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By Karl Fetters, John Chipman

The relationship between the composition of the slag and that of the underlying metal during the refining of a heat of liquid steel may best be studied in the light of the two broad physicochemical concepts of equilibrium and reaction rate. Actual steel-making processes, typified by basic open-hearth practice, involve such complexities of operating variables that it is impossible to distinguish with any degree of certainty between the general limiting conditions imposed by chemical equilibrium and the effects associated with rates of diffusion or of chemical reaction. Further advances in the physical chemistry of steelmaking will depend upon our ability to distinguish clearly between these two kinds of effects, and the experimental work that must be done falls naturally into two classifications. The first is the study of chemical equilibrium that cannot be carried out with assurance under operating conditions but must be done in the laboratory. The second is the -subject of rates of reaction and diffusion and the mechanism of the process as a whole, which can best be studied under operating conditions. The latter is not entirely independent of the former, since its interpretation often requires a knowledge of the equilibrium state. It is the purpose of this and of several papers that will follow to present the results of labora- tory investigations of equilibria involving liquid steel and slag. Open-hearth slag is a complex mixture containing at least eight major components and perhaps twice as many whose influence may be classified as probably minor. It is not surprising that progress toward a complete understanding of such a material at high temperatures has been slow. Attempts to apply the established principles of physical chemistry to the behavior of the individual components of this mixture have been beset by an almost complete lack of data on its chemical properties in the liquid state. This has necessitated the adoption of various methods of approximation based upon such assumptions as, for example, that for a given component the ratio of its mol fraction in the slag to that in the metal is a constant, or that the molecular composition of the liquid slag is the same as its crystalline constitution after solidification. From the thermo-dynamic viewpoint, such assumptions are merely useful dodges, which enable one to hazard a guess as to the magnitude of the more fundamental quantities, the chemical potentials and activities of the components of slag. The problem of determining the activity of each substance in an eight-component svstem seems too complex to be undertaken without the aid of generalizations derived from experimental data on similar systems containing a smaller number of components. Accordingly, it was planned in the present investigation to study the equilibrium of molten iron with the simplest

Jan 1, 1941

By M. L. Holzworth, Joseph C. Kremer, Paul A. Beck, L. J. Demer

FOR alloys which are in practice heat treated to obtain increased strength, such as steels, duralumin, copper-beryllium, and others, the treatment usually involves heating to a relatively high temperature. At such temperatures the grain size of the product is largely determined by grain growth. Even in metals and alloys annealed merely to relieve work hardening, recrystallization is generally followed by a certain amount of grain growth. Thus, effective grain size control, which is often of great practical importance in manufacturing processes, depends on the grain growth behavior of the material used. Despite its importance, grain growth has been the subject of few investigations of a fundamental nature. The term "grain growth" has been used to designate a group of related, but distinctly different, phenomena. The two most important and best known of this group are illustrated by the following example. Curve a in Fig r shows the increase of the average grain size of a copper-beryllium alloy, containing 2 pct Be and 0.15 pct Co, with increasing annealing temperature. The time of annealing was 2 hrs. The grain size was quite uniform in all specimens. The results of a similar experiment with an alloy containing 2 pct Be and 0.31 pct Co are shown by curve b. It is seen that for any annealing temperature below T. the grain size was smaller than in the previous case. Grain growth became slower with the higher Co content. This "inhibiting" effect of the higher Co addition was associated with the appearance in the microstructure of fine, light blue particles of the CoBe phase. Up to temperature T. the structure of the inhibited alloy (curve b) was just as uniform as the structures represented by curve a. However, after annealing at T, or at higher temperatures, the inhibited alloy showed some extremely large grains (much larger than the grain sizes developed by the uninhibited alloy with low Co content) mixed with the small grains according to curve b. The presence of these mixed or "duplex" structures is indicated in Fig 11 by the vertical lines branching off curve b. The type of grain growth occurring in uninhibited Cu-Be alloys (curve a) has has been most frequently and best investigated in brass. This type has been designated as "normal grain growth," while the grain growth phenomena occurring in inhibited materials were, at times, referred to as "abnormal grain growth." However, since the latter term has been applied occasionally to the phenomenon of critical recrystallization, which also results in large grains although by an entirely different mechanism, in the present paper a different nomenclature has been adopted in order to avoid confusion. Typical of the grain growth in uninhibited metals and alloys is the continuous

