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By S. Rash Ahmadi

Welding is highly reliable and efficient metal joining process. In welding the metal adjacent to the weld joint is subjected to severe thermal conditions. As a result, complex changes in metallurgical structure occur in this region. These changes in structure depend on the material and the temperature history experienced. Friction stir welding (FSW) is relatively a new welding process in which, heat is generated by friction between the tool and the workpiece. The amount of heat conducted into the workpiece determines the quality of weld, residual stress and distortion of the workpiece. The objective of the current work is to study the transient temperature in a friction stir welding. So, a three dimensional transient analytical model is used to study the thermal distribution during the welding. Heat input from the tool shoulder alone is considered in the model. The process parameters like axial load, welding speed and tool rotational speed, used in actual FSW process are taken to build the model. This analytical model is very useful for select the optimized affected parameters in friction stir welding. The model illustrates the comprehensive equation including actual affected parameters in FSW and it can be used for different materials. In addition to the above the thermal history finds application in design of welding tools.

Oct 1, 2011

By F. Filzwieser, K. Gamweger

The process of gas purging in molten aluminium has been an industrial practice in Europe for many years. The advantages are a reduction in the hydrogen content and impurities in the melt, as well as a homogenisation of the temperature and chemical analysis in the molten metal. Formerly used lances or impellers are being replaced by porous plugs which are installed at the bottom of the furnace. This special product of RHI Refractories has proven its efficiency in primary melting as well as in die cast, sheet and extrusion plants.

Jan 1, 2004

By S. A. Sadough vanini

In this paper, Stress-Strain-Temperature relations for Shape Memory Alloys are studied. Temperature effects on Shape Memory Alloys are different from those related to ordinary materials. In ordinary materials, elastic characteristics can be assumed to be constant in low temperature ranges, and only the deflection arising from temperature changes could be added to the elastic defection. As long as two phases of austenite and martensite could be present in Shape Memory Alloys simultaneously, elastic modulus follows temperature and temperature gradient. In continue a smart actuator is investigated considering a homogeneous cantilever beam. Beam bending is established by using shape memory wires. An initial strain is imposed to shape memory wires in a low temperature, and then, they are installed in the outer surface of the beam. Therefore, since the temperature is imposed in these wires and they cannot have free recovery strain, the compressive recovery stress will be produced in the outer surface. This will result in a deflection in axial direction of the beam. At first, beam deflection is calculated on the basis of theoretical relations and solving the relevant differential equations. Afterwards, experimental tests are performed on an elastomeric beam equipped with shape memory wires. When a voltage is applied, a temperature rise will occur in the wires; then, this temperature rise causes a deflection in the beam. Finally, the theoretical and experimental results? comparison indicates a good conformity. One capability of this actuator is its high flexibility, and by controlling the inlet current, the end-beam deflection can be controlled.

Oct 1, 2011

By W. M. Silva, Bittencourt. L. R. M.

Three newly developed alumino-silicate refractory bricks for use in safety lining of aluminum electrolysis cells were compared to one commonly used bricks for the same application. It was shown that the increase in silica content and decrease in permeability led to a sensitive decrease in cryolite attack. Both parameters are of utmost importance in selecting bricks for these cells. The reasons for this observation were the formation of a more viscous liquid after the reaction between molten cryolite and the brick, and the reduction of the rate of penetration. Moreover, a novel mortar with high silica content was tested and has shown improved resistance to molten cryolite. The use of oxidizing atmosphere led to increased attack rate in the brick when compared to reducing condition. The opposite effect was observed in the mortars.

Jan 1, 2004

By F. Rojas, M. Sanchez, J. Palacios, O. Pavez

Copper sulfide is the main mining resources in Chile, and most of this metal is obtained via pyrometallurgical extraction in seven copper smelter plants, which extends from the northern Atacama desert to the central part of the country. In 2002, 1,522,000 metric tons of fine copper were produced, with a notorious environmental impact due to the large amount of slag generated, including transportation and disposing problems. Therefore, there is a great interest in finding alternative uses in order to give additional value to the slag. This is a total project development concept, which consider residues as new resources where new components could be obtained, improving sustainability in mining activities and also ensuring clean production processes. Thus, the present work shows a review of copper slag characterization as well as several ways of utilization, including compact material for road and railway installation, part of admixtures in concrete.

