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By A. L. Foell

THE development of the modern blast furnace began more than one hundred years ago, with the abandonment of the small hillside furnaces. Its development, especially during the past 50 years, has been accomplished through a rapid succession of enlargements and improvements. The remarkable growth in furnace output during this period is a tribute to the engineers and operators who have constantly endeavored to build larger and more efficient blast furnaces. The blast-furnace operators and their mechanical and electrical maintenance staffs have originated most of the furnace improvements as a result of their practical operating experience. FURNACE LINES About 50 years ago furnaces consisted of hearths about 11 ft. in diameter, which merged into rather high flat boshes, with no cylindrical section between the bosh and inwall and no cylindrical section at the stock line. Since then the lines of the furnace invariably have included a cylindrical section above the bosh and a cylindrical section at the stock line. Notable increases have been made in both hearth diameters and furnace heights. During the past 10 years hearth diameters in new and replaced furnace stacks have rather consistently fallen within the range of 25 to 28 ft. while their heights have varied between 100 and 106 ft. The lines of most large furnaces using Mesabi ores have followed a fairly uniform pattern (Fig. I) in which the principal dimensions for 25-ft. hearth furnaces are as follows: [Hearth diameter 25 ft. o in. Height of bosh 10 ft. o in. Bosh angle 8 1 ½° Diameter top of bosh 28 ft. o in. Inwall batter per foot 15/16 Stock-line diameter 19 ft. 6 in. Large-bell diameter 14 ft. 6 in. Height from iron notch to top ring casting 100 ft. o in.] In determining the size of a new furnace for the replacement of an existing stack or for an addition to productive capacity, it is not possible to formulate a procedure that can always be followed. Local conditions, requirements as to capacity, available raw materials and prospects for future expansion dictate the size of such proposed improvements or additions. However, where the immediate requirements indicate a stack or furnace of a certain productive capacity, and the future prospects indicate that more capacity can be utilized, it is well to consider building the furnace for the ultimate capacity rather than to install a smaller hearth with provision for future enlargement. The decision to build the larger hearth and stack for the ultimate capacity probably will require no greater initial investment, since the saving in the cost of brickwork will about offset the greater cost of the hearth jacket, tuyere breast and bosh bands. In the meantime, the furnace of larger hearth dimensions, while operating below its ultimate output, will yield a better coke rate and

Jan 1, 1942

By I. Fatt

Relative permeability and relative electrical resistivity curves are obtained for networks of tubes with a tube radius distribution by means of a network of resistors used as an analog model. These curves are similar to those obtained from real porous media. The effects of pore size distribution and network structure on relative permeability and resistivity are demonstrated. INTRODUCTION Study of the dynamic properties of networks of single size tubes in paper IT' of this series has shown that the network model has flow properties similar to those observed on real porous media. The comparison of properties of single size tube networks with those of real porous media cannot be carried far because very few porous media have uniform size pores. The capillary pressure curve from most porous materials such as soil, sandstone, and sintered glass indicate that these materials have pore size distribution similar to those shown in Figs. 5-1, 9-1, and 10-I.† To properly test the network model, it is therefore necessary to compare the dynamic properties of real porous media with those of networks of tubes in which the tube radii are distributed accord- ing to the distributions in the aforementioned figures. A network in which the tube sizes are distributed cannot be treated in the same manner as a network of single size tubes. In the single size tube network, the relation between tube geometry, flow resistance, and tube volume did not have to be known if the assumption was made that whatever relation did exist was the same for all tubes in a particular network. In a network of distributed tube size, the relation between tube geometry and flow resistance must be known or assumed in order to replace the tubes by equivalent electrical resistors. Relation of Tube Geometry to Flow Resistance The interchangeability of tubes and electrical resistors in the network model is possible because of the analogy between Poiseuille's law and Ohm's law. Poiseuille's law for a cylinder is q= pr4/8µl ?P.........(1) where q is the volumetric rate of flow, µ is the viscosity, ?P is the pressure gradient, r is the tube radius, and 1 is the tube length. Ohm's law is I=1/R?E..........(2) where I is the flux and is equivalent to the volumetric rate in Poiseuille's law, R is the resistance, and ?E is the voltage gradient. Both laws give the flux as a function of the potential drop and the resistance of the medium. By analogy then, 1/R=pr4/8µl ?P...........(3)

