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By S. Orangi

A representative sample of ramming paste from a peripheral seam in an aluminium electrolysis cell was taken in order to develop a process to fabricate ramming paste samples in the laboratory. To this end, paste material was compacted in multilayers in a mould designed to be representative of peripheral seams in Alcoa's smelters. The density distribution in the representative sample was measured ranging from 1.51-1.76 g/cm3. The density range obtained by the proposed methodology in laboratory is 1.47-1.77 g/cm3. The results demonstrate that the proposed fabrication method adequately duplicates paste density from the cell for both one and two layer compaction. Finally, preliminary results related to the compressive strength and Young's modulus of laboratory samples were obtained at various temperatures and are presented in this paper.

Jan 1, 2011

By S. M. C. Santos

Preliminary bench-scale studies were carried out on the leaching of a zinc sulphide concentrate from Somincor, Portugal, and the purification of the resulting pregnant solution using solvent extraction techniques. The sulphide concentrate contained 36% Zn, 36% S, 2% Fe and 4% Cu. The leaching was carried out with sulphuric acid in the presence of ferric sulphate as the oxidant. Important leaching parameters, such as the effect of reaction time, the solid-liquid ratio, temperature and concentrations of acid and oxidant, were investigated. After leaching, the recovered solution was contacted with an organic phase containing Acorga 5640 to remove the copper. Subsequently, the removal of iron from the leaching solution was achieved with a mixture of Cyanex 272 and TBP. This solvent mixture was relatively selective for iron over zinc. The stripping of the loaded solvent was performed with 200 g/L H2SO4. Six countercurrent extraction stages achieved a separation of about 99% of the iron from the leaching solution. The iron-free leachate can be further treated to recover minor metals by cementation, and finally, zinc by liquid-liquid extraction. The advantages of the suggested process relative to the traditional jarosite process are discussed.

Jan 1, 2006

By K. Scholey, S. Marcuson

As high grade nickel sulphide ores are being depleted and with the continuing challenges experienced in economically processing nickel laterite ores, it is important to investigate technologies that can extract nickel from low grade ultramafic ores which are present in large quantities worldwide. In the Thompson Nickel Belt, there are some hundred million tonnes of mineralization that are potentially amenable to surface mining. Since the original discovery of the Thompson orebody, recovery of nickel from these ultramafic deposits has been an elusive goal. Research and development projects as well as commercial processing have been attempted. In the 2000's as other resources became scarcer, a major drilling, mine evaluation and research project was initiated at Vale. In 2007, Vale Base Metals Technology Development invited Cytec and potential academic partners to participate in an industry-university research consortium with the goal of developing new technologies and methods of processing the ultramafic deposits. Three university professors, J. Finch of McGill, P. Somasundaran of Columbia and R. Pelton of McMaster accepted, each group attacking the problem with a different approach. This paper describes the management of the research consortium and the significance of the results from Vale's perspective. The next four papers in this session will summarize the project and results from the partners' point of view. Vale is pleased to share the experience of the collaborative research and development with the mining industry.

Jan 1, 2011

By M. Cala

Underground coal gasification is technology which enables energy to be extracted from coal beds where mining by means of classical methods is either impossible or uneconomical. The process of coal gasification itself is a complex phenomenon which includes chemical and physical processes: thermal, hydrological and mechanical. Additionally, the analysis of underground coal gasification is difficult to carry out for environment reasons, this being due to the local characteristics of the areas where it is carried out. This paper deals with interaction of geo-reactor with surrounding rock mass, it omits the chemical processes inside geo-reactor itself. Due to the complexity of the processes proceeding and during underground coal gasification coupled with minimal practical experience in using this technology, it is difficult to estimate its influence on the surrounding rock mass. Within this scope, the use of numerical programs can be useful. This paper presents a trial of modeling the processes accompanying underground coal gasification. The processes proceeding and during the underground coal gasification are characterized, and the significant, specific phenomena are discussed, with respect to the influence on the surrounding rock mass. For the chosen processes, examples of numerical calculations are presented. These enabled conclusions to be drawn and also provided directions for the modeling of the underground coal gasification processes.