Jan 1, 1947

By I. J. Demer, M. L. Holzworth, J. C. Kremer, P. A. Beck

For alloys which are in practice heat treated to obtain increased strength, such as steels, duralumin, copper-beryllium, and others, the treatment usually involves heating to a relatively high temperature. At such temperatures the grain size of the product is largely determined by grain growth. Even in metals and alloys annealed merely to relieve work hardening, recrystal-lization is generally followed by a certain amount of grain growth. Thus, effective grain size control, which is often of great practical importance in manufacturing processes, depends on the grain growth behavior of the material used. Despite its importance, grain growth has been the subject of few investigations of a fundamental nature. The term "grain growth" has been used to designate a group of related, but distinctly different, phenomena. The two most important and best known of this group are illustrated by the following example. Curve a in Fig I shows the increase of the average grain size of a copper-beryllium alloy, containing 2 pct Be and 0.15 pct Co, with increasing annealing temperature. The time of annealing was 2 hr. The grain size was quite uniform in all specimens. The results of a similar experiment with an alloy containing 2 pct Be and 0.31 pct Co are shown by curve b It is seen that for any annealing temperature below T, the grain size was smaller than. in the previous case. Grain growth became slower with the higher Co content. This "inhibiting" effect of the higher Co addition was associated with the appearance in the microstructure of fine, light blue particles of the CoBe phase. Up to temperature T, the structure of the inhibited alloy (curve b) was just as uniform as the structures represented by curve a. However, after annealing at T or at higher temperatures, the inhibited alloy showed some extremely large grains (much larger than the grain sizes developed by the uninhibited alloy with low Co content) mixed with the small grains according to curve b. The presence of these mixed or "duplex" structures is indicated in Fig I by the vertical lines branching off curve b. The type of grain growth occurring in uninhibited Cu-Be alloys (curve a) has been most frequently and best investigated in brass. This type has been designated as "normal grain growth,'' while the grain growth phenomena occurring in inhibited materials were, at times, referred to as "abnormal grain growth." However, since the latter term has been applied occasionally to the phenomenon of critical recrystallization, which also results in large grains although by an entirely different mechanism, in the present paper a different nomenclature has been adopted in order to avoid confusion. Typical of the grain growth in uninhibited metals and alloys is the continuous

Jan 1, 1949

By M. Cohen

THERE seems to be a natural urge for the human mind to wonder about the beginning of things. When an explosion occurs, we immediately inquire "what set it off?" If a person contracts a disease, we are likely to ask "how did it happen?" On a much loftier plane, when we reflect about the universe, there is the inevitable question "what, or rather Who, started it all?" In principle, these varied queries have at least one attribute in common: they are attempts, whether earnest or casual, to search out the origin of events in nature. Accordingly, they involve not only scientific, but philosophical and even re1igious matters of deep concern. It is evident that, in a broad sense, the phenomenon of nucleation is enmeshed in this enticing concept of "the beginning", but we must extract the scientific component of the problem for our present purposes. Nucleation, as in the case of phase transformations, is best regarded from the standpoint of kinetics. There are then two main steps, which may come in either order: (a) Experimentally, one attempts to measure the frequency with which transformation centers spring into existence; and (b) theoretically, one seeks a model that will account for this observed birth-rate. Temperature, composition, strain, and prior history are some of the important variables that must be considered both experimentally and theoretically when dealing with nucleation in the solid state. Such interaction of theory and observation is an integral part of science in general, but it is particularly significant in the nucleation problem because the very beginning of a phenomenon invariably occurs on too localized a scale in both space and time to be detected with available techniques. Thus, there is little hope of making direct measurements on the nucleus during its birth or to ascertain the exact nature of the process; one can only infer the details of nucleation from the model whose predicted behavior seems to harmonize best with the measured rate of nucleation and its dependence on known parameters. In the field of solid-state nucleation, both theory and experiment call for much ingenuity, but somehow the conceptual schemes have spawned faster than they can be tested by observation. This is not to say that there are many basically new ideas in modern nucleation theory; rather, as we shall see, it is because the required fine-scale measurements are of immense technical difficulty. Quite likely, some of the nucleation models existent today have survived only because of the latitude permitted by meager data. There is great need to bring theory and experiment into better balance in this important area of physical metallurgy. Although one can