Jan 1, 2004

By W. P. Armstrong, O. Owens

"The process of arriving at the size and grade of· (a) a newly discovered body of mineralization, (b) a potential ore resource, (c) an orebody proposed for mining, or (d) the ore reserves in a mine, requires fundamental geological, and geometrical determinations as well as physical and chemical analyses. This paper outlines geological and geometrical features considered critical, in the authors' experience, in realistic reserve determination. These are discussed under the headings ""The Four Cs"". They include the Character, type or nature of the mineralization; the Continuity of various types of mineralization in the deposit; various key concerns in the Calculation besides the mathematics; and the Classification section which refers to basic considerations in classifying a mineral estimate. It is suggested that the responsibility for the calculation of a Resource or Reserve should be that of a geologist experienced in the ore type under review. Further, it should be the responsibility of the board of directors of the company owning the deposit to ensure that a sufficiently experienced person is chosen to carry out the process. IntroductionThe key issue of ore reserves is that they are intended as, a clear-as- possible statement of metal in place in a mineable orebody. Precise, widely understood definitions help convey understanding of the figures, but accuracy requires careful geological input before the calculation is made and a definition is applied. Many recent new mining operations in Canada have experienced serious shortcomings between original ore reserve figures and what was mined. This suggests deficiencies in the actual tonnage and grade calculated in advance of production. The authors suspect that much of the problem is due to a less-than-adequate outline of the orebody before calculating reserves for production or alternatively, treatment of grade and thickness data without regard to an orebody outline. Careful consideration of mineralization and ore continuity is one of the most important aspects of ore geology. Ore reserve calculation should be more than a mathematical exercise."

Jan 1, 1994

By M. R. Coffin

In recent years, improved operation of the Kidd smelter has resulted in an increase in blister production capacity. Due to manpower and equipment limitations anode production and treatment rates could not be increased without incurring significant additional operating expenses. The option chosen to expand casting and refinery capacity to meet the available blister supply was to increase the anode thickness while maintaining the same anode exchange cycle in the refinery. This has resulted in a cathode production increase of almost 10% for minimal expenditure. Equipment and process modifications required to cast and refine the thicker anodes are discussed in this paper, along with the Six Sigma methodologies used to identify them. Key areas covered are Hazelett continuous caster operation, refining process parameters, plating performance and cathode quality.

Jan 1, 2007

By E. R. Dixon

Copper SX/EW plants often bleed part of their electrowinning electrolyte to control impurities and maintain consistent cathode quality. Depending on the specific situation at each site, the bleed is either returned to raffinate, to an SX extraction stage, to an SX wash stage, or to the PLS pond, to avoid losing the copper in the bleed. This practice can have undesirable effects on the overall process. An alternative is to electrowin all or most of the copper in the bleed, thus avoiding the recirculation of the copper in the bleed. In this manner, the bleed is converted to metallic copper without interfering with the SX circuit. This in turn reduces the copper concentration in the raffinate, improving global copper recovery because of improved leaching conditions.

Jan 1, 2007

By R. W. McConnell, R. P. Racher

High quality steel production requires extended treatment of the steel in the steel ladle. This has a remarkable impact on the steel ladle refractories, e.g. the need for high performance functional refractories like purging plugs. Operational changes such as increasing tapping temperatures, longer hold times and more aggressive secondary metallurgy are countered by the need for thinner refractory linings and longer refractories life. These combined factors have led to a resurgence in interest in magnesium aluminate spinel raw materials. Magnesium aluminate spinels have been used in steel-making refractories for many years, in a variety of different forms. This paper reviews the production, properties and performance of spinels. Recent developments in the applications of spinels will also be discussed.

Jan 1, 2004

By S. Rash Ahmadi

One of the most important elements in power plants is rotors and repairing the damaged rotors is very important in view point of economics. One of the most complicated problems in power plants is increasing of stiffness of the turbine rotors. This problem which occurs mainly due to thermal shock or rubbing makes to exit damaged rotor from service. These elements can be repaired effectively by heat treatment methods. Tempering heat treatment is the most common solution for straightening of damaged rotors but it requires having good knowledge about heat treatment parameters (temperature and time) and their affects on fundamental properties of rotors. In this article, a suitable method is introduced in order to modify the increased stiffness in journal part of rotors due to martensite transformation, using heat treatment tempering process.

Oct 1, 2011

By H. T. Michels

Recent laboratory studies show that several bacteria, known to be human pathogens, die when they come in contact with copper and copper alloy surfaces. The amount of live bacteria drops by several orders of magnitude, to zero, on copper alloys in a few hours. In contrast, no reduction is seen in the concentration of live organisms on stainless steel during the six-hour test period. Aluminum painted and coated surfaces and plastics would show behavior similar to stainless steel and show no effect. Coatings and other surfaces claiming to be antimicrobial showed little to no effect. These results suggest the selection of copper alloys for surfaces exposed to human touch can materially assist in reducing the transmission of infectious organisms. In order to make antimicrobial claims in the United States, the approval of the US Environmental Protection Agency (EPA) is required. The EPA-required efficacy testing is described and the test results are summarized. It is anticipated, that once regulatory approval is obtained, that this will facilitate the introduction of antimicrobial copper alloys in hospitals, nursing homes and other healthcare facilities, as well as schools, and public buildings. Some of the application and barriers, to entry into the healthcare markets are mentioned.

