a period of years, to examine petro-graphically a great number of basic steel-making slags having a very wide range of chemical compositions and made under various conditions of operating practice. Although certain of these slags exhibit some unusual features, it is a remarkable fact that the great majority of mature slags show certain typical characteristics, which persist throughout the wide range of chemical compositions. The typical mature slag usually appears under the microscope to consist of two phases. The phase of primary crystallization is light colored and doubly refracting. If separated mechanically and subjected to chemical analysis, it is found to consist essentially of SiO2, CaO, and P2O6. Sometimes, although not usually, two such silicate-phosphate phases are found. The other conspicuous phase is dark in color and optically isotropic, and occurs as the interstitial material between the grains of the light colored phase. This dark colored interstitial phase when analyzed is found to consist essentially of FeO, Fe2O3, MnO, and MgO. In some 'lags high in iron oxide, particularly those from low-carbon heats, dicalcium ferrite is found. This phase is dark reddish brown in color and anisotropic.

Jan 1, 1944

By Helmut Thielsch

During the last three decades a great many arguments have been presented on the subject of "mosaicJ' or "blockJJ structures of metals. Apparently because of insufficient evidence, the "block-structure" theories have never been widely understood among the physical metallurgists in this country, and most investigators among the few that have tried to demonstrate the existence of such an inner strutture Of crystals or grains have failed to recognize also the existence of a lamellar structure. Moreover, little thought has been given to justify the existence of such "lamellar" or "mosaic-block" structures on a theoretical basis. Since properties such as Plasticity; ferro-magnetism, hardness, diffusion, and others may be explained by structural faults in the lattice network of the crystals: the great importance of a more detailed knowledge of the structure within crystals or grains becomes now evident. Because Of the vast extent of the field Of submicroscopic structures, it shall be the purpose Of this paper only to review the more important of the results obtained by other investigators, especially in Germany, where a great deal of attention has been given to mosaic structure during the last three years. The origin of this mosaic patternt and effects of cold reduction and recrystallization will be shown in further studies later on. Imperfections in Crystals The many terms used in the literature to denote structural types of crystals are often not clearly defined. To clear up some of the confusion, the meaning of the more important terms will be given here. ideal, or perfect without any structural imperfections are called "ideal crystals,,or ''Perfect'' crystals,n meaning a Homogeneous interior structure of atoms, ions or molecules, as the case may be. In other words, at every point in the interior of the crystal exactly the same orientation of the crystallographic axes of the coordinate system would exist. The Surface of such a body, if etched with an appropriate etching reagent, would reflect light with perfect uniformity. Crystals of this type are almost nonexistent. Real Crystals.—L'Real crystals"' may contain various types of structural defects, which can be classified into: (I) lineage structure, (2) mosaic-block structure, (3) lamellar structure. The inhomogeneities many,in these groups mean that the orientation of the crystallographic aies will not be the same at every point within the interior of a crystal (or grain of a poly crystalline body). 'Perjecl Real Crystals.—The term "perfect real crystals " is generally used to describe crystals with minute structural or thermo-dynamical inhomogeneities. The former

Jan 1, 1946

By Jim Douglas, H. H. Rachford, D. W. Peaceman

The problem of unsteady-state gas flow through porous media has been solved numerically only for the case of linear or radially symmetric reservoirs. A recently introduced numerical method for solving the unsteady-state heat flow equation in two dimensions is applied to the calculation of the depletion of a square region containing a perfect gas. Solutions are presented in graphical form for various values of dimensionless parameters. The solutions are compared with published .solutions for radial reservoirs. I NTR ODUCTION The problem of unsteady-state flow of gas through porous media gives rise to a second-order non-linear partial differential equation for which no analytical solution has been found. Numerical approximations to solutions of the gas flow problem have been obtained by the stepwise solution of an associated difference equation1,2. However, the methods so far developed have required that the reservoir be either linear or radially symmetric. This restriction in shape has been necessary so that only two independent variables be considered, namely, one distance variable and time. In order to deal with reservoirs having more realistic shapes, it is necessary to develop numerical procedures for the solution of the gas flow problem involving two distance variables. A numerical procedure, denoted as the alternating-direction implicit method, for the solution of the heat-flow problem in two dimensions has recently been introduced" By the use of this procedure, approximate solutions have been obtained for heat-flow problems in a square8, and in regions having various non-rectangular boundariesa. Because of the similarity between the equation for heat conduction in solids and the equation for gas flow in porous media, it is reasonable to expect that the alternating-direction implicit method should also be useful for solving the gas flow problem in various two-dimensional regions. Solutions have been calculated for the simplest two-dimensional region, a square reservoir with a single well in the center. While reservoirs of such simple geometry seldom, if ever, exist, the solution of this problem is of some practical importance because it is also the solution of another problem, that of determining the depletion history about an individual well in an infinite uniform reservoir containing wells spaced throughout on a square lattice and producing equally from each well. Finally, it is of interest to compare solutions for a square reservoir with those for a circular reservoir and to determine the effect of the shape of the boundary for that particular case. METHOD OF CALCULATION Basic Differential Equation By combining the equation of continuity, the perfect gas law,

