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By Albert E. Wiggin

PagE I. Early History of Boston & Montana Mill at Great Falls (1891 to 1905). 210 a. Original Mill Built in 1891.........210 b. Coarser Concentration Tried...211 c. Screen Sizing of Fine Jig Feed Introduced..211 d. Installation of Finer Grinding.......211 e. Steam Stamp Tried in Place of Blake Crushers..... 211 j. Mill Increased from Three to Six Sections........ 213 g. Tonnage Increased from 300 to 450 Tons per Section... 212 h. Round Tables Replaced by Wilfley Tables....212 I1. Hancock Jig Replaces Evans Jig...212 a. Description of Hancock Jig...213 - b. Tests Made on- Hancock Jig..213 1. Treating Natural Feed..215 2. Treating Sized Feed..215 3. Treating Classified Feed .215 c. Tests Made on Evans Jig...216 III. Richards Pulsator Classifier System...218 a. Experimental Work.....218 b. Installation of System in Section No. 4,....... 220 IV. Woodbury Classifier and Jig System.............222 V. The Great Falls System................ 222 a. As Installed at Anaconda............ 224 1. Coarse Crushing and Jigging Division...... 225 2. Hancock Jig Division........... 226 3. Fine Middling Division.......... 229 4. Table Division............. 230 5. Slime Division.........230 b. Special Features of Great ails Flow sheet....... 231 1. Development of Hancock Jig Flow Sheet..... 231 2. Development of Finishing Table Flow Sheet.... 232 3. Treatment of Coarse Middling Table Products .. 232 4. Results of Test Made on 500-Ton Section at Great Falls Mill...........234 VI. Comparison of Great Falls and Evans System at Anaconda.... 236

Jan 1, 1914

By Auguste J. Rosh

The use of titaniferous ores in the blast-furnace has been the subject of much controversy for many years. Divers objections have been raised against them, and, for one cause or another, the verdict

Jan 1, 1893

By O. J. Huber

HYDROGEN effects in titanium alloys have been the subject of extensive research in recent years. Lenning, Craighead, and Jaffee1 showed that hydrogen embrittles a titanium and, at the same time, elevates the temperature at which the transition from brittle to ductile failure occurs during impact testing. In later work: the same investigators concluded that several all-ß alloys tolerate large amounts of hydrogen without serious damage to mechanical properties, but two-phase alloys suffer varying degrees of embrittlement, depending upon the specific ß-stabilizing addition used and whether or not an a stabilizer is also present. The mechanism of hydrogen embrittlement has not been clearly established. Strain rate has been shown to be an important factor and, therefore, a strain-aging phenomenon is suspected to cause the effects that hydrogen has produced on mechanical properties.3-5 Ripling6 has pointed out that ductility damage varies inversely with strain rate in a-ß alloys and directly in a alloys. This effect in a alloys can be associated with transition-temperature behavior, but the embrittlemeat mechanism in two-phase alloys remains in question. During the course of research conducted for the U. S. Air Force, a dark-etching phase has been observed at the grain boundaries of certain two-phase titanium alloys after duplex (solution plus aging) heat treatments.5-7 An example of the dark-etching interface phase is shown in Fig. 1. Decrease in ductility accompanies the appearance of the minor phase but has not always been attributable solely to the presence of the phase. Although the dark-etching phase has been observed in alloys under a rather narrow range of heat-treatment conditions, it is of general interest since it is always associated with the presence of hydrogen. The known embrittling effect of hydrogen makes any facet of its behavior of particular importance. The intergranular phase has been observed in titanium-base alloys with relatively high amounts of the ß-stabilizing elements. Specific examples of such alloys include Ti-5 pct Mn-2.5 pct Cr, Ti-3.5 pct Cr-3.5 pct V, Ti-8 pct Mn, and Ti-3 pct Mn-1

Jan 1, 1958

By Andrew Hyslop

In our never ending search for new and better ways of underground mining, we find that transportation has had its share of new ideas in the past few years. The old and still effective method of track haulage has had some competition from rubber-tired cars and belt conveyors, each of which has its own safety hazards which demand close scrutiny in any safety study. The use of shuttle cars, in particular, has introduced clearance hazards caused by the absence of the more or less positive guides formed by the rails of a track sys- tem; likewise the requirement of greater clearance tends to increase roof hazards which we all know to be great enough with the best of methods. However, the subject of transportation hazards is too broad to be covered entirely in one paper, so I will confine myself to track methods which carry the preponderance of underground tonnage. I am quite sure that to this group it is an evident fact that haulage accidents are of major importance. However, to stress the point, it may be well to look at a few figures. Safety statistics can be quite boring and often are subject to question as to mathematical accuracy because of different