Aug 1, 2013

By Stanislaw Trenczek

Natural hazards such as rock bumps, methane, coal dust explosions, airborne respirable dust, outbursts of gas and rocks, water, radiation caused by natural radioactive materials, spontaneous fires, and climatic hazards, occurring in the Polish hard coal mines, should be controlled. These hazards are characterized by different scale levels numbered from 2?5. To recognize the amount and levels of hazards, research works were carried out in 109 mining districts of mines belonging to Jastrzebska Spólka Weglowa, Katowicki Holding Weglowy and Kompania Weglowa. These are 86 % of all mines and could be regarded as representative of the majority of Polish mining. The hazards have been classified as regards the frequency of their occurrence as: commonly occurring ? with a frequency of 100 % (like airborne respirable dust and fire hazards), high occurrence frequency ? frequency from 60 to below 100 % (methane hazard ? 83.5 %, coal dust explosion hazard ? 92.0 %, and water hazard ? 99.1 %), medium occurrence frequency ? from 30 to below 60 % (rock-bump hazard ? 52.3 % and climatic hazards ? 51.4 %), and episodic occurrence frequency ? below 30 % (outburst of gas and rocks and radioactive hazards). The dynamics of effects of growth in hazard levels to their intolerable values is diverse. Some of them are passive in nature, which allows for longer observation of changes and appropriate early response (as for climatic and spontaneous fire hazards). However the majority of them take on the character of disasters, like methane or coal dust explosions and damage of the excavation structure ? as occurs after a rock-bump or rock outburst; and creation of an atmosphere unfit for breathing ? during open or spontaneous fires, or after gas outbursts containing methane. There are also latent hazards whose effects do not influence indeed a process of production; however they are detrimental to health when a worker is exposed for a long time to airborne respirable dust and radiation. For other types of hazards a level of danger may be only estimated. Since the systems monitoring allows a wider range of control, therefore, aside from rock-bump and methane hazards, there are monitored also fire hazards including measurements of other air parameters (velocity, pressure, humidity, temperature, O2, CO2 concentration). A few types of monitoring systems are used in Polish mines, like the monitoring systems for environmental parameters such as SMP-NT, SMP-NT/A, the telemetric systems CST-40, CST/A, including the computer-aided system for methanometry control officer SWµP, the computer-aided measuring systems KSP-1, KSP-2, KSP-2C, or the production and safety control system VENTURON. The underground part of the systems monitoring of natural hazards contains measuring devices and equipment for automatic control (power-off) of machines and electric devices in case of increased methane hazard. The surface part of the monitoring system allows the measuring data to be visualized and pre-alarm (warning) and alarm states to be displayed. Furthermore it makes it possible to archive and report the data and to control the underground supply and signalling devices. The EMAG Institute developed monitoring methods to extend a measuring range of monitored parameters (such as methane and fire hazards) as well as to monitor so far unmonitored hazards like dust hazards (by continuous monitoring of dust levels in mine air) and climatic hazards (by online monitoring climatic parameters of mine air).

Aug 1, 2013

By G. Song

Magnesium has excellent bio-compatibility in terms of its density, strength, elastic modulus and toxicity. However, due to its poor corrosion performance, so far magnesium has not been successfully used in the human body as a permanent implant material. Nevertheless, there is a possibility to utilize the low corrosion resistance of magnesium to make magnesium into a temporary implant component that can gradually dissolve in the human body after surgical region heals. This will avoid the secondary operation to remove the temporarily implanted component and the chronic inflammatory discomfort caused by the implant. This paper is aimed at exploring the possibility of using magnesium as a degradable bio-material through investigating the corrosion behaviors of pure magnesium and surface treated magnesium in a simulated body fluid (SBF) solution. It was found that magnesium corroded rapidly in the SBF solution, resulting in vigorous hydrogen evolution and a strong alkalization effect. Hence, it is impractical to use magnesium as a permanent implanted material or even a degradable implant. However, a proper anodizing treatment can significantly improve the corrosion resistance of magnesium, and hence slower down the hydrogen evolution and alkalization processes, which will allow to control the corrosion or degradation of magnesium at a desired rate in the human body. With a controllable corrosion rate, it is believed that magnesium as a degradable implanted material will be eventually achievable.