Jan 1, 1957

By Susan B. Leiter

That oxygen in copper has been a source of trouble is well known and that that trouble has been real in the commercial world has been shown by Fuller.' Moore and Beckinsale's paper2 at the annual meeting of the Institute of Metals in London, 1921, called forth considerable discussion. Prof. T. Turner expressed the opinion that it was not necessary to have cuprous oxide present in sufficiently large quantities to form either globules or seams in order to produce a bad effect if the copper were gassed. This brought up the question of the solubility of oxygen in copper and the authors desired to know whether there were any evidence of such solubility, because their experience was that whenever there was any oxygen in copper it was present in the form of free cuprous oxide, which was practically always in the form of globules. Later Hanson, Marryat, and Ford3 stated that 'for all practical purposes cuprous oxide may be regarded as insoluble in copper. However, they found particles of the eutectic to coalesce to form much larger particles. They suggested that cuprous oxide was actually slightly soluble in copper, for it was difficult otherwise to understand the mechanism by which such coalescence could take place. W. E. Ruder, in discussing that paper, said that his experiments had led him to conclude that a slight solubility must exist to allow for the ready coalescence of oxide particles, but conductivity tests convinced him that that solubility was very small. Nevertheless, there appeared to be a state of admixture of oxide with copper that closely resembled a colloidal mixture which at first was mistaken for a true solution and which usually existed at the grain boundaries. The purpose of this paper is to give the results of some investigations, begun in September, 1921, which would seem to show that although cuprous oxide may be only slightly soluble: (1) this solubility is sufficient

Jan 1, 1926

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 Jack White, Ralph B. Adair

The Mufulira mine in Northern Rhodesia is 13° south of the Equator and at an altitude of 4100 ft above sea level. The concentrator was planned in 1930 to treat about 10,000 tons of ore per day, but before construction work had gone very far the size of the plant was reduced to 1500 tons daily capacity. Then just as the construction was finished in December 1931, the price of copper did not warrant the commencement of operations and it was not until October 1933 that the mine re-opened. Extensions have been made to the plant in 1934, 1935, 1936, 1937, 1940 and finally in 1945. The capacity of the plant when the 1945 extension is completed will be 9500 short tons per day. The various extensions have been carried out with the minimum confusion and with great skill on the part of the designers and the erection engineers. In dealing with the plant in this paper it is proposed to give an outline of the present practice and only to refer to past practice when it is considered of particular interest. Ore Treated The ore consists of fine grained highly siliceous, felspathic and argillaceous quartz- ites, the latter containing graphitic carbon and locally termed graywacke. These rocks are considerably altered near the surface and on the fringes of the ore body. Despite extensive efforts at mixing, both underground and in the crushing plant, many sudden changes of ore take place in the mill feed. The minerals are chalcocite, bornite and chalcopyrite with relatively unimportant amounts of malachite, native copper, azurite, covellite and chrysocolla. Gold is present at about I oz to a thousand tons, and silver at about 2 dwt. per ton. With increasing depth the nonsulphide content or,, as commonly termed locally, the oxide content of the ore is decreasing and is now less than 0.25 pct against a high of 0.77 pct- Crushing Operations The first stage of crushing is done under. ground where the oversize from I2-in. grizzlies is fed to a 56 X 72-in. jaw crusher. At the Selkirk shaft two 10-ton skips deliver the run of mine ore at a rate of 450 tons per hour to the 400-ton capacity shaft bins. One 6 ft wide Ross chain feeder and one locally made air-operated finger feeder feed the two 30-in. McCully crushers. Ahead of each crusher is a 6 X 9-ft spring grizzley spaced at 5 in. on a 35O slope. Neither the Ross chain feeder nor the finger feeder is entirely satisfactory and for the wet, muddy and sticky ore that has to be handled it is planned to replace these with two 6-ft wide apron pan feeders. The McCully crushers deliver a minus 5-in. product, at a.rate of over 500 tons per

Jan 1, 1949

By B. M. Larsen, T. E. Brower

Introduction and Summary By "thermochemical factors" we refer to those variables which affect the net heat which must be put into the bath in order to make a heat of steel from any given set of charge materials. This is admittedly only one phase of the production rate problem. The whole problem includes also consideration of rate of charging, flame radiation intensity, rate of optimum fuel input obtainable without undue damage to the furnace structure and any variations in conditions such as stirring, slag volume or viscosity which affect the rate at which heat can flow down and away from those exposed surfaces where the heat is first received from the flame. Because a given type of charge in a shop is often considered as being nearly constant in both physical and chemical characteristics from one heat to another, and because such a state of affairs may be thought of as resulting in a reasonably constant net heat requirement, this requirement is usually neglected as an invariable, inevitable matter, about which nothing can be done. With normally variable charge, and variable percentages of limestone and cold pig, however, the net heat requirement can be subject to very appreciable change; it may also be affected by such things as the currently popular procedure of blowing oxygen into the bath. To bring the general problem of production rate into better perspective, therefore, it seems worthwhile to try to evaluate the net bath heat requirement and the amount by which it may change through variation in different factors. Because our calculated values of net heat are admittedly uncertain, we have tried to check them in part by statistical data on actual production rates over rather large groups of commercial heats. The results of calculation of net heat requirements in a wide range of actual commercial practices may first be summarized briefly. We find a wide range between the extremes of different practices, as would be expected, with duplex practice (essentially blown metal plus hot metal) having essentially a zero net heat requirement, an all-cold charge practice somewhat over I million Btu per ton of steel and a high hot metal practice about 0.75 million Btu per ton. Over the commercial range of scrap plus hot metal practice, increasing the percentage of hot metal from 40 to 78 pct, with other factors nearly constant, decreased the net heat by only some 5-10 pct. The net heat is increased by about 1.2 pct for each I pct of the metallic charge present as cold pig. Calculated values of oxygen supplied by air varied from about 25 up to 60 lb per ton of steel, and in a 60 pct hot metal practice, an increase from 32 to 52 Ib oxygen from air decreased the calculated net heat from 0.88 to 0.74 million Btu per ton. Use of pure cold oxygen to substitute for about one half of the total charge ore (about 28 Ib oxygen replacing 145 Ib ore per ton of steel) decreased the