Jan 1, 1956

By Franz R. Dykstra

DEFINITIONS The ores of iron are classified in three general categories: direct shipping, concentrates, and agglomerated-i.e., pelletized or sintered. Direct Shipping As the name implies, direct-shipping ores are shipped as mined or, perhaps, after screening. Generally, direct-shipping ores are hematitic (R203), magnetitic (R304), or limonitic (2Fe2O3.3H20) in nature. Grades of direct-shipping ores vary widely. Prices are frequently related to the historical Mesabi standard of 51.5% iron, although certain premium lump ores may contain up to 68% iron. The use of direct-shipping ores is diminishing as the advantages of beneficiated ores become evident and reserves are depleted. Concentrates Where the nature of the deposit and economics allows, certain ores are upgraded. This may include no more than washing and screening, or may be as elaborate as fine grinding followed by magnetic, gravity, or even flotation procedures for separation. Coarser concentrates may be smelted "as is.'; Fine concentrates usually are sold as sinter feed. (Sinter, as used here and in the following, refers to a process by which a fine ore-carbon mixture is agglomerated at elevated temperatures on a direct-fired moving grate to eliminate fines and improve chemical and physical homogeneity.) Agglomerates-Pellets or Sinter The development of economic techniques of mining and concentrating taconite (fine-grained, ferruginous jasperoids) led to the introduction of the iron-ore pellet, which is now becoming the major form in which iron is introduced into the furnace. The tremendous reserves of magnetic taconites of the northern United States and Canadian Precambrian shield had been recognized for many years. A century of mining has seen the reserves of the direct-shipping or "red ores" of the Minnesota, Michigan, and Wisconsin ranges approach depletion. Research started in the 1930s has seen the evolution of motives and techniques to concentrate these stubborn refractory ores. The efficacy of concentrate pellets in iron-making has been such as to induce mines throughout the world to grind, concentrate, and pelletize otherwise shipping-grade ores. Table 14.1A.1 shows typical analyses of iron ore. Marketing-Prices of iron may be quoted on a value per long-ton (2240 lbs) or metric-ton (1000 kg or 2204 lb) basis, or on a value per long-ton-unit or metric-ton-unit basis. One iron unit represents 1 % of contained iron per ton. (Thus, a price of $0.45 per iron unit for ore containing

Jan 1, 1976

By William J. McCaughey, Richard L. Barrett

For sixty years—in fact, ever since the inception of the basic steelmaking process —basic slags have been the subject of study by chemists, metallurgists and petrog-raphers! with the purpose of providing a better understanding of the reactions between the slag and the metal during the refining process. The result of this work and of the researches of mineralogists and physical chemists into the chemistry of oxide systems is a considerable body of literature dealing not only with slags themselves but with equilibrium relationships in systems synthesized from pure components. Since any actual slag is a multicom-ponent system more complex than any yet worked out in the laboratory, a complete solution to the problem is still far away. The writers have recently published a paper1 which they believe sheds light on the role of the slag in the elimination of phosphorus and it is the purpose of the present paper to discuss the metallurgical applications of that work. Since the pioneer investigations on the constitution of basic slags carried on by Stead and Risdale, Carnot and Richards, Hilgenstock and others in the I88o's, a considerable body of literature on this subject has appeared. Many of the more important of these papers were summarized in the previous paper,l therefore they will not be reviewed here. PetRographic Study The present writers have had occasion, over a period of years, to examine petro-graphically a great number of basic steel-making slags having a very wide range of chemical compositions and made under various conditions of operating practice. Although certain of these slags exhibit some unusual features, it is a remarkable fact that the great majority of mature slags show certain typical characteristics, which persist throughout the wide range of chemical compositions. The typical mature slag usually appears under the microscope to consist of two phases. The phase of primary crystallization is light colored and doubly refracting. If separated mechanically and subjected to chemical analysis, it is found to consist essentially of SiO2, CaO, and P2O6. Sometimes, although not usually, two such silicate-phosphate phases are found. The other conspicuous phase is dark in color and optically isotropic, and occurs as the interstitial material between the grains of the light colored phase. This dark colored interstitial phase when analyzed is found to consist essentially of FeO, Fe2O3, MnO, and MgO. In some 'lags high in iron oxide, particularly those from low-carbon heats, dicalcium ferrite is found. This phase is dark reddish brown in color and anisotropic.