Jan 1, 1949

By L. D. Jaffe, J. H. Hollomon

THE effect of tempering temperature and time upon the properties of quenched steel is clearly a subject of great practical importance, as well as of considerable theoretical interest. It would be very desirable to be able to predict the properties of a quenched steel when given any selected tempering cycle, with a minimum of experimental work upon that heat or even type of steel. Two problems are involved: one consists of relating the structure obtained to the physical properties, and will not be discussed here; the other, with which this paper deals, involves the relations of time, temperature and composition with the structure obtained on tempering. Indentation hardness is perhaps the most convenient quantitative measure of the tempered structure, or of what might be called the "degree of tempering." Undoubtedly, it is not an exact measure, and in some cases (as when temper-brittleness occurs) pieces of the same quenched and tempered steel may have widely differing properties at the same hardness. However, hardness has the advantage of being simple to determine and is certainly the most widely used indication of the degree of tempering. Moreover, for fully quenched steels that are not temper-brittle and do not contain retained austenite when quenched, it appears that, in general, if the hardness of the steel is the same, the tensile and impact properties will also be identical, whether a high or a low tempering temperature is used. The tempering charts available in the metallurgical literature usually give the hardness as a function of tempering temperature for only one tempering time. However, in practice, tempering times frequently vary, and a method of converting tempering curves for one time to tempering curves for some other time would be very valuable. It is also advantageous, in determining the tempering treatment necessary for a given part, not to have to temper samples at several temperatures for the time used for the commercial tempering operation. A more satisfactory procedure would be to employ times of the order of 10 to 30 min., rather than 5 or 10 hr., and if possible to use only one temperature. Furthermore, it is frequently desirable, for reasons such as temper-brittleness,* to obtain a given hardness with short times at relatively high temperatures, and it would be convenient to be able to compute without tests the time required to produce this hardness. Remarkably few quantitative studies of the hardness of quenched steel tempered over wide ranges of temperature and time

Jan 1, 1945

By H. LeChatelier, B. Bogitch

Page Introduction........................... 134 Methods of Investigation....................... 135 The Tridymite Network...................... 137 Independent Variables....................... 146 Manufacturing Operations..................... 153 Introduction Silica brick are indispensable in the manufacture of steel because they alone are able to withstand the high temperature of regenerative furnaces. All attempts to replace silica brick by other refractory materials for this purpose have failed, but the reason for this failure has remained obscure; we shall give an explanation later in this paper. Before the war, silica brick employed in France came principally from abroad, for which reason, since the beginning of hostilities, certain French steel works have been seriously handicapped. Our attention was first directed to the question by M. Bied, Engineer of the Teil Works. With him, we began certain investigations, at first using our laboratory and the furnaces of neighboring steel works. The larger part of our experiments, however, have been made in the laboratory of the Faculty of Sciences at the Sorbonne. For the heating of our samples, we are deeply obliged to MM. Charpy, Yeatmann and Guerineau. In undertaking these studies, our first aim has been to render assistance to French industry, by indicating, as precisely as possible, the necessary conditions for the manufacture of high-grade brick; but at the same time me have