Jan 1, 1949

By J. R. Long, C. E. Armantrout, A. H. Roberson, T. R. Graham

The preparation and fabrication of copper-manganese-zinc alloys and the evaluation of their engineering properties have for some time been an integral part of a research program of the Federal Bureau of Mines. In this project, the use of electrolytic manganese, along with high purity copper and zinc, has permitted the preparation of alloys which contain a minimum of impurities which are capable of producing detectable effects in the properties studied. The initial work on the physical properties of wrought alpha solid solution alloys and a general outline of the alpha solid solution area for alloys containing up to 40 pct manganese have been presented in previous reports. 1,2,3,4,5 The evidence accumulated in these investigations clearly showed that additions of manganese to the copper-zinc alloys improve the strength properties of the brasses without seriously reducing their characteristic ductility and that considerable quantities of manganese could be added to the copper-zinc alloys without exceeding the mutual solubilities of manganese and zinc in copper. In continuation of these studies, additional data have been obtained in a more extensive investigation of the phase relationships of the copper-manganese-zinc ternary system. The present report delineates the solid phase boundaries of the ternary system from the copper-zinc binary to the manganese-zinc binary for alloys containing up to 50 pct zinc. Summary The alloys used in this investigation were conditioned by working schedules designed to homogenize the structures prior to heat treatments required for the equilibrium phase sludy. The treated alloys were examined by metallographic methods including hardness and X ray data for confirmation. The composite data of the investigation are summarily presented in a series of isothermal sections of the ternary system at 1100, 1200, 1300, 1200, and 1500°F. The salient features of the system as outlined by these data are: (1) the continuous alpha solid solution which extends across the diagram to the gamma-manganese phase of the manganese-zinc system at temperatures of 1200°F and higher, (2) the beta phase of the copper-zinc system similarly forms a continuous solid solution with its counterpart the beta field of the manganese-zinc binary, (3) at 1100°F (593°C) these alpha and beta fields are greatly restricted by complications arising from the allotropic transitions of manganese and the decreasing solubility of manganese in the alpha solid solution. The alpha + beta fields intersect the alpha + alpha manganese field to produce the beta + alpha manganese field and two adjacent three phase fields consisting of alpha + beta + alpha manganese and gamma + beta + alpha manganese. Typical microstructures representative of the various phase areas at each temperature are also presented. Review of Previous Work The copper-manganese-zinc alloys have periodically been the subject of numerous investigatioris of both prac-

Jan 1, 1950

By C. D. Woodward

PrioR to 1902, the tramming of ore from the stopes to the shafts, in the Butte mines, was done by man or animal power, but the demand for greater tonnage and the need for more improved methods of tramming the ore resulted in the installation of the compressed-air locomotive in a few mines. Some of the objections to animal haulage were thus eliminated, but this locomotive was not generally adopted, because of a number of limiting features. It was superseded by the electric trolley locomotive. The early types of trolley locomotives were not satisfactory from the operators' viewpoint, but they had many economic advantages and after a number of years, in which improvements were constantly made in the structural details, they became dependable, so that the use of animals for main haulage in the mines has now been practically abandoned. There are now operating in the Butte mines of the Anaconda Copper Mining Co., 185 trolley-type locomotives, each of which has replaced five animals. It cost approximately $50 per month to keep an animal, hence the economies that resulted fully justified the expenditure of electrifying the haulage systems. The haulage conditions in this company's mines possess many advantageous features that arc not always found in underground mine workings. The drifts and crosscuts are large, approximately 5 ft. (1.5 m.) wide by 71/2 ft. (2.3 m.) high, and have curves of no less than 18 ft. (5.5 m.) radius; and the roadbeds of the drifts and crosscuts have a uniform grade of 0.5 per cent. toward the shaft, or in favor of the loaded trips. In all of the mines, except two, the track gage is 18 in. (45.7 cm.): and all tracks in the main haulageways are laid with 25-lb. (11.3 kg.) rails. The stations at the shaft are large, well-lighted, clean, and cool. The average temperature of the stations, however, is about 75" F. (24" C.), while the average temperature in some of the drifts and crosscuts is 92" I?. (33.5" C.). As the orebodies lie at varying distances from the hoisting shafts,