Jan 1, 2007

By X. B. Wang, Z. Q. Guo

Slagging coal gasification process became a highlight of coal chemical industry in China during the last decade. Refractory lining's life of slagging gasifiers is one of the most critical factors for a cost-effective operation. The paper introduces current status of coal gasification in China, lining structure of slagging gasifiers and performance of refractory lining. It also summarizes the major factors impacting on refractory wear in slagging coal gasifiers in four Chinese chemical plants, based on ten years of industrial experience. The utilizability is discussed in terms of cost-effectiveness of high chromia refractories and possibility of the alternatives.

Jan 1, 2004

By MKS Vel, S. Mukhopadhyay, R. Mishra

Off late, the criteria of selecting the refractory have acquired a trend line aiming to a cleaner environment and the utmost importance is given to the eco-friendly approach. The stainless steel making furnaces normally use mag-chrome refractories for the obvious reasons of changing slag basicity from acidic to basic. Such refractories generate toxic fumes and compounds with hexavalent chrome, which is unhygienic if inhaled. The present paper describes the development of a chrome free alumina magnesia carbon refractory, it's different test properties, simulative testing and microstructures. The optimum quantity and distribution of carbon in the brick restricts the carbon pick-up by the steel. Bricks with the same composition were manufactured in the commercial scale and used in a stainless steel making furnaces in USA. The performance of same refractory in this furnace was quite encouraging and at present the same quality brick has become a normal practice in this furnace. Since no chromite is used in making this brick, so no toxic compounds are generated environment remains pollution free.

Jan 1, 2004

In recent years, China and India have emerged as major players in the copper sector. Over the last decade, around 50% of additional global refined copper usage growth can be attributed to them. The paper provides an overview of the current and future copper supply and demand situation in both countries. Results from two market studies commissioned by the International Copper Study Group (ICSG) are complemented with recent copper statistics on North-East and South-East Asia, as well as further sectoral analysis. Developments and trends in copper mining and metal production, semis production, and major end use areas are highlighted. While providing insights into sectoral patterns and growth trends, the paper provides the basis for comparing structure and output of the copper sectors in some of the major copper-using countries in Asia. Afterwards, the current copper reservoir in use associated with infrastructure, buildings, industrial equipment, transportation systems and households is assessed using the ICSG Copper Flow Model. Finally, the identified copper flows are analyzed regarding the potential impact on the future world supply and demand situation.

Jan 1, 2007

By M. Sakamoto

Copper foil is an indispensable material for Printed Circuit Boards (PCBs). PCBs in turn are essential elements of all electronic equipment today and thus important for our living in the new age of IT. The requirements from the copper foil market have lately been increasingly strict and diversified due to the rapid technical advancements in miniaturized high-density electronic equipment and highly integrated semiconductors. Tight control of thickness, metallurgical properties, surface morphology and characteristics is needed. In this paper, both electrodeposited copper foil for PCB and rolled copper foil for the flexible printed circuit board are discussed, and the recent technical developments in these copper foil products are reviewed.

Jan 1, 2007

By S. Asano

Hydrometallurgical processes for treating copper sulfide concentrates have attracted considerable attention over thirty years and many processes have been developed. However there have been still problems in those processes because of difficulties of iron removal and high purity copper production with low operating cost. Although SX-EW is highly cost effective method, it is difficult to process the chalcopyrite. Sumitomo Metal Mining Co., Ltd. (SMM) conducted a review of hydrometallurgical copper concentrate processing and has successfully developed a novel process for the hydrometallurgical production of copper from copper concentrate. In this process, copper sulfide is leached by chlorine gas under atmospheric pressure. Most of hydro metallurgical processes can leach only some of chalcopyrite under atmospheric pressure then they need high pressure leaching facility like autoclave. In this process, copper in chalcopyrite can be leached completely by controlling oxidation reduction potential and chloride ion concentration. Cu(I) ion in leached liquor is separated from Fe(I!) ion by SX using TBP then pure copper powder is produced by electrowinning. Results in batch and continuous testworks and pilot plant tests at Niihama Research Laboratories are presented in this paper. Cu2007