Jan 1, 1919

By Claude P. Heiner

W-hile the litle of this paper embraces the entire West Coast, the author, in the interest of simplification, has confined the discussion to California—particularly the central section. California's population has risen 45 pct since 1940. Its electric requirements have also increased, not only because of the growth in industry and population but also because of the widespread tendency of all types of electric consumers to use more electricity than ever before. The growth of California's electric utilities is shown by published data covering operations of three of its large systems and is given in Table 1. New Capacity Steam Driven In meeting these additional electric loads there has been a substantial increase in generation from fuel burning plants as shown by the published energy statistics given in Table 2. Increased Fuel Oil Consumption A study of construction plans of the three electric utility systems named in Table 2 clearly shows that expected new electric loads are to be met, to a large extent, by new steam generating capacity as shown by Table 3. D. D. Smalley, Vice President of the Pacific Gas and Electric Co., in an address before the Pacific Coast Electrical Association in June 1948, stated that California utilities plan to meet new electric loads through greater use of steal11 plank and that in 1951 approximately 45 pct of the area's electric production would be by steam as compared to 33.6 pct in 1946. He stated that if load growth develops as expected and if the year 1952 is dry, thereby requiring high load factor steam operation, the Pacific Gas and Electric Co. would need the equivalent of nearly 25 million barrels of fuel oil. Federal Power Commission reports show that the energy input to the Pacific Gas and Electric Co. system was approximately one billion kilowatt-hours greater in 1947 than in 1946. They also show that the steam plant operating capacity factor in 1946 was approximately 35 pct; in 1947 it, was 72 pct due, probably, to the extreme drought. able 3 shows that Pacific Gas and Electric Co. now has under construction 327,000 kw of hydro capacity which, by 1950, will bring its total hydro generating capacity to 1,313,899 kw. In addition to hydro capacity under construction that company also has 975,000 kw of steam generating capacity under construction, which by 1951 will bring its total steam capacity to 1,560,834 kw. If it is assumed that this total steam electric capacity is operated at a capacity factor of 45 pct, in 1951, over 6 billion kilowatt-hours would be generated. If the load growth on the Pacific Gas and Electric system continues at the current rate of approximately one billion kilowatt-hours per year and if it is assumed that 70 pct of this increase would be generated by steam (30 pct assumed to be generated by hydro facilities with average water conditions), the steam electric production in 1960 would amount to 12 billion kilowatt-hours, which would require fuel the equivalent of 24 million barrels of oil or 6 million tons of coal. Government Projects Inadequate Much has been written with respecl to the plans of the Department of Interior in regard to the installation of hydroelectric plants as a part of multipurpose dams relating to reclamation. flood control, and power generation. An examination of the effect of such plans on the power supply for central and northern California is of interest. The Depart,ment of Interior now has five 73,000 kw units at its Shasta hydro plant on the Sacramento River. It now appears that its three 25,000 kw unit Keswick hydro plant on the same river will be available during the winter of 1949 to 1950. Its estimates show that in a dry year there is sufficient water for operation of Shasta units at an average load factor of 36 pct and Keswick units at a load factor of 41 pct. It is also giving consideration to the development of the Pine Flat and Haas hydroelectric plants on Kings River for generating capacities of 45,000 kw each. The total installation of Government, units in Central Valley and Kings River in California is relat.ively small when compared with t.he

Jan 1, 1950

By A. N. Winchell

In connection with law suits between mining companies at Bingham, Utah, a few years ago, the writer made petrographic studies of more than 1400 rock and mineral samples in thin sections, and also careful studies of their field relations. In petrographic studies, even when an area is studied intensively, attention is commonly centered very largely on the unusual features of special interest, so that the relative abundance of rock types (or minerals or textures) can only be determined by a study of map areas outlined largely by field methods, and cannot be based directly on microscopic work. It is very uncommon, and usually impossible, to take samples at regular short intervals along and across formations. It is precisely because such methods were used at Ringham that the work presents a rare opportunity for determining, on a microscopic basis, the relative abundance of rock types and the continuity of gradations between rock types. At the same time, a study was made of the alteration of sediments under the influence of igneous intrusions, with results that are believed to be of interest and importance. • Sandstone-limestone Gradation The sedimentary rocks of the Bingham district are chiefly sandstones, with some beds of limestone, all now lying with their strike nearly east and their dip nearly north at an angle of about 30°, near the surface. The limestone beds are remarkably irregular in thickness in some places, but usually change very slowly in composition along the strike. However, the most interesting results are obtained from a study of a section across the beds at right angles to the strike. In some places, such sections show the usual alternation of pure sandstone with nearly pure limestone, in the simple manner assumed in most geological discussions.

Jan 1, 1924

By Fred D. Rosi

Introduction There is probably no field in which materials research has played a greater role than that of electronics. However, to trace present and future patterns of materials research in electronics is not an easy assignment, since this industry has a high degree of dynamism in its growth, and is busily engaged today in the scientific improbabilities of only recent yesterdays. On the other hand, this task seems especially appropriate since electronics is a truly frontier industry - one whose place in American industries has advanced from 50th prior to World War II to 6th in 1967, with sales of more than $22 billion. And this growth has been associated with the equally rapid progress of science and technology over the period - in particular with the emergence of materials science as a vital force in underscoring this progress. For several reasons this parallel growth is not too surprising. First, by its very definition electronics is a science that essentially deals with the nature, behavior, detection, generation, control and utilization of electrons in solids or at their surfaces. Second, in the electronics industry, systems are made of an integration of components, and these components with their interconnections are made of materials. Thus, the basic building blocks of systems are materials; and it has been largely the advances in materials research and technology that have led to new and improved devices and systems. It follows, therefore, that the broadening of the frontiers in electronics through the exploration of new territories is tantamount to scientific discovery and materials innovation to a degree found in no other major industrial activity. But to put this in the proper perspective of present and future materials trends, it would be appropriate first to survey historically the progress in electronics by pointing out major scientific discoveries and associated materials research patterns that have led directly to its tremendous growth. Then from this base we can consider recent trends in materials research that could form the basis for future progress in the electronics industry. In my review I shall examine the areas most familiar to me, so I must acknowledge at the outset that this survey is not all-inclusive.