Jan 1, 2006

By S. G. Shabestari

In the metal casting industry an improvement of component quality mainly depends on better control over the production parameters. Thus, thermal analysis cooling curve of the alloy is used for process control in aluminum casting industry. Cooling rates of the alloy during solidification process affect microstructure, grain size, eutectic silicon morphology, and dendrite arm spacing (DAS). In this research, effect of cooling rate on the microstructure and solidification parameters of 319 aluminum alloy that is a widely used alloy in automotive industry, has been investigated by means of thermal analysis. Seven different cooling rates have been obtained by using CO2-bonded silica sand molds with two different wall thicknesses, hot-work tool steel molds (H13) with and without coating, thin-wall steel molds with different coatings. In each case, cooling curve and first derivative cooling curve have been plotted by use of very accurate thermal analysis equipment. Effect of different cooling rates on solidification parameters e.g. Nucleation temperature (TN,a), nucleation undercooling (ATN,a), recalescence temperature (TR,a), solidification range (AT,s), and total solidification time (t 0 have been studied in the liquidus region. Microstructural evaluation has been carried out and DAS were measured in all solidification conditions. A numerical equation was proposed to predict cooling rates via measuring DAS in 319 aluminum alloy. Nucleation process and the effect of cooling rate have been interpreted by using thermal analysis cooling curves and microstructural study.

Jan 1, 2004

By P. A. Bahri, D. G. Dixon, T. M. Woodward

A comprehensive mathematical model of the Sherritt-Gordon ammoniacal pressure leaching process at K winana Nickel Refinery has been constructed. The process is comprised of six autoclaves functioning as a three-stage leach circuit, operating over the temperature and pressure ranges of 85-95°C and 750-1000 kPa, respectively. The process chemistry forms a complex series-parallel reaction network, characterised by: (1) the gas-liquid mass transfer and reduction of oxygen, (2) the oxidation of eight distinct minerals, (3) the oxidation of sulphur, and successive reactions involving various intermediately oxidised sulphur species, and (4) the oxidation of Fe(II) to Fe(III), and subsequent precipitation as a hydrated ferric oxide. Material balances were developed for species in all three phases, and an energy balance to account for all reactions and phase conversions. The multiple convolution integral (MCI) statistical reactor model was employed for the scale-up of particle kinetics. The model has been validated against plant data, and simulation results are in agreement with plant performance.

Jan 1, 2005

This work illustrates the potential of two welding processes for joining AA1100-16 vol.% B4C metal matrix composite: laser welding process using a 4 kW Nd:YAG laser and Friction Stir Welding. A comparison is made between these two welding techniques in terms of microstructure and mechanical properties of welded joints. A large amount of brittle needle-like phases, together with some residues of B4C particles were observed in the fusion zone of laser welded joints. The use of Ti filler can improve the microstructure and increase the joint efficiency from 63% to 75%. On the other hand, the friction stir welding process being a solid state welding technique is interesting as it avoids the formation of brittle intermetallic phases. In addition, the breakage of B4C particles and the grain refinement of the matrix were observed in the weld zone. Consequently, FSW joints show much better mechanical properties than laser welded joints. Up to 100% joint efficiency can be achieved by FSW for annealed AA1100-16 vol.% B4C materials.

Jan 1, 2011

By C. Karpuz, Y. S. Istanbulluoglu

This paper describes the results of convergence measurements conducted about five years for the re-use gate roadways at OAL lignite mine in Turkey. Double lignite seams separated with a marn layer, are mined with long-wall retreating mining system at the mine. Rib pillar has been abandoned and gate roadways were planned to be packed for the re-use of full extraction. Various packing systems have been attempted, namely three rows of woodenchock, one row of wooden chock plus concrete wall and concrete wall only. The re-use of maingate roadways packed with wooden chock yielded 62% of closure. Lastly developed concrete packing of 3 meters wide and specially developed support set composed of three friction props and a cap, which is a modification of yieldable set, have successfully maintained the main and tail gate roadways stability with a total vertical convergence of 32%. Good correlation has been established between pack stiffness and floor heave as well as maingate and tailgate convergences. The elimination of rib pillars by re-use of gate roadways increased the coal recovery by 20% and decreased the development/production ratio from 0.065 m3/ton to0.022 m3/ton.