Jan 1, 2007

By Raj Thamburaj

"Over the last few decades, the emphasis on affordability and reduced cost of ownership has necessitated the development of innovative processes to carry out repairs in aero engine components. Conventional weld and braze repairs have evolved into advanced, sophisticated processes using state of the art knowledge in lasers, robotics and materials technology. This paper illustrates past and present scenarios in an attempt to illustrate progress that has been made in this area. The problems encountered in the past have been detailed along with the solutions that have been developed and commercially implemented to address these issues. Apart from technical progress, this presentation also addresses the progress made in business approaches and in Certification/Regulatory issues surrounding aero engine repair. Progress in Technology Repair technologies have also been the embryo from which new and revolutionary manufacturing technologies have evolved as well. Electron Beam Free Forming and LENS are examples of how a completely new manufacturing concept can evolve what was originally only a process to join metals. The current and future potential of these spin offs is discussed providing examples of application. While several problems have been solved over time with the implementation of advanced repair technologies, the demands of the industry have created new challenges. The paper describes these issues, outlines potential solutions and discusses the future of repair technologies in terms of the far reaching influence it is sure to have in design, manufacturing, maintenance management and life extension. Progress in Business Trends.Business approaches to repair and maintenance have also gone through considerable change with the introduction of ""Power by the Hour"" and other similar arrangements between the companies responsible for engine overhaul and the end-users. Program Based Logistics (PBL) is yet another innovation to provide a win-win situation for the repair service provider and the end user. This paper traces the development of these business initiatives and highlights successful applications. Progress in Repair Certification, Regulatory Issues.Understanding of the issues surrounding certification of repairs has also evolved with time and regulatory issues have been clarified considerably. Procedures for analysis and testing are much clearer and ""Check Lists"" are being drafted for certifying repairs on various engine components. The PMA phenomenon has added yet another dimension to the issues regarding certification and these are discussed as well."

Jan 1, 2010

"At the May 15, 2006 and the May 1, 2007 Canadian Securities Administrators (CSA) Canadian Institute of Mining, Metallurgy and Petroleum (CIM) meetings in Vancouver and Montreal, CSA requested CIM consider certain issues arising out of the CSA review of Technical Reports and public disclosure, in general, regarding the practice of estimation and reporting of Mineral Resources and Mineral Reserves. The following is a summary of the issues raised by the CSA and the responses of the CIM.Preamble: At the May 15, 2006 and the May 1, 2007 Canadian Securities Administrators (CSA)-Canadian Institute of Mining, Metallurgy and Petroleum (CIM) meetings in Vancouver and Montreal, CSA requested CIM consider certain issues arising out of the CSA review of Technical Reports and public disclosure, in general, regarding the practice of estimation and reporting of Mineral Resources and Mineral Reserves. The following is a summary of the issues raised by the CSA and the responses of the CIM Reserve Definition and the CIM Estimation Best Practices Committees (the Committees). This information is intended to provide the Qualified Person (QP) with further guidance when estimating Mineral Resources and Mineral Reserves and in preparing a technical report written under National Instrument 43-101 (NI 43-101). Several members of the CIM Reserve Definition Committee, the CIM Estimation Best Practices Committee and some members of the Committee for Mineral Resources International Reporting Standards have reviewed these issues and provide the following commentary.Issue 1. - CSA requested CIM review and comment on the selection of an appropriate commodity price to be used in Mineral Resources and Mineral Reserves estimates.Commodity prices are used in the estimation of Mineral Resources and Mineral Reserves and in the economic analysis of a property. In times of rapidly changing commodity prices, or when prices are at the extreme ends of a commodity price cycle, the QP has a difficult job in selecting an appropriate commodity price.• The selection of appropriate technical variables, including commodity price, is clearly the responsibility of the Qualified Person (QP). The QP must describe the reasons for selecting these variables, including price, in the technical report.• The definition of a ""Mineral Resource"" contains the wording ""reasonable prospects for economic extraction,"" therefore, a QP must select economic parameters, including commodity price, that will result in an estimate of Mineral Resources and Mineral Reserves that have ""reasonable prospects for economic extraction""."

Jan 1, 2003

By M. Matsuda

The Hitachi refinery of Nikko Smelting & Refining Co. Ltd. began its electrolytic copper refining operations in 1911. In December 2002, the refinery changed its operation scheme by introducing the ISA permanent cathode technology for the first time in Japan. The change resulted in higher productivity, better cathode quality, and lower operational costs. The operation has been continuously improved to reach a 20% higher production capacity than the original one. For the electrolyte purification process, the Hitachi refinery has developed a new process for removing impurities. The process involves As, Sb and Bi adsorption from the electrolyte by means of chelating and ion exchange resin. The new resin process will achieve higher efficiency in removing impurity.

Jan 1, 2007

By P. Lauzon, C. Oprea, S. Zhou, G. Oprea, J. Rigby, T. Troczynski

Hydration of basic refractories could occur during storage, drying after installation or in use. In order to assess the hydration resistance of various commercially available magnesia-chrome bricks, hydration tests were performed in steam at 110, 120, 130 and 150°C. The changes of the modulus of elasticity by the impulse excitation method, apparent porosity, air permeability, average pore size and pore size distribution were correlated with the hydration data. Mineralogical and microstructural changes were also studied on selected specimens by XRD and SEM/EDS. The hydration mechanisms were discussed in correlation with the chemical and mineralogical compositions of the experimental bricks, in particular with the nature of the mineralogical phases at the grain boundaries.

Jan 1, 2004