Jan 1, 1971

By H. S. Chiang, S. S. Peng

INTRODUCTION Underground coal mining disturbs the original in-situ conditions which induces a series of strata activities and results in creating "mine pressures," the source of all ground control problems. Adoption of self advancing powered supports in modern longwall mining adds a new dimension to ground control problems and thus research. Roof stability, in general, refers to the integrity and stability of the immediate roof which is measured by the maximum exposed area and time duration without support. There are many factors that con- tribute to roof stability problems. In addition to mining height, rock property and stratum components and caving angle of the immediate roof, characteristics of joints and fissures and their degrees of development, faults and underground water, the operational techniques also play a very important role. This paper summarizes these operational techniques and methods of controlling stable and unstable roof. CLASSIFICATION OF THE IMMEDIATE ROOF There are many ways of classifying the roof (1). For practical purpose, the immediate roof in this paper is divided into three groups, i.e. unstable. medium stable and stable. Unstable Immediate Roof It has the following features (1) It consists of weak or soft carbonaceous shale, black shale, clay shale and well-jointed or fractures sandy shale

Jan 1, 1983

By Frank J. Tolonen, Nicholas H. Manderfield, Paul Jasberg

EARLY in the study of the low grade iron formations of Michigan, wide variations in their structure and texture became evident. Because of these variations no simple method of concentration is possible, and those portions of the formations that can be exploited profitably under a given stage of metallurgical progress and existing economic conditions must be searched for carefully. Both structure and texture of the formations have an important bearing on their amenability to bene-ficiation. By structure is meant the banding planes of easy fracture, the porosity, and the degree of leaching. Texture, which includes grain sizes, shapes, and degree of interlocking, determines the amount of grinding necessary to liberate the mineral grains. Structure determines the liberation of portions richer in one mineral. Structure and texture may be termed the gross features of the formation. Earliest surveys of the formations were conducted to outline the parts that could be concentrated at % in. (3 mesh). Operators agreed on this size because anything finer required sintering or other agglomeration processes. At 3 mesh only the structural features, as defined above, would be liberated. With suitable ores concentration was easy, as any of the gravity methods could be used. Sink-and-float gave good results, but with this method only limited portions of the iron formations yielded a desilrable product.1,2 n general, the iroa content could be raised to shipping grade, but the silica content remained too high—sometimes 20 pct—instead of 9 or 10 pct. Grinding did not greatly increase the liberation ofsilica until 2010 mesh or finer was reached. To find the reason fpr this T. M. Broderick began micros~opic examin'ations of the formations in 1933.3 Procedure: The purpose of this discussion is to correlate the appearance of typical portions of the iron formations with their amenability to concentration. As liberation is essential before separation becomes possible, much of the work is based on measuring the liberation achieved by crushing and grinding. Both heavy media and magnetic tube tests were used in this work. On the basis of general structural features such as banding, degree of alteration, and leaching, a specimen was selected from each part of the iron formations studied. The specimen represents the gross features of the formation and not necessarily the particular formation quantitatively. One half of the specimen was polished for macro-study, and the remainder was used for analyses to obtain the grades represented by variations appearing in the macrosection. Specimens for microscopic examination were also prepared for each variation in gross appearance. For correlation of microstructure with liberation, the previous work by sink-and-float methods was supplemented by magnetizing roasting followed by magnetic separation. The results show the liberation of silica to be very important at the sizes used, because any silica particle with iron minerals occluded would be held in the concentrate. A magnetizing roast changes the crushing and grinding character of the sample. For partly leached soft samples the change is slight, but with harder types and those in which there is a considerable change in crystal structure of the minerals, the increase in liberation of the iron minerals may be 30 pct more than that of unroasted samples at the same crusheH size. Gogebic Range Iron Formations: The Gogebic Iron Range is located in the extreme western and southern parts of Michigan's Upper Peninsula, extending westward into Wisconsin. Samples for this study were obtained from the Ironwood formation, comprising three chief members—the Plymouth, Norrie, and Ahvil—with several intermediate slates and thick overlying slates. (The slates are not considered in this discussion because grinding finer than present practice is usually required to liberate the iron minerals.) The predominant iron mineral is hematite, about half of which is hydrated to goe-thite. Limonite occurs in some of the partly leached areas, and siderite in parts of the formation.