Jan 1, 1997

By Seong-Taek Lim

Recently, 7xxx aluminum alloys have been evolved into new variants for thick semiproducts which have low amount of 2nd phases and low quench sensitivity. Commercial 7xxx alloys, especially in the thick forgings made of big ingots, often entail microstructural inhomogeneities and concurrent poor mechanical properties due to limited heating ranges and slower quench cooling. In this study, high strength aluminum alloy 7175 and 7050 are adjusted as an attempt to control the equilibrium phases (M-, T- and S-phase) to have optimum microstructure for the thick forging applications. The effects of the relative content of (Zn, Mg, Cu) on the evolutions of the coarse equilibrium phases, hardening response and resultant mechanical properties are investigated. Equilibrium phases (M,T,S) are evolved depending on the constitutional effect, primarily the change of Zn:Mg ratio, and cooling rate following solutionizing. The formation of the T- and S-phases is effectively controlled, and M-phases are homogeneously precipitated in the adjusted (dilute and high Zn:Mg ratio) alloys. It provides extended heating range and lower quench sensitivity than conventional alloys. The attempts ensure the microstructural homogeneity and improved properties, and is expected to be uniquely applicable in 7xxx thick forgings.

Jan 1, 2004

By A. Ghirian

Once cemented paste backfill (CPB) is transferred and placed into a mine stope, various coupled mechanisms will take place in the CPB material or structure. It will be subjected to strong coupled thermal (T), hydraulic (H), mechanical (M), and chemical (C) processes. Field studies have shown that the in-situ properties and performance of CPB differ from those obtained in the laboratory. This is mainly due to effects of the aforementioned coupled THMC mechanisms or processes. For a reliable and cost-effective design of a CPB structure and barricade, it is crucial to have a proper understanding of the THMC behaviour and evolution of CPB. Also, it is important to consider the effect of coupled THMC factors (e.g., self-weight pressure, drained/undrained and thermal conditions, pore pressure) while curing the CPB specimens. For this purpose, a laboratory setup is developed to investigate the properties of CPB materials. The setup is capable of curing CPB specimens (10 cm in diameter and 20 cm in height) under controlled vertical pressure (curing under stress) and various coupled THMC conditions, while continuously monitoring the evolution of total stress, pore pressure, suction, temperature, water drainage, chemical composition of the pore water and vertical deformation. Once the required curing time is achieved, the specimen can be extracted and then subjected to experimental tests of interest, such as those that determine the Unconfined Compressive Strength (UCS), shear strength parameters, saturated hydraulic conductivity and thermal properties. In this paper, we describe the developed experimental setup and present some results of the THMC behaviour of CPB under various curing stresses and rates of backfilling. The obtained results show that the THMC properties of CPB are strongly coupled due to several mechanisms, such as self-weight pressure, heat of hydration and suction development as a result of self-desiccation. The findings can assist researchers and practitioners to better understand THMC behaviour and thus design more cost-effective CPB structures.

Aug 1, 2013

By J. Q. Chen

The elastic-plastic behavior and the fracture mechanisms of two 2198 Al-Cu-Li thin sheets are investigated. The first material (2 mm thick) is in a recrystallized state after cold rolling. The second material (6 mm thick) is hot rolled and has a fibrous grain structure. The two materials are studied in both T351 and T851 conditions. Tensile tests are carried out along different sheet directions using flat and notched specimens. Fracture resistance was characterized using Kahn tear specimens and M(T) panels. Macroscopic fracture surface of smooth tensile specimens depends not only on testing material but also on the loading direction. For Kahn tear specimens, fracture is initiated in a small flat triangle whereas slant fracture is observed during crack propagation. Fracture mechanisms were investigated using scanning electron microscopy (SEM) and X-ray 3D tomography.