Jan 1, 1959

By William Kelly

I AM-glad to have the opportunity at this time to say that I consider it a very great honor to be elected President of the American Institute of Mining and Metallurgical Engineers. It fulfills the proudest hopes of my ambition. There is, ,however, one drawback to my personal gratification-a feeling of unworthiness to have my name placed on the list with former Presidents of the Institute, with the brilliant Raymond who guided our society for so many years, with the versatile and lovable James Douglas, my first employer and my friend, a most generous benefactor of our Institute, with the skilful Holley, who gave to the manufacture of steel in this country, its first great impulse, to mention only three of the accomplished men who have preceded me. I assume that the honor of my being elected President of the Institute is not merely a personal one but that it should be considered a tribute to the wonderful progress in the art of mining, both underground and in open pits, and in the beneficiation of native copper and iron ores, which have been shown in the Lake Superior District and also a recognition of our members there and elsewhere who are living at the mines and directing the operations, upon the success of which the whole mineral industry depends.

Jan 1, 1924

By Charles E. Locke

IN gathering material for this review the aid of the individual members of the Milling Committee was invoked and the assistance received is hereby most grate- fully acknowledged. The replies were much alike; almost everyone stated that in 1932 his operations had been cur- tailed or stopped entirely, that the only activity and progress were in milling gold ores, and that the Hadsel mill' looked like a coming machine in the crushing and grinding field. However, further inquiry and search have shown that the year was not quite so barren of developments as the foregoing statement would indicate.

Jan 1, 1933

Beverley S. Randolph, Frostburg, Md. (communication to the Secretary): It has always appeared to me that each coalseam has its peculiar character or habit, due to the conditions of its formation, by virtue of which it is either persistent or variable in its section over extended areas. One seam will hold its thickness, chemical character, number and position of partings, beds of slate, etc., over a large area, while another will be found to vary in some of these characteristics every few feet. As the position of the outcrop is an accident of the topography, depending on folding and erosion which have taken place since the bed was formed, no one opening in the outcrop, or, in fact, anywhere else, can supply reliable evidence as to the general character of the seam. To determine the character of an untried seam, a number of sections are necessary from widely separated points, in order to show such variations as may exist. Should material variations be developed, more numerous sections are necessary, in

Jan 1, 1901

By Thomas T. Read

ONE of the major purposes of the Institute is to "maintain ... a library of books relating to subjects cognate to the sciences and arts of mining and metallurgy." In conformance with this purpose the Institute maintained its own library for a number of years until 1912 when it was merged with the libraries of the other Founder Societies. At that time the A.I.M.E.'s share of operating expenses was wholly covered by the income from a $100,000 gift from James Douglas. But interest on the Douglas Library Fund has declined from 51/2 per cent to 31/4 per cent; the library has grown from some 50,000 volumes in 1913 to more than 170,000 in 1945, with consequently increased costs; and its costs nave otherwise risen. The Institute today contributes to the library annually about 65c per member, of which about 25c is income from the Douglas Fund, or a net charge, from regular income, of 40c per member. The annual library budget runs about

Jan 1, 1946

By AIME AIME

MOST of us are far .from home, and yet our Japanese hosts- have made us feel very much at home. Here in the Orient we engineers are .learning a new meaning for the word "orientation"- hereafter that engineering term will be a synonym for gracious hospitality, and "to orient" will mean to turn a whole country over to the World Engineering Congress. Mere geographic distance is no longer able to separate nations, for the conquest of distance is one of the triumphs of 'modern engineering. We of the Americas are fortunate in the position of our continents: with their shores lapped by the waves of two oceans, we face' two great civilizations, the' Occidental and the Oriental, and thus we can share the intellectual resources of these two older cultures.