Jan 1, 1958

By S. J. Aresco, George E. Keller, J. Visman

INTRODUCTION The accurate sampling of coal, as with most minerals, is a difficult task. Coal is a very heterogeneous material made up of different types of coal and varying amounts of mineral matter. The product as mined may contain all of the layers of coal and impurities found in the seam as well as portions of the strata above and below the coal seam. The preparation plant is the device to size, crush and/or remove impurities so that the coal may be shipped as a saleable product. Sampling may be needed at many stages in the preparation process. Although this chapter is mainly concerned with sampling in connection with preparation processes, the principles will apply to all coal sampling. The main reasons for sampling in connection with coal preparation are: 1. To determine the washability characteristics of the raw coal by means of float and sink tests. These may be used for the design of a preparation plant, prediction of results to be obtained or for monitoring raw coal delivered to the plant. 2. To check the performance of various operating units in the plant, either by float and sink tests or chemical analyses. 3. To determine the analytical characteristics of the products produced, such as moisture, ash, Btu, sulfur, etc. HISTORY The earliest accepted methods of sampling coal in the United States were given in U. S. Bureau of Mines publications by J. A. Holmes,1 G. S. Pope2 and A. C. Fieldner.3 The American Society for Testing and Materials more or less adopted the methods proposed by the U.S. Bureau of Mines in their Standard D-21-1916, and it remained a standard for many years. Briefly, the standard called for a 500 pound sample for coals less than. 3/4 -in. in size and a 1,000 pound sample for all coals over ?4 -in. in size. No mention was made of increments but there was an instruction that the sample should spread over the coal to be sampled. Sample preparation was by hand crushing with the alternate shovel method for reduction to 250 pounds followed by coning and quartering below 250 pounds. Obviously, with the amount of work involved, this method of sample preparation was rarely followed. This method of preparation resulted in samples that were practically air dried because of long exposure while crushing, shoveling and quartering. In the late nineteen twenties and early nineteen thirties, studies for more practical methods were begun. Dr. E. S. Grummell4, Imperial Chemical Industries, Ltd, London, summarized the work to date at the

Jan 1, 1968

By L. W. Kempf, R. S. Archer

The binary aluminum-silicon alloys have certain characteristic advantages which are now well known, and these alloys have come into considerable use during the past several years.' Their field of application has been limited to a certain extent, however, by their low yield point and hardness, low endurance limit, and relatively poor machining characteristics. These properties are improved by the addition of copper, and the ternary aluminum-silicon-copper alloys constitute an important class. The addition of copper decreases the corrosion resistance of the aluminum-silicon alloys and increases specific gravity. Magnesium is a hardening addition which seems to have relatively little effect on corrosion resistance, and which, of course, reduces specific gravity. The object of the work described in this paper was the development of alloys and heat treatments for the production of sand castings and permanent-mold castings having substantially all the advantages of the binary aluminum-silicon alloys together with mechanical properties improved to a degree permitting wider application. Constitution of Alloys Magnesium and silicon combine in aluminum alloys as the compound Mg2Si, which forms a binary system with aluminum. In alloys containing an excess of silicon over that required to form the compound, solidification ends with the freezing at 1022' F. (550' C.) of a ternary eutectic of aluminum, Mg²Si, and silicon. Judging from the horizontal projection of the liquidus surface as given by Hanson and Gayler,² this ternary eut,ectic contains about 13 per cent. silicon and 6 per cent. magnesium. All of the alloys discussed here contain excess silicon, so it

Jan 1, 1931

By Chester A. Rowland, David M. Kjos

Mineral ore comminution is generally a feed preparation step for subsequent processing stages. Grinding, the fine product phase of comminution, requires a large capital investment and frequently is the area of maximum usage of power and wear resistant materials. Grinding is most frequently done in rotating drums utilizing loose grinding media, lifted by the rotation of the drum, to break the ores in various combinations of impact, attrition and abrasion to produce the specified product. Grinding media can be the ore itself (autogenous grinding - primary and secondary), natural or manufactured non- metallic media (pebble milling) or manufactured metallic media - steel rods, steel or iron balls. This chapter covers rod and ball mills which utilize manufactured metallic grinding media. Fig. 1 shows the cross section of an overflow rod mill, Fig. 2 an overflow ball mill, and Fig. 3 a diaphragm (grate) discharge ball mill.

Jan 1, 1978

By A. A. Rauth

In this paper, the author derives a series of formulas from basic principles and illustrates the application of these formulas to practical grinding charge problems. The paper establishes the nearly proportional relationship of mill power to charge level and shows how this relationship can be used to advantage in the design, manufacture and operation of grinding mills. The procedures outlined offer a rapid means of anticipating the power requirements for a given charge or determining makeup charges for a given power reading. The theories which have been developed concerning the dynamics of grinding have been motivated largely by the desire to derive workable formulas for the accurate determination of grinding mill power. This accurate determination has always been handicapped by the large number of variables to be considered, some of which are mill diameter, length, speed, liner design, grinding charge and material density, volumetric mill loading, internal friction, and charge size and gradation. In efforts to determine mill power, attempts have been made to utilize torque concepts. The formulas derived consider the grinding mass as a rigid body and utilize factors that are based on empirical data so that the movement of the charge within the mill is compensated for. These formulas are of principal interest to the mill designer since he is charged with the responsibility of analyzing all of the variables and from them predicting a mill size and a motor size which are compatible both with each other and with the grinding job for which they were intended. The mill operator, on the other hand, has an entirely different problem. The mill dimensions are already established and so is the driving motor. The operator's main concern is to obtain maximum performance from the mill he already has. For him, the many variables which perplex the mill designer are fixed values. Mill diameter, length and speed are set and, to a large extent, so are the conditions inside the mill from which the torque formula advocates derive their empirical data. It is conceivable that if the major mill dimensions which affect power demand are held constant, and if the variables influencing empirical factors are held fairly constant, as they are in an operating mill, then the only major variable remaining which affects power is the level of the charge itself. Under this condition.