Jan 1, 1923

By Arthur Dwight

ARTHUR SMITH DWIGHT, president of the American Institute of Mining and Metallurgical Engineers, was born in Taunton, Mass., on March 18, 1864. He is descended on both sides from early settlers, one of whom was Richard Warren, of the "Mayflower." His forebears included Col. Benjamin Church, Tim-othy Dwight, and the Rev. Jonathan Edwards, third president of Princeton College. Mr. Dwight was graduated in 1882 from the Poly-technic Institute of Brooklyn, N. Y., and three years later from the Columbia School of Mines, with the degree of Engineer of Mines. In 1914, he received the honorary degree of Master of Science from Columbia. On leaving Columbia in 1885, he went to Pueblo, Col., and for thirteen years was associated with the Colorado Smelting Co. Beginning as assayer he rose to be general superintendent. When he gave up the latter position he became connected with several large companies in the mining and smelting of lead, copper and the precious metals in the Rocky Mountain region. This work occupied him from 1897 to 1906, and six years of that time were spent in Mexico. He was general manager of the Greene Consolidated Copper Company at Cananea, Mexico, in 1906, when trouble first developed against the régime of Diaz. A general uprising was planned to seize the mines, and with money and supplies so obtained, carry the revolt through the interior. Mr. Dwight turned his industrial organiza-tion into a military unit almost over night, stemmed the tide of revolution, and had the situation well in hand before the arrival of troops. In the fall of 1906 he returned to New York and began practice as a consulting mining and metallurgical engineer. He next developed important metallurgical patents for the roasting and agglomeration of fine ores, known as the Dwight and Lloyd sintering process, now extensively used ail over the world.

Jan 3, 1922

By Hugh R. Van Wagenen, Allen H. Rogers

There are few natural monopolies comparable with the nitrate industry. Perhaps the only other one is, curiously enough, also an essentia1 fertilizer material, viz., potash, of which the Germans have heretofore held practically a monopoly due to the existence in their territory of the most important known deposits of potash salts. And although nitrates in minute amounts are found in many desert regions, the only deposits capable of being worked commercially exist in Chile. Combined nitrogen in the oxidized form is an essential for plant life. Nature provides it mainly through the agency of nitrogen-fixing bacteria. But where lands are cropped artificially this supply is too small, and gradually the nitrogen supply becomes exhausted. In order to continue farming, it is necessary to furnish a supply of nitrogenous plant food, and this is done by putting on various substances containing combined nitrogen. These consist of various animal wastes, ammonium sulphate, the ammonia of which is obtained in the destructive distillation of coal, and Chile saltpeter. The latter is immediately available as a plant food, the nitrogen being in the required form. The other substances must oxidize before they are available. Resides its use as a fertilizer, Chile saltpeter is the source from which the bulk of the nitric acid of commerce is derived. The use of nitric acid in the manufacture of almost all modern explosives is, of course, well known. Importance of the Nitrate Industry Chilean nitrate, the existence of which was first mentioned in 1809, is said to have been first exported in 1830. Only a few thousand tons per annum were exported for some years, but the amount gradually increased until, in 1879, when the Chile-Peruvian war began, the export amounted to about 300,000 tons. This nitrate was largely produced from the Province of Tarapaca, until then, Peruvian territory. By the terms of peace with Peru in 1884, this province, as well as Tacna, became Chilean. The Bolivian Province of Antofagasta was also acquired as a result of this war, and thus Chile, with the deposits in her own territory, acquired control of the whole supply of nitrate. At the present time, exports are approximately 3,000,000 metric tons per annum,. having a

Jan 1, 1918

By C. Kolm, E. P. Warekois, S. A. Kulin

MUCH insight has been gained into the nature of the cold-worked state of metals in recent years through the use of modern X-ray techniques. These methods have revealed the existence of stacking faults together with regions of high internal strain and have provided means of measuring the atomic perturbations in plastically deformed metals. In view of the recent increased interest in the solid state, it is desirable to extend these techniques to the study of lattice imperfections introduced into semiconductors during plastic deformation. It is of particular interest to compare the state of imperfection sustained by metallic bonding with that sustained by the covalent bonding found in semiconductors. A knowledge of the imperfections which can exist in semiconductors is important from both a theoretical and a practical point of view since they can greatly influence many of the physical properties. In order to determine the possible existence of stacking faults in covalently bonded structures, precise measurements were made of the diffracted peak positions of plastically deformed germanium, gallium antimonide, and indium antimonide. These measurements were based on the theoretical treatment of Paterson1 and are similar to those employed by Warren and warekois2 in their studies of deformed a brass. In addition, diffraction peak profiles were measured on the annealed and plastically deformed materials in order to obtain information concerning the distribution of internal strains through the use of the Fourier methods developed by Warren and Averbach.3 EXPERIMENTAL PROCEDURES AND TECHNIQUES Because of the room-temperature brittleness of the semiconductors studied, it was necessary to plastically deform the materials at elevated temperatures. The brittle-ductile transition temperature ranges of GaSb and InSb are sufficiently low to permit hot-filing operations. Therefore, high-purity, polycrystalline GaSb and InSb were filed in an argon atmosphere at 400' and 300°C, respec-