Jan 1, 1929

By REED H. HYDE

IN these days of low metal prices and difficult marketing conditions, any treatment that will improve the grade of a product is of interest, particularly when the operation involves little or no addition to the total cost and may even result in a marketable by-product. Such a' combination of circumstances exists, in some cases, in the zinc industry, where it has been found that certain impurities can be removed from .the ore during the Dwight-Lloyd sintering operation, previous to reduction to metal. Consequently it is not surprising that zinc smelters having these sintering machines are paying particular attention to this phase of the operation. Loss of zinc as fume is very low under the conditions obtaining in sintering zinc ores, but impurities such as cadmium and lead are more readily fumed off and it is on this fact that the purification is based. As a result of preferential volatilization of these impurities a sintered product' is made from which purer zinc metal or oxide can be produced, while the fume may be collected and treated to recover the impurity metals. To be effective the operation must be carefully conducted, but no special equipment other than that of a well designed Dwight. Lloyd plant is needed.

Jan 1, 1931

By L. F. Reinartz

FROM the earliest times when our prehistoric ancestors laboriously fashioned crude tools and weapons from meteoric iron until our day when we manufacture steel in 150-ton open-hearth furnaces, the production of iron and steel has played a dramatic and important role in the development of civilization. Progress in the science of refining iron ore into iron and steel was painfully slow for many centuries. The keen scimitars of Damascus, the broadswords of the English knights, the coats of mail of French knights, and the Iron Pillar of Delhi are well¬known examples of medieval metallurgical technique. Expense and the scarcity of raw materials originally limited the distribution of iron and steel products. It was not until the nineteenth century that a determined effort was made to adapt the use of steel to peaceful pursuits. The spectacular and rapid strides made in the manufacture of steel during the last hundred years were hastened by the invention during the decade 1860 to 1870 of two great steelmaking processes-the Bessemer and the open-hearth process.

Jan 1, 1936

By C. H. Mathewson

UNFORTUNATE evasions of metals specifications recently brought to public attention through news items and editorials have caused executives of at least two great corporations to set up defensive procedures and to re¬affirm the patriotic purpose and conscientious effort of their plants in this battle of production. Whatever the exact conditions affecting these cases, in which the public interest has been safe-guarded by vigorous action, my reaction to such offenses in general is a feeling that they arise from the pressure and limitations that afflict our overextended war effort and that inevitably there will be more of them, doubtless more and more expertly conceived and less and less subject to detection as simple faked, or substituted analyses or tests. To the ladies, who doubtless are already beginning to ac¬quire a sense of painful resignation to a dry technical talk, may I say that the cookbook is full of specifications which customarily are varied within rather wide limits but it is generally recognized that the proof of the pudding is in the eating without regard to its exact composition or some scientific evaluation of its texture.

Jan 1, 1943

By JAMES J. DOUGHERTY

THIS paper is a general discussion of developments in our reverberatory smelting practice during the past five years. It deals briefly kith changes in furnace types ; changes in furnace feed ; de- crease in the amount of slag produced; relation of slag assays to copper loss in the slag; increase in the grade of matte and furnace capacities. The reverberatory is but one unit in the copper plant ancl 'any discussion of it must be considered with reference to the other units and to the plant as a whole. A change in the grade of concentrates at the concentrator puts an entirely new aspect on reverberatory smelting and, likewise, a change in the grade of matte at the reverberatory affects the rate and cost of converting. The introduction of differential flotation in 1927 had a very marked influence on all smelting operations and its effect will be noted