Jan 1, 1970

By R. B. Adair, J. S. Browning

The laboratory batch and continuous flotation pilot plant tests demonstrated the technical feasibility of recovering high grade mica concentrates from weathered mica pegmatite ores of Alabama and Georgia. The research indicated that combinations of anionic and cationic collectors may be used effectively for flotation of fine size mica from weathered pegmatite ores. In continuous tests, concentrates containing 98.5% mica were obtained from the Georgia pegmatite ore; the Alabama pegmatite ore concentrates contained 98.4% mica. The recoveries were 91 and 89% respectively. INTRODUCTION The principal uses of fine ground mica are as a filler in wallboard joint cement, as a filler and surface coating for roofing, as an ingredient in paints, and in oil well drilling mud. The mineral has other uses in the manufacture of rubber, wallpaper, plastics, welding rods, electric insulation, house insulation, and textiles, and as an annealing agent in metal treatment. In recent years, more than 99% of the domestic mica produced has been scrap and flake mica (mica which does not meet specifications for sheet mica and is used for producing fine ground mica). There has been a continued increase in mica production for several years, the 1963 production of scrap and flake mica totaling 117,251 tons.1 Ground mica is obtained primarily by crushing and milling pegmatites and schists. To a lesser extent, mica is produced as a byproduct of kaolin washing and feldspar and spodumene flotation operations. The processes used in recovering mica by crushing and milling pegmatites are generally simple, consisting of various combinations of alternate roll crushers and trommel screens that separate the mica and gangue at screen sizes coarser than 6-mesh. As these processes are designed to recover only coarse mica, high losses in the plant rejects are common. Large tonnages of tailings from the crushing and screening plants have been accumulated in a number of areas. Methods for treating such products were developed by the Bureau of Mines in 1941,2 but have not been generally applied. More recently, mica flotation research has been completed and published by the Bureau of Mines.3 These methods required complete removal of 150- to 200-mesh materials from the flotation feed with consequent fine mica losses. Later, the Bureau of. Mines investigated methods for-recovering fine size mica from pegmatite ores after desliming sufficiently to remove clay materials, but not so drastically as to remove the fine sands. This report summarizes the results of these studies. The process developed was effective on pegmatite ores from two locations and should be applicable to the commercial treatment of other mica-bearing pegmatite ores and fine rejects that have been accumulated at various mica-milling operations. DESCRIPTION OF ORES The ores used in the investigation were obtained from the Dixie Mines, Inc., Heflin, Alabama, and the Ruberoid Corporation, Hartwell, Georgia. The sample from Alabama contained muscovite and quartz, with a high percentage of clay, and minor amounts of biotite, kaolin, limonite and tourmaline. The mica in the ore was essentially all minus 4-mesh in size and was free of attached mineral grains. The Georgia sample contained muscovite and quartz, with minor amounts of biotite, kaolin, and limonite. The mica in the ore, which was essentially all minus 4-mesh, was liberated. Petrographic analyses of the two samples are given in Table I. THE ANIONIC-CATIONIC MICA FLOTATION METHOD Previous investigators2,3 have reported that complete desliming of mica ores at 150- to 200-mesh was required prior to flotation with cationic collectors to obtain satisfactory selective separation of the mica from the other mineral components. Numerous tests were made at the Tuscaloosa Metallurgy Research Center to determine if some reagent combination could be used to selectively float finer size mica without complete desliming. The investigation led to development of a process using a simple reagent com-