Jan 1, 1959

By K. Torssell, U. Lindborg

The kinetics of precipitation deoxidation is considered from a theoretical point of view. The size distribution and the total content of deoxidation products are estimated statistically as a function of time, taking into account Stokes and gradient collisions between the particles and separation at the top surface of the bath. The assumption is made that two particles coalesce into one larger particle as a result of a collision. General expressions are derived and calculations are carried out numerically for the case of silica particles in liquid iron. The analysis predicts a three-stage behavior for the removal of oxygen, an incubation stage, a stage of rapid separation, and a slow final stage where the content approaches the equilibrium value. The agreement with experimentally determined size distributions and deoxidation times is considered to be good. A quantitative estimation of such growth mechanisms as diffusion from the melt and redistribution of oxygen from small particles to large ones shows that these latter mechanisms cannot explain the experimentally observed gvowth of inclusions. This also indicates that collisions provide the important growth mechanism. OXIDE inclusions precipitate when a deoxidizer like silicon or aluminum is added to a steel bath. The inclusions grow and the large particles tend to separate from the bath. For each type of oxide the growth determines the sizes of the final inclusions as well as the total inclusion content of the steel. The mechanism of growth is controversial, however. It has been suggested that an inclusion grows principally by diffusion of atoms through the melt to the inclusion particle or principally by collisions and coalescence with other inclusions. Diffusion growth is always present to some extent but recent experiments and calculations by Torssell,' Kniippel et 'a1.,2 Sano et al. and Miya-shita4 indicate that collisions may be more important than previously realized. A detailed analysis has so far been lacking. The present paper is a quantitative, statistical analysis of the growth and separation of inclusions and is based on a collision theory. Nuclea-tion is not considered. The numerical estimates are based on the experimental conditions of Torssell's' investigation and comparisons are made with his observations. Torssell' studied the growth and separation of silica particles in liquid iron. Samples were taken from a 0.6 kg iron bath at various times after the addition of silicon. By a particle-counting technique developed by Bergh and Lindber~the size distribution of the inclu- sions was determined. The number of particles at the first sampling, 10 sec after silicon addition, was of the order of 3 x lo7 to 10' per cu cm, the largest particles having a radius of 2 to 4 pm. The volume fraction was 0.001 to 0.004; i.e., the dispersion was very dilute. During subsequent holding the largest particles increased their radius by a factor of 10 after about a minute, and the whole size distribution was displaced toward larger values. These results were obtained with allowance for precipitation of the equilibrium concentration of oxygen during solidification. The bath contained less than 0.01 pct of C. Figs. 1 and 2 show the typical appearance of the inclusions. Most particles are very closely spherical and appear to have been liquid or semiliquid in the melt. The observed number of inclusions, about 5x 10' per cu cm, is of the same order of magnitude as found by ~er~h.' This is a large value. It follows that the diffusion distances are very short and that the precipitation

Jan 1, 1969

By A. D. Schwope, L. R. Jackson, A. M. Hall

IN the course of an extensive investigation of the comparative properties of several types of copper, data were obtained on the cold working and subsequent recovery and recrystallization of the copper. In this paper, relations between the degree of cold work and the course of recrystallization are developed. In particular, it is shown that the course of recrystallization over long periods of time and at low temperatures can be predicted with reasonable accuracy from short-time high-temperature recrystallization data. MATERIALS USED IN THE INVESTIGATION Three types of copper were used in this investigation; these were tough pitch, OFHC, and OFHC copper with 15 oz per ton of silver added identified herein as Lots C, D, and F, respectively. The material was supplied by the American Metal Co. Ltd., and processed by the Rome Cable Co. The analyses of the three types of copper are given in Table 1. Originally, it started as wire bars 4 X 4 X 54 in. These bars were heated to 871°C in air and hot rolled to 3/8 in. rod. This rod was cold drawn to 0.204 in. rod (70 pct reduction) in three passes and annealed at 427°C for 4 hrs. A portion of the 3/8 in. rod was saved for more detailed cold-drawing experiments. Starting with the annealed 0.204 in. rod, hard-drawn wires were produced by cold drawing to 0.081 in. wire in 7 passes (84.4 pct reduction in area). Half-hard wires were made by cold drawing the 0.204 in. rod to 0.102 in. wire, (75 pct reduction) in 6 passes and annealing at 427°C for 4 hrs. This annealed wire was then drawn to 0.081 in. wire, (37.1 pct reduction) in 2 passes. Square rod was made by hot rolling wire bars to 9/16 in, rod in 8 passes. This rod was then cold drawn to 0.445 in.-diam rod and annealed for 3 1/2 hrs at 538°C. It was then cold drawn to 0.325 in. rod and again annealed at 538°C for 3 1/2 hrs. Hard square rods were then made by cold rolling this material to 0.257 X 0.257 in. rod, a reduction in area of 20.5 pct. Half-hard square rods were made by cold rolling to 0.268 X 0.268 in. square, annealing for 332 hrs at 538°C and cold rolling to 0.257 X 0.257 in., a reduction of 8.5 pct. Soft wire or rod was made from all types of copper by annealing the hard-drawn material at 343°C for 3 hrs in steam. The grain size of the annealed 0.081 in. wire varied slightly among the three lots: from 0.015-0.025 mm in the silver-bearing OFHC to 0.035-0.045 mm in the OFHC copper. The annealed 0.257 in. wires were more uniform in grain size, averaging about 0.035-0.045 mm. Representative structures are shown in Fig I. EFFECT OF COLD DRAWING AND TENSILE STRAIN ON STRENGTH OF COPPER Conventional tensile tests were performed on the three types of copper in the various degrees of hardness described above. Results of these tests are tabulated in Table 2. The results in Table 2 are