Jan 1, 1944

By Gerald Edmunds

In a paper1 before this Institute in 1940, the writer reported that the surface orientation texture of zinc and cadmium differed from the texture existing within the casting, in that basal planes were parallel to the surface. He was unable to rationalize the , origin of this surface texture. It is conceivable that the surface orientation texture is influenced by the atomic force fields, which are different at the surface and within the body of metal. It was considered that a radical changc in the surface against which the metal is cast might alter the surface texture. In trial of this, zinc has been cast against a surface of molten lead, but the same result has been obtained—i.e., (001) parallel, ± 2oo, to the surface—as was obtained when it was cast against air, Transite or iron.' Into the bottom of an open cast-iron tray, 7 by 14 in. by 2 in. deep, preheated to about 275°C., about 1/4 in. of lead, then 1/2 in. of zinc was poured, and the whole was covered with an electric heater to enforce freezing from the bottom upward. After a lapse of time sufficient for the zinc but not the lead to solidify, the zinc slab was raised free of the molten lead. The bottom surface of the zinc casting was coated with a thin layer of lead. A specimen of the slab 136 in. square was metallographically polished to flatten it and remove the slight film of lead, and the orientation was determined by the method used before,' with the result stated above. Some determinations have also been made on other metals, as follows: Surface orientation determinations were made on the 3/8-in. diameter grip section of two 1/4-in. diameter aluminum-alloy die-cast tensile bars and on a 1/8 by 1/2-in. flat aluminum-alloy die-cast tensile bar. None of these three aluminum die castings exhibited any preferred orientation at the surface. A brass die casting (nominal composition: 60 Cu, 37.75 Zn, 1.00 Sn, 1.00 Pb, 0.10 Al, 0.15 Si) furnished by C. S. Smith was also examined. The surface showed a random orientation of alpha and beta. Summary A zinc casting solidified against a molten lead surface was found to have the same surface orientation texture, (001) parallel to the surface, as other zinc and cadmium castings. Aluminum and alpha-beta brass die castings were found to have random grain orientation textures at the surface. Acknowledgment The X-ray determinations were conducted by M. L. Fuller.

Jan 1, 1945

By W. F. Dietrich

Mineral fillers are relatively inert chemically under the conditions of use but have physical properties* that modify those of the materials • The properties. uses, and other data on 15 classes of important *The pro listed in the second edition of Industrial Minerals and Rocks.l A third edition of this reference is in preparation. in which they are incorporated. The mineral fillers considered in this article are asbestos, barite, clays, diatomite, crushed limestone, limestone whiting and lime, mica, silica, talc and soapstone, and pyrophyllite. Slate and stone, other than limestone and its derivatives, are excluded because, even though used in large quantities, they are exceptionally low-cost materials generally produced close to the area where they are used. Carbon black is excluded because it is manufactured from natural gas and more than 90 pct of the output is used in rubber; hence the factors for estimating requirements are easily evaluated. OVERALL GROWTH FACTORS Table I gives the population, retail sales, and value added by manufactures in the U. S. and in the eleven western states in 1954. These data are rough guides to the proportionate part of total U. S. markets for products containing mineral fillers that may be expected in a given area. For example, the population of the eight Mountain states in 1954 was 3.6 pct, and retail sales in these states were 3.8 pct of the U. S. total, but the value added by manufactures was only 1.3 pct of the U. S. total. On the other hand, the three Pacific Coast states, with 10.3 pct of the total population, had 12.0 pct of the retail sales and produced 9.6 pct of the value added by manufactures. On an industry-by-industry basis the correlation between the three guideposts will not be as close as shown in the 1954 data for the Pacific Coast states, but in the long-term view the continuing rapid population growth in the western states is certain to result in expanded industrial production at an even more accelerated pace, which will shorten the gap between local consumption and production in most major groups of manufactured consumer goods. Of course, there will always remain favorable areas for production of specific products. Such special situations must be individually analyzed. Fig. 1 compares the population trends in the U. S., the western states, and California with Real Gross National Product from 1910 to 1957, with forecasts to 1970. It is estimated' that the U. S. Real Gross National Product, as measured by the value of goods and