Jan 1, 1967

By J. H. Schulman, M. H. Buckenham

Although much interest has been taken in the use of mixed collectors in flotation, this investigation is probably the first in which oppositely charged collectors have been considered. The results obtained and the techniques used could well be applied in the behavior of other mixe the behavior of other mixed collector systems and could possibly explain the effective flotation results which have been reported when various collector combinations have been used. Collectors conventionally employed in flotation systems are soluble in water, but many of their homologs of longer hydrocarbon chain length are insoluble. The properties and behavior of these insoluble compounds may be conveniently studied when they are spread as monolayers at the air/water interface on the Langmuir-Adam trough. Although some extrapolation is involved in applying effects observed at this interface to the solid/liquid interface where the action of collectors is most important in flotation, the technique nevertheless is most useful for the study and interpretation of flotation phenomena. Of particular interest in this field are investigations on the insoluble monolayers of the fatty acids, alkyl sulfates and alkyl amines; the penetration of these insoluble monolayers by soluble surface active components and their interaction with metal ions from the underlying solution.'-' Unfortunately, the insoluble xanthates and related compounds do not exhibit stable monolayer properties due to rapid oxidation at the air/water interface and, therefore, cannot be studied directly in this way. These approaches have enabled Leja and Schulman8 to suggest mechanisms explaining dynamic attachment of mineral particles to air bubbles involving collector-frother interaction and the adsorption of collectors onto mineral surfaces. In this and other papers 9-12 considerable evidence is presented to support the concept of collector-frother and metal ion-monolayer interaction and to emphasize the value of monolayer techniques in elucidating the flotation system. Molecular interactions resulting from monolayer penetration are determined by the nature of and the association between both the polar and nonpolar groups of the two molecules concerned. Stable complexes are formed on penetration when interaction takes place between both the polar and nonpolar groups, and although the resultant complexes are not necessarily true chemical compounds, the properties of the molecularly associated complexes are very different from those of the individual components. Shortening of, or changes from, a straight hydrocarbon chain in one of the reacting molecules reduces considerably the stability of the associated complex as do changes in temperature, pH and substrate composition. The effect of hydrocarbon chain length becomes most important when observed effects are to be applied in flotation studies where soluble homo-logs and, therefore, much shorter hydrocarbon chain lengths are used. The present investigation is based on Langmuir trough work carried out by Bowcott,l3 who studied the penetration of insoluble amine monolayers by potassium lauryl xanthate. Bowcott observed that cetyl amine monolayers were readily penetrated by xanthate, but found that with time the high film pressures resulting from penetration and association fell off, indicating decomposition and ejection of xanthate from the film. This decomposition was pH dependent. Of particular interest in this work were studies on an equimolecular mixed monolayer of the fully N-substituted ammonium compound, for example, cetyl trimethyl ammonium iodide (CTAI) and potassium cetyl xanthate. Despite the fact that the CTAI is water soluble and the xanthate on its own is incapable of forming a monolayer, the mixed film was stable up to a surface pressure of 67 dynes per cm. In this condensed state the xanthate was stabilized against atmospheric oxidation, although iodine injected beneath the film caused an immediate collapse. The stabilizing of xanthate against oxidation by association with an alkyl trimethyl ammonium bromide (TAB) could be important in flotation, and a study of the performance and behavior of mixed collectors therefore was undertaken. A modified Hallimond tube operated under controlled conditions was used to evaluate flotation. Surface tension measurements were made to investigate the properties of the soluble

Jan 1, 1963

By T. F. Bower, M. C. Flemings, H. D. Brody

A series of experiments are reported which show thai reasonable assumptions for analysis of solute redistribution in solidification of castings and ingols illclr(de: negligible undercooling before nuclcation of solid phases, negligible increase of solute in advance of the tips of growing dendrites, complete diffusion within the Liquid oer distances the order, of dentrite arm spacings, platelike dentrite t/o?$holog?.. Qzmli/ali,e and periment is obtained JOY Al-Cu alloys front measurements of amount of nonequilibrium second phase, minimum solute content at the centers dentrites arms (after solidification), and 3) change in minimum solute content in dentrite arms during solidification. In a previous paper' analyses were given describing solute redistribution in dendritic solidification. The analyses were undertaken primarily to permit prediction of "severity of microsegregation" in a casting or ingot after solidification and cooling to room temperature, but can also be used to predict "local fraction solid' as a function of temperature in the solidifying alloy. Numerical results were given for Al-Cu alloys. The aims of this paper are to examine the validity of some of the assumptions of that analysis, and to compare predictions of the theory with experiments. All experiments reported are on Al-Cu alloys, the bulk on Al-4.5 pct Cu alloy. EXPERIMENTS Experiments conducted were on small ingots, 41/2 in. in diam by about 10 in. high. solidified in a controlled thermal environment (i.e., in a resistance-heated, re-circulating air furnace, whose temperature could be controlled to 1°C). In one series of experiments, the ingots were solidified very slowly (solidification time was varied from 8 to 1000 hr) and at constant rate of heat extraction. In a second series of experiments the ingots were solidified ( 'unidirectionally". Fig. 1 is a sketch of the method of making the two different types of ingots. The unidirectionally solidified ingots were fully columnar, and the slowly solidified ingots had equiaxed structures, Fig. 2. In making the slowly solidified ingots, the mold employed was carbon steel, coated with inert refractory. Typically the mold and its environment were heated to 700°C. The molten alloy was then poured into the mold and the temperature of the system equilibrated above the liquidus. The environment of the mold was next cooled with a controller responding to a differential thermocouple that measured the difference between the temperature of the melt and the temperature of the mold environment. The differential thermocouple consisted of one chromel-alumel junction in the melt connected in opposition with a second junction in the furnace. The potential across the differential thermocouple was input to the controller which acted to keep this potential at a set. constant value; hence the temperature difference between the two junctions was maintained nearly constant. Major resistance to heat flow in the above apparatus was between the metal surface and the furnace atmosphere, not in the metal itself. By maintaining a constant temperature difference between the metal and the furnace atmosphere, the controller maintained an essentially constant rate of heat extraction during solidification, regardless of amount of heat released by the metal per unit temperature change. When the metal temperature dropped just below the eutectic temperature. the ingot was removed from the furnace and water-quenched. The unidirectionally solidified ingots were cast in a similar mold to the foregoing except that provision was made to extract heat through the bottom face of the mold by passing air or water through the mold base, Fig. 1. For these experiments, metal and mold temperature were again equilibrated above the liquidus. Temperature of the mold environment was then held