Jan 1, 2011

By A. J. McLaren

Introduction Gold holds an important place among the mineral products of Manitoba. In value, it ranks second only to copper, which in 1931 attained first place. The gold production increased from 23,189 fine ounces in 1930 to 102,969fine ounces in 1931. The production for 1930, worth $479,359, came almost entirely from the Central Manitoba mine. The production for 1931 was worth $2,128,558, of which $1,509,018 came from the Flin Flon mine, $528,951 from the Central Manitoba, and $83,497 from the Sherritt Gordon. The Gem Lake mine and some prospects produced $7,785. The total output of gold in Manitoba, from the first recorded production in 1917 to the end of 1931, is estimated at 178,669 fine ounces, valued at $3,693,332. The production for 1932 promises to reach a new high record, due chiefly to the stepping-up of tonnage at the Flin Flon plants and the coming into production of the San Antonio mill in May. History The Manitoba Act, constituting Manitoba a Province of the Dominion, was passed in 1870 and provided for the vesting in the Crown of all un-granted or waste lands of Manitoba, as well as for the administration of these lands by the Dominion of Canada for the purposes of the Dominion "subject to, and except and so far as the same may be affected by, the conditions and stipulations contained in the agreement for the surrender of Rupert's Land by the Hudson's Bay Company to the Crown". Included in these waste lands were large areas later prospected and staked out as mineral lands. Up to the year 1912, that vast territory extending from the 12th base line to the 60th parallel of latitude, and from the Saskatchewan boundary to Hudson bay, was part of the District of Keewatin. Although added to Manitoba in 1912, the administration of its mineral lands also remained vested in the Dominion, so that all mineral lands within the Province upon which deposits of gold ore have been found were disposed of and administered by the Mineral Lands Division, Department of the Interior, until the transfer of the natural resources to the Province of Manitoba, on July 15th, 1930.

Jan 1, 1932

By Michel Épiney, COREM, Mario Drapeau, Caroline Olsen, Claude Bolduc, Benoit Levasseur

"Several metal sulfide minerals (such as copper, zinc and iron), generally abundant in precious metal-containing ores, are known to dissolve during the cyanidation process. These unwanted reactions consume a significant amount of cyanide and oxygen, which is required for the extraction of gold and silver. Leaching kinetics of sulfide minerals are very fast in contact with oxygenated cyanide solutions. Therefore, the solution quickly becomes charged with oxidation products that are mostly metal ions, metallo-cyanide complexes, metal oxides and other sulfur species including thiocyanate, sulfides, polysulfides, thiosulfate, sulfites, sulfates, etc. COREM’s Extractive Metallurgy team has been conducting a research program on the improvement of the gold cyanidation process. As a part of this program, the current study aims to investigate the effect of certain operating parameters on the reactions involved during pre-oxidation and cyanidation. The effect of pre-treatment under ozone was investigated using an industrial pulp recreated from process water (charged with thiocyanates) and homogenized flotation tailings material from Agnico Eagle's LaRonde mine. In terms of mechanisms, the ozone treatment provides a complete deactivation of the material surface (characterized by EDTA extraction) and the solution (characterized by Ionic chromatography). This resulted in a lower reactivity of sulfide minerals that led to substantial gains in terms of consumption of cyanide and thiocyanate formation during the cyanidation process. The ozone-pre-treatment edges the classical pre-oxidation treatment (such as oxygen, hydrogen peroxides, etc) providing a quicker deactivation of the sulfide matrix and higher reagent savings in subsequent cyanidation process.INTRODUCTIONThe presence of sulfur in the process of gold leaching by cyanidation is a major drawback to optimizing the reagents consumption with suitable operating conditions. The coexistence of sulfide mineral species, such as pyrite, chalcopyrite, pyrrhotite or sphalerite along with the gold-bearing ore have, indeed, a negative impact on the extraction of precious metals by cyanidation (Bayat et al., 2003), (Azizi et al., 2010). These minerals are known to dissolve with cyanide under alkaline conditions and release in the slurry different kinds of sulfide by-products like polysulfides, thiosel, sulfite and sulfate (Seal II & Hammarstrom, 2003) (Breuer et al., 2008a), (Marsden & House, 2006) (Ghasemian Langeroudi et al., 2013). Once these sulfide by-products are released in solution they react with cyanide to form thiocyanate (Marsden & House, 2006) (Breuer et al., 2008b). The consequence of the dissolution of these cyanicides, is a significant increase in cyanide consumtpion as well as a slow-down of gold extraction."