Jan 1, 1960

By Helmut Thielsch

During the last three decades a great many arguments have been presented on the subject of "mosaicJ' or "blockJJ structures of metals. Apparently because of insufficient evidence, the "block-structure" theories have never been widely understood among the physical metallurgists in this country, and most investigators among the few that have tried to demonstrate the existence of such an inner strutture Of crystals or grains have failed to recognize also the existence of a lamellar structure. Moreover, little thought has been given to justify the existence of such "lamellar" or "mosaic-block" structures on a theoretical basis. Since properties such as Plasticity; ferro-magnetism, hardness, diffusion, and others may be explained by structural faults in the lattice network of the crystals: the great importance of a more detailed knowledge of the structure within crystals or grains becomes now evident. Because Of the vast extent of the field Of submicroscopic structures, it shall be the purpose Of this paper only to review the more important of the results obtained by other investigators, especially in Germany, where a great deal of attention has been given to mosaic structure during the last three years. The origin of this mosaic patternt and effects of cold reduction and recrystallization will be shown in further studies later on. Imperfections in Crystals The many terms used in the literature to denote structural types of crystals are often not clearly defined. To clear up some of the confusion, the meaning of the more important terms will be given here. ideal, or perfect without any structural imperfections are called "ideal crystals,,or ''Perfect'' crystals,n meaning a Homogeneous interior structure of atoms, ions or molecules, as the case may be. In other words, at every point in the interior of the crystal exactly the same orientation of the crystallographic axes of the coordinate system would exist. The Surface of such a body, if etched with an appropriate etching reagent, would reflect light with perfect uniformity. Crystals of this type are almost nonexistent. Real Crystals.—L'Real crystals"' may contain various types of structural defects, which can be classified into: (I) lineage structure, (2) mosaic-block structure, (3) lamellar structure. The inhomogeneities many,in these groups mean that the orientation of the crystallographic aies will not be the same at every point within the interior of a crystal (or grain of a poly crystalline body). 'Perjecl Real Crystals.—The term "perfect real crystals " is generally used to describe crystals with minute structural or thermo-dynamical inhomogeneities. The former

Jan 1, 1946

By J. W. Craig, H. L. Walker

Industry has for many years recognized the dependence of certain mechanical and physical properties. as well as workability, upon grain size variations in brass. Although the dependence of properties upon grain size has been recognized there are not many instances where a planned program of testing has been conducted and where the only intentional variable has been grain size. In particular the literature is limited with respect to the effect of grain size on the endurance limit, though there are many industrial applications where the brasses are subjected to cycles of repetitive stresses. Literature A number of the physical and mechanical properties of a given brass sheet, in the annealed condition, will depend upon: (I) The ready-to-finish grain size before final rolling, (2) the percentage deformation by cold working, and (3) the time and temperature of annealing. The first and second variables affect the recrystallized grain size, and the third variable affects the coalesced grain size. Gibbsl has shown the effect of two different ready-to-finish grain sizes upon the tensile strength and hardness of deep drawing brass strip after a definite amount of cold rolling. The smaller the ready-to-finish grain size, the higher the tensile strength and hardness, but with lowered ductility, Gibbs also demonstrated, for a given time and temperature of anneal, that the tensile strength, hardness, and elastic limit are higher for the smaller ready-to-finish grain size, but the elongation is lowered. Townsend and Greena112 have reported data which show that cold working increases the tensile strength, hardness, and load carrying ability of deep drawing brass sheet under reversed stress. Greenall and Gohn3 have reported data which show that the smaller grain sizes have higher tensile strength and hardness properties, and the data also show that increased cold working increases the tensile strength and hardness properties of deep drawing brass sheet. Kommers4 has reported data for tests of brass of known ready-to-finish grain size, a specific amount of cold reduction, and annealed at different temperatures above and below the recrystallization temperature. Kommers' results indicate that annealing below the recrystallization temperature does not change the tensile strength and hardness properties, but the endurance limit may be increased from 22,000 to 28,000 psi. The increased endurance limit is explained as resulting from the reduction of internal stresses by a stress-relief anneal. Burghoff5 and associates have reported data on creep tests, over

Jan 1, 1949