Jan 1, 1967

By G. R. Brophy, A. J. Miller

The Grossmann principle1 for the calculation of hardenability of steel from composition is attractive because of its simplicity. It postulates that the hardenability of a steel for any particular grain size may be expressed in terms of an ideal critical diameter, which is the product of an ideal critical diameter for a "pure" iron-carbon base multiplied by a succession of factors for each element of composition contained, including the incidentals. It infers that the multiplying factor for a given quantity of an element is constant for all combinations of composition. Gross-mann has stated that in the great majority of cases the experimental values of hardenability are found to be well within 10 per cent of the calculated values. The validity of the scheme has been confirmed in principle by Crafts and Lamont2,3 and by Kramer et al.4 Their results differ from the original in the magnitude of the effect of some elements but, since they accepted the product concept and followed its direction, it is to be ex~ected that similar results would be obtained. Crafts and Lamont, in their second Paper, recognized that the factor relations for manganese and nickel were not continuously linear, but beyond certain critical amounts increase sharply. Austin, Van Note and Prater6 demonstrated nonlinear relations between hardenability and alloy contents. Their curves for chromium, silicon, manganese and nickel were all convex upward to show decreasing incremental effects. They concluded that Grossmann's factors under-evaluate the hardening effect of low percentage additions of these elements, and overevaluate the larger additions. More recently W. Stevens has found that the factor method fails when applied to complex steels containing two or three principal alloying elements other than carbon. Multiplying factors derived from his results bear a complex relation to composition and are not constant for a given amount of an element as the base composition varies. C. A. Liedholm7 found that, using either the Grossmann or the Crafts-Lamont multiplying factor values, not only were the relative hardenabilities of two heats of S.A.E. 6130 chromium-vanadium steel

Jan 1, 1947

By A. J. Miller, G. R. Brophy

The Grossmann principle1 for the calculation of hardenability of steel from composition is attractive because of its simplicity. It postulates that the hardenability of a steel for any particular grain size may be expressed in terms of an ideal critical diameter, which is the product of an ideal critical diameter for a "pure" iron-carbon base multiplied by a succession of factors for each element of composition contained, including the incidentals. It infers that the multiplying factor for a given quantity of an element is constant for all combinations of composition. Gross-mann has stated that in the great majority of cases the experimental values of hardenability are found to be well within 10 per cent of the calculated values. The validity of the scheme has been confirmed in principle by Crafts and Lamont2,3 and by Kramer et al.4 Their results differ from the original in the magnitude of the effect of some elements but, since they accepted the product concept and followed its direction, it is to be ex~ected that similar results would be obtained. Crafts and Lamont, in their second Paper, recognized that the factor relations for manganese and nickel were not continuously linear, but beyond certain critical amounts increase sharply. Austin, Van Note and Prater6 demonstrated nonlinear relations between hardenability and alloy contents. Their curves for chromium, silicon, manganese and nickel were all convex upward to show decreasing incremental effects. They concluded that Grossmann's factors under-evaluate the hardening effect of low percentage additions of these elements, and overevaluate the larger additions. More recently W. Stevens has found that the factor method fails when applied to complex steels containing two or three principal alloying elements other than carbon. Multiplying factors derived from his results bear a complex relation to composition and are not constant for a given amount of an element as the base composition varies. C. A. Liedholm7 found that, using either the Grossmann or the Crafts-Lamont multiplying factor values, not only were the relative hardenabilities of two heats of S.A.E. 6130 chromium-vanadium steel

Jan 1, 1947