Jan 1, 1930

By William F. Boericke

THERE was a time when the selection of fire brick was .left to the judgment of the head bricklayer of the plant, whose choice was not unaffected by a box of Christmas cigars from a friendly salesman. But the days are past when it was generally believed, with complacent philosophy, that bricks were bricks without much distinction, and should be bought on a price basis alone. Gone, too, is the belief that in certain types of industrial work the eventual failure of refractories was assured. Modern metallurgical practice, with its trend toward handling larger tonnages at higher temperatures, demands the use of refractories that cannot be supplied by random guess. The logical development is to inquire into the properties of the brick to be purchased, and this resolves itself into the use of specifications. In 1925, the General Refractories Co., with the active support and hearty cooperation of some of its larger customers, established a laboratory, at its Baltimore plant, for testing and research in refractories. This was the outgrowth of a growing appreciation of the value of research in the refractory field. Since then the work has become more involved' and the aims more ambitious, so that the present laboratory now employs a staff of 11 men working, under the direction of trained refractory technologists, on problems of research as well as the routine control of manufacture. It is believed s that `this type of laboratory is a comparative novelty among refractory manufacturing plants. It handles the testing and research work for all the 15 plants of the organization. Being at one of the works has the advantage of making it possible to carry on large scale plant tests on new products after the preliminary laboratory tests have been successfully completed.

Jan 1, 1929

By NORMA D. MACFADDEN

WHILE the library work of the Woman's Auxiliary to the A. I. M. E. was founded three years after the formation of the Auxiliary, its present policy of establishing permanent libraries in mining camps throughout the United States dates only from 1924. Since then sixteen libraries have been established and thousands of books have found their way to homes of far-away miners, bringing pleasure and knowledge to a multitude of Americans and future citizens. Library work was initiated under the presidency of Mrs. H. W. Hardinge in 1922 and firmly established with her aid as one of the main activities of the Auxiliary. The first chairman served but a short time and Mrs. A. O. Ihlseng then took over the work of chairman of the Library Committee. To place the surplus books of Auxiliary members and their friends in use in mining camps was the immediate work of the committee. This was accomplished by placing a traveling library in the Bureau of Mines' cars and also by sending books for distribution to section chair- men in our larger mining camps.

Jan 1, 1929

By W. R. Ingalls

THE main objective of everybody, individually and collectively as the people of nations, is to earn their living and improve the scale thereof as much and as rapidly as possible. We are able to earn" our living only by working and producing. We I are able to rise to higher standards of comfort only by increasing our production of goods, or diminishing the waste of those that we do produce, or both. This statement is trite. It is equally trite to dwell upon the importance of increased production to be derived from increased efficiency of labor and improved manage-ment; and the good results that would accrue to every-body if employers and employees would work together to secure the maximum of production at the minimum of cost. All of this is nothing more than platitude, to which every intelligent person subscribes in the abstract; but what concerns us especially, and what is neither so easy nor so understandable, is to translate the expres-sion of the abstract principle into formulas for action. The national net income obviously may be increased in two ways, or by both together. One is to diminish the waste of the goods that we already have made available. The other is to increase the supply of goods. .Increasing the supply of goods may involve the elimina-tion of waste, but a distinction is to be drawn between the waste of things that we have and the failure to obtain those that we might have. If we limit the term "waste" to the careless and profligate use of the materials that have come into our possession, together with the absorption of labor in doing obviously unnecessary things; and if we character-ize by the term "inefficiency" the failure to accomplish in our industrial operations the best of which we are capable, we shall create a distinction that will be pro-motive of clear thinking. In this paper I am going to deal with inefficiency, not waste, observing the distinc-tion, arbitrary if you please, that I have made. Without any doubt the greatest inefficiency that exists in our economic affairs is that which causes hundreds of thousands, perhaps millions, of men to be idle a good deal of the time. The major reasons for such idleness are two-fold. One of them is the conse-quence of what for convenience may be called business cycles, although I do not hold to the hypothesis of business cycles as it is now being rather widely expounded. That hypothesis involves the idea of rhyth-mic undulations due to causes unknown, but which it is hoped may be ascertained. The movement of busi-ness in waves up and down is undeniable, but that there are recurrences of cycles every so often is purely imag-inary, I think. It is unnecessary-to digress into that subject. The extents of the rises and falls above and below a median line undoubtedly is less than is commonly supposed.