Jan 1, 1947

By Arthur Fleischer

The Kalunite process+ for the production of metal-grade alumina from alumina-con-taining ores is applicable, considered from a general point of view, to any aluminous raw material that can be converted to potassium alum or equivalent normal alum. This result of modern technology has been the subject of a continuous study and development since 1929, on a laboratory and test-plant scale, with initial emphasis on the utilization of alunite as the raw material. The research and developmental program was carried out by the Kalunite Company and its successor, Kalunite, Inc., an affiliate of the Olin Corporation of East Alton, Illinois. The process is now approaching the time for a major test in its history with the completion of construction of a plant having a capacity of IOO tons of alumina per day in Salt Lake City for the conversion of Marysvale, Utah, alunite ores to alumina and potassium sulphate. The Salt Lake Alumina Plant is a Defense Plant Corporation project. Production of Aluminum: The known existence of alunite deposits, especially in the Marysvale district, furnished the motive for the original inquiry into the utilization of this raw material for aluminum production. The deposits in this region were actively explored during World War I and utilized for the production of potassium sulphate, an essential fertilizer, of which a shortage of monumental proportions then existed. Up to the twentieth century—for alunite is a mineral with an ancient history—it was used in Europe and in China as a source of potassium alum. It never had been used successfully in this country as a source of oxide for reduction to metal. Although the known reserves of this ore, which undoubtedly will be greatly expanded with a commercial outlet for this ore, are recognized to be sufficient for only a part of the present-day needs of aluminum, it has a definite place in the aluminum industry. Academically it points the way for future raw materials. The aluminum industry has undergone a remarkable growth in the past few years as a result of defense and war requirements. Its expansion in many ways has been beyond belief and prediction, both in volume and location. This wartime status of the industry has accelerated the consumption of bauxite to such an extent that a re-evaluation of the raw material reserves for the future peacetime industry and for eventual wartime reserves is seemingly of concern. The generally accepted picture of bauxite ore reserves in the United States, especially in raw material suitable for treatment by the Bayer process, focuses attention on other possible sources of raw material of metal-grade oxide. The perspective for the development of a suitable process may have changed in the interim since the original work by Kalunite, but the ultimate goal is the same.

Jan 1, 1944

By Walter Crafts, C. M. Offenhauer

IN the course of study of the heat-treatment of low-alloy steels, the behavior of alloy carbides at subcritical temperatures was found to vary from that indicated by published investigations. In order to establish the ranges of formation of carbides in low-chromium steels, a series of steels containing up to 0.60 per cent carbon and 7.5 per cent chromium has been investigated with respect to the type of carbide formed after quenching and tempering at subcritical temperatures. The types of carbide formed as products of austenite transformation to pearlitic and pseudomartensitic structures have also been determined. There have been numerous investigations of the carbides in chromium steels and diagrams of the iron-chromium-carbon system.1 Westgren, Phragmén and Negresco2 identified the following carbides in chromium steels: [Cementite Fe3C (containing up to about 15 per cent Cr) Trigonal carbide Cr7C3 (containing up to about 55 per cent Fe) Cubic carbide Cr4C (or Cr23C3) (containing up to about 25 per cent Fe) Orthorhombic carbide . Cr3C2 (containing only a few per cent Fe)] The most complete information on the iron-chromium-carbon system was supplied by Tofaute, Sponheuer and Bennek3 and by Tofaute, Küttner and Büttinghaus.4 By means of dilatometric and microscopic studies, sections of the diagram were established. This diagram showed the presence of the special carbide Cr7Ca in steels containing about 2.5 per cent to 12 per cent chromium in low-carbon steels and from about 5 to 20 per cent chromium in r per cent carbon alloys from A1 to room temperature. The present investigation has shown that a carbide inversion from Fe3C to Cr7Ca occurs in chromium steels containing more than about 1 per cent chromium after hardening and tempering at subcritical temperatures above about 500°C. The type of carbide observed to be more stable in quenched and tempered specimens was also found to be produced by direct austenite transformation in corresponding ranges of temperature and composition. EXPERIMENTAL PROCEDURE The steels used in these experiments were made in magnesia-lined crucibles in high-frequency furnaces and were poured into 2-in. ingots. The ingots were forged into 1-in. round bars, and all heat-treatments were conducted on specimens of this section .size. Sections of the bar stock 8 in. long were hardened in air, oil or water depending on the composition, after heating to a temperature sufficiently high to dissolve the carbides. The low-carbon and low-chromium steels were not entirely martensitic after quenching, and contained some ferrite and pseudomartensite. No pearlite was observed in the microstructures after auenchine. The quenched bars were cut into