Jan 3, 1922

By James Boyd

In critical times such as the present, when the whole world is agitated by the aftermath of war and the road to peace is blocked by seemingly insurmountable obstacles, it is fitting that we should pause to take inventory of the material resources essential to our national security. Our status as a world power, in peace as well as in war, is intrinsically bound to the availability of minerals, for the foundation of our industrial and economic structurewhich in turn largely determines our military potential and our limits of national prosperity-rests on our ready access to economic sources of iron, copper, lead, zinc, manganese, bauxite, and at least threescore of other metals, minerals, and mineral fuels. By applying the well-known facts of mineral resources to recognized fundamental concepts of preparedness, we can obtain a- clearer picture of the essential needs of our country. Historically, the lure of minerals and other raw material resources has all too frequently led nations to policies of imperialism and war. For more than a century the staking of colonial territory for new sources of raw materials has been a primary objective of many nations. These national policies. of aggrandizement were accelerated by increasing industrialization. The nations, in their aggressive search for

Jan 1, 1948

By Frank V. Hicks

THE following paper-in no sense a technical paper-is a summary of a safety campaign instituted by a coal-mining company to improve an unfortunate safety record. The experience should be suggestive equally to coal and metal-mining companies. With few precedents to follow in the beginning, the course was charted by trial and error. The endeavor, often disheartening, finally resulted in the capture of the most coveted safety trophy in the mining industry, "The Sentinels of Safety," awarded by the Hercules Powder Co. of Wilmington, Del., through the U. S. Bureau of Mines. The period described covers the 10-year interval, 1924 to 1933, the year 1933 being that for which the award was made. The coal company considered has produced annually for a number of years an average of 2,750,000 tons of coal, employing at various times from 1.800 to 3000 men. Prior to 1924, the

Jan 1, 1935

By M. F. COOLBAUGH

WHEN I was asked to speak on the subject of leaching, I did not realize that a complete summary of recent progress in leaching had been given by Stuart Croasdale. I shall try to give some other phases of the subject that were not touched by Mr. Croasdale. Not all metallurgists are in harmony as to their methods of treating metals. If they were it would probably mean lack of progress. They can be divided into two classes-the pyrometallurgists, using fire means, and the hydrometallurgists, or those using leaching methods. Conflict is always good for progress; we have it in politics, and in religion there are fundamentalists, and those who are not fundamentalists. As representing pyrometallurgy, may I hope not to be classed among the fundamentalists. The leaching of ores is not new. The leaching of ores for the recovery of metals, however, is quite new. The older leaching was simply to recover the salts. Agricola, back in 1555, I think it was, outlined a great many methods of leaching for the recovery of salts. They called them solid juices at that time. There was no real competition, however, between leaching meth-

Jan 1, 1926

By W. O. Crosby

INTRODUCTION. THE crystalline belt of the Atlantic Seaboard, south of New York, attains its maximum breadth of 220 miles on the northern border of North Carolina; and in this State it is most widely characterized by the occurrence of gold in workable deposits. Half a dozen auriferous belts have been recognized by Nitze and Hanna.1 These are, in the main, coincident in position and trend with the NE.-SW. zones of metamorphic slates and schists, which, more than any other feature, give character to the geological map of North Carolina. The central gold-belts, accompanying the main zone of slates and associated igneous rocks, are much the more important and persistent, and may be regarded as continuous northward across Virginia and southward into South Carolina. Tile eastern belt, on the other band, is the shortest and, economically, one of the least important. Its extreme length does not exceed 25 miles, the narrow band of slaty rocks to which it belongs passing, both NE. and SW., beneath the coastal-plain formations. But, although limited in area and production, this belt is, perhaps, comparable with the central belts or any part of the sea-board crystallines in the variety of conditions under which the gold occurs. It lies chiefly in the NE. part of Franklin county and the NW. part of Nash county, on the watershed of Fishing creek and other tributaries of Tar river. The elevation is between 400 and 500 ft. ; and the Tertiary peneplain has here an exceptionally perfect development, the reliefs separating the slightly incised stream-courses consisting of broad, flat-topped peneplain remnants, bounded by gentle lateral slopes.

Mar 1, 1908