Jan 1, 1942

By A. W. Schlechten, C. M. Hsiao

The apparent vapor pressures of a number of metal sulphides were determined by measuring their rate of weight loss when they were heated under vacuum. The calculated pressures are due in some instances to the volatility of the sulphide and in others to the decomposition pressure. FIE direct reduction of metallic sulphides, as in the precipitation method for lead or antimony, is not a widely used process today. However, it might be employed for the production of a number of metals if the operation were carried out under reduced pressures. Two general procedures are possible; the reducing agent could form a stable nonvolatile sulphide from which the valuable metal could be removed by volatilization or liquation. The other approach would be to choose a reducing agent which would form a sulphide that could be volatilized away from the valuable metal. A vacuum operation would serve to protect the sulphides and metals from oxidation and would increase the evaporation rates. A related process is the separation of metallic sulphides by selective volatilization either at atmospheric pressure or under vacuum. This procedure is already used commercially for the elimination of lead and cadmium as PbS and CdS from zinc calcines; it might well have other applications. To predict such processes it is necessary to know the relative volatilities of the metallic sulphides and to know whether they volatilize as sulphides or whether the predominant weight loss is due to decomposition. Such data would also be of value in studying problems such as the use of sulphides for refractories, as described by Brewer,] or in the evaluation of the theory of ore deposition from the vapor state, as proposed by Brown.' Qualitative statements concerning the volatility of metallic sulphides can be found frequently in the literature and are well summarized by Mellor, but accurate determinations of rates of evaporation or vapor pressures are very scarce. Kelly" lists vapor pressure data only for PbS; his reference being to the work of Schenck and Albers,4 who measured the vapor pressure of PbS by a dynamic method between 850" and 995°C. More recently Veselovskii5 has determined the vapor pressures of the sulphides of antimony, lead, cadmium, and zinc at temperatures ranging from 360" to 1000°C using Knudsen's method. A second Russian worker, Pogorelyi,6 determined the vapor pressures of CdS and ZnS at temperatures from 900" to 1250°C. The results obtained by these workers are shown in subsequent graphs in comparison with the data of this paper. Brewer and coworkers1 have studied some of the metallic sulphides to determine their suitability as refractories in vacuum. Veselovskii's determinations on PbS checked well with those of Schenck and Albers, and his determinations of CdS check almost exactly with Pogo-relyi. For the vapor pressure of ZnS the data of Veselovskii and that of Pogorelyi are in fair agreement, as shown in Fig. 1, but it should be pointed out that Lumsden7 has discovered that the equation given by Veselovskii for the vapor pressure of ZnS: - 14,200 log P9.495 is in error by a factor of ten when compared to the experimental data. In contrast with the scarcity of data on vapor pressures, the decomposition pressures of many metal sulphides have been determined and are summarized by Smithells.8 Theoretical Considerations The experiments described in this paper consisted of determinations of the rate of weight loss of certain metallic sulphides under very low pressures at different temperatures. These data plus observation and analyses of the products reveal the mechanism of the weight loss and also provide a basis for the calculation of the vapor pressure or apparent vapor pressures of the sulphides.

Jan 1, 1953

By Christopher H. Bierbaum

The first significant fact observed in the study of bearing metals is that not a single pure homogeneous metal has given satisfactory service; all bearing metals are alloys made up of two or more phases; that is, they consist of hard and of relatively soft microscopic particles intimately mixed. The function of the hard particles, or bearing crystals, is to support the load and resist the wear when actual metallic contact exists between the bearing surfaces. The functions of the softer particles are to allow the harder particles to adjust themselves to the surface requireinents of the journal and to wear down slightly below the surface of the harder, forming slight depressions on the apparently smooth wearing surface of the bearing, in which some of the lubricant is held when the bearing surfaces are brought into contact with each other. It is this characteristic of certain alloys to form these slight depressions, and thus provide the means for retaining a lubricant, that characterizes them as true bearing metals; in fact, a bearing metal has been defined as "an alloy that is capable of retaining a lubricant upon a bearing surface."' The extent to which the lubricant can be so held determines the most valuable characteristic of an alloy as a bearing metal. An alloy which, perhaps, most characteristically represents a bearing metal is the composition of copper and tin that contains sufficient tin to produce the tin-copper eutectoid, or delta crystal. The depressions worn upon the surfaces of the softer crystals of the teeth of a motor-truck worm wheel, made of an ll-per cent. tin bronze, in many cases were from 5 to 6 microns in depth; all other conditions remaining constant, this depth of wear increases with an increase of working pressure. This copper-tin bronze contains intercrystalline shrinkage cavities, which also

Jan 1, 1923

By Lester C. Uren

Petroleum occurs, in nature, as a fluid saturating the pore spaces between the grains of porous rocks or aggregations of rock particles such as sand, sandstone, conglomerate, shale, limestone, etc. The oil, under the influence of gas pressure, hydrostatic pressure, gravity, earth pressure, and, perhaps, other natural forces, is caused to flow through the porous "reservoir rock1' into wells penetrating the stratum in which the oil occurs. The principal moving force is the pressure of dissolved or occluded natural gas within the oil, though this force is assisted by gravity and by the hydrostatic or buoyant pressure of ground water about the edges of the "pool." The wells, providing outlets to the surface, are centers of reduced pressure and the flow of rock fluids into a particular well is usually an expression of the difference in pressure existing between the space within the well and that of the stored oil within the reservoir rock. The greater this differential pressure, the more rapidly will oil flow from the source rock into the well. Opposing movement of the oil from the reservoir rock into the well are certain natural forces related to the rock structure, such as pore friction and capillarity, and certain others related to the physical properties of the oil, such as viscosity and adhesion. The differential pressure between the well and the boundaries of the area drained by it must be sufficient to overcome the forces opposing flow if there is to be movement of oil into the well. If by any device the resistance to movement of the oil may be reduced, the oil will flow into the well at a more rapid rate and the effective area of drainage will be increased.

Jan 1, 1925

By John D. Sullivan, Edwin J. Rogers, Chester R. Austin

The problem of making a building unit combining the necessary physical and mechanical properties and good thermal insulation has been foremost in the minds of architects and ceramic and construction engineers for many years. This paper presents the results of studies on thermally expanding shales or clays to produce lightweight cellular products suitable for making building units. An expanded clay block suitable for building purposes should be large enough qo that substantial savings may be effected in labor costs in laying the wall. The permeability should be low and it should have sufficiently good "dry-wall" characteristics to permit exposing the exterior surface to the elements, and to permit plastering directly the inside wall surface. The thermal conductivity should be low and the mechanical properties should be adequate. Obviously, a unit possessing satisfactory qualities for constructing an - outside wall would be satisfactory for interior walls and for back-up purposes. The results of studies on bloating various shales or clays† and the properties of the expanded products are reported. In another paper1 basic factors involved in bloating of clays are discussed. Manufacturers of ceramic products, partitularly structural clay, may encounter bloating of the ware during burning, and precautions must be followed to avoid this phenomenon. About 1927 the C. F. Burgess Laboratories, Madison, Wis., while carrying on an investigation for the American Face Brick Research Corporation, conceived the idea of intentionally bloating clay while holding it in a restrained condition, with the hope of producing a unitary cellular mass. Work was carried on until about 1931, when studies were terminated because of business conditions. These studies were continued later by The Western Brick Co., Danville, Ill., which developed a process of "inwardly expansive bloating."² The major purpose of the latter investigation was to produce back-up tile to compete with concrete blocks made from Haydite or cinder aggregate. Haydite is a light-weight aggregate formed by heating certain clays or shales rapidly in a rotary kiln. While the investigations at the C. F. Burgess Laboratories or at Western Brick Co. were not carried far enough to lead to the commercial production of material for the construction of walls, particularly outside walls, they showed that certain clays could be thermally expanded and that it was possible to produce a material of low permeability with a large percentage of the total voids or cells closed. commencing in 1939, the Ozark Chemical Co. sponsored a research program at Battelle Memorial Institute for the Purpose Of determining whether it is technically feasible to make thermally expanded building units, and specifically to get answers to the following questions:

Jan 1, 1942

By W. H. Newhouse

During the past few years the writer has been impressed by the close relation of many epigenetic orebodies with anticlinal structures. In the literature on ore deposits there is occasional mention that an oreshoot or district is on an anticline, but in most of the descriptions no weight or significance is attached to the relation, and usually the fact is concealed in a mass of structural detail. A few writers have stressed the relationship in a few districts or on a certain type of deposit. Church, Spurr, Butler, Stahl and Schuette have called attention to certain features, but the general extent of such a correlation has not been made known in any publication that the author has seen. A recent article1 on the localization of ore deposits, by well-known geologists, does not consider this common association. The author has seen in the field a number of the structural features described, and in addition has made a fairly complete review of the literature. This paper presents enough of the examples found to show the frequency of the relation to anticlines, and since only a few deposits on synclines are known, all of these of any importance of which the writer knows are mentioned. With certain qualifications which are discussed later, epigenetic ore deposits of replacement or vein type are mostly found where local upwarps of the earth's crust have taken place. Where formations antedating the ore deposits are present in the proper attitude to demonstrate vertical warping (i. e., more or less horizontal beds) the structural feature on which a mineral district, or mineralized area is located is almost always anticlinal, or domelike in nature. Some or even most of the ore deposits in a given district may be on the flanks of the upwarp, but few major districts are located definitely on downwarped areas. Synclinal basins within certain limits of size appear to be unfavorable to the type of fracturing that admits ore-bearing solutions. Replacement orebodies frequently are localized in small anticlines or domes, the size of the anticline or roll often being more or less commensurate with that of the enclosed oreshoot. This feature certainly ranks

Jan 1, 1931