Jan 1, 2016

By P. H. Rodriguez

The aquatic hazard classification system of the OECD and EU requires that sparingly soluble metal substances (SSMS) be tested using the OECD Dissolution/Transformation protocol in order to quantify the release of the ecotoxicological relevant species (dissolved ions). The SSMS category contains massive forms of metals, which due to their low solubility and slow transformation characteristics are a special case. The main factors that produce the release of metal into solution are exposed surface loading, pH, and stirring rate. The classification system at present prefers the use of mass loading as opposed to surface loading, in which case the amount of metal released will primarily be a function of the pH, and mass loading. Within the framework of the European Copper Voluntary Risk Assessment, coordinated by the European Copper Institute, we have proposed and developed a methodological procedure in which we demonstrate that surface area is an intrinsic property of a SSMS and we link the exposed surface loading to the toxicity reference value in order to obtain an aquatic hazard classification for massive metals. As example, the aquatic hazard classification for copper massive will be discussed. This approach is recommended for metal massives and metal powders.

Jan 1, 2007

By A. Hekmat-Ardakan

Conventional hypereutectic Al-Si alloys such as A390 are used principally for the casting of components used in wear applications requiring abrasive resistance such as in engine or compressor blocks. A comprehensive study was undertaken to investigate the potential of improving the mechanical properties of these alloys by the addition of magnesium. A thorough thermodynamic study of the effect of the addition of Mg to the conventional A390 alloy showed that Mg2Si starts to form as a primary phase at 4.2% Mg as well as in the products of the binary and ternary eutectic reactions forming the matrix. Experiments were carried out in producing castings with different cooling and solidification rates of alloys with up to 10% Mg. Mg additions were found to increase the hardness over the as cast alloy due to solid solution strengthening. Also, T6 heat treatment greatly improved the tensile properties of these alloy compositions due to the strengthening effect of the theta-Al2Cu phase. The elongation of these alloys generally decreases marginally with Mg content. The most significant property improvement of the alloys with higher Mg content is the substantial increase in wear resistance. This is attributed to the dispersion of smaller particles of Mg2Si and their coherence with the matrix as compared to the large Si particles in the conventional alloy. A new rheoforming process for A390 is presented that improves the processing of the semi-solid slurry. Structure modification elements were also added to refine the primary and eutectic silicon greatly improving the processing of the semi-solid slurry.

Jan 1, 2011

By R. MacRosty

The demand to increase production levels in smelting furnaces has driven the increase in the power levels. Consequently, greater cooling capacity of the furnace shell has been necessary, resulting in the widespread use of water-cooled elements to protect the refractory linings. Since water ingress into the furnace is an explosion hazard, monitoring and maintenance of the water-cooled elements is of key importance. Some of Hatch's recent research and development efforts have been focused on methods to provide an increased level of monitoring of water-cooled furnace elements; this paper focuses on two technologies developed for this purpose. The first involves the installation of a fibre optic temperature sensor in a water-cooled tapblock. The sensor is capable of providing high accuracy temperature measurements with a fine spatial resolution throughout the tapblock. Hatch has already developed a diagnostic system that uses multivariate statistical analysis to interpret the large quantities of data generated by the sensor. A second technology under development is concerned with enhancing the operating integrity and safety through detection of leaks in the water circuits. A successful leak detection strategy requires minimal maintenance and the ability to detect minute leaks. An instrument that meets these criteria has been investigated and is currently under development. This paper focuses on the technology and results from the test work that has been completed to date.

Jan 1, 2007

By A. R. Naji Meidani, A. Cameron, A. Richardson, M. Isac, R. I. L. Guthrie

The supersonic core of shrouded jets remain coherent over longer distances vs conventional supersonic jets. This phenomenon should allow for greater penetration of oxygen into slag/steel reactor systems. As such, they hold the promise for faster slag/metal mixing in BOF type metallurgical reactor systems, possibly creating greater surface area/volume ratios of reacting phases, and thereby faster kinetics, as compared to conventional supersonic jet systems. In order to assess the potential of shrouded supersonic jets versus their conventional counterparts, an experimental investigation of impinging shrouded supersonic jets into a water model of a simplified BOF system was carried out in the MMPC's water modelling laboratory. The experimental results for three different designs of a shrouded supersonic jet nozzle have been compared in terms of greater penetration depths and reduced mixing times. Based on a novel dimensional analysis, the depth of penetration of a gas jet into a liquid bath is shown to depend on the nozzle-bath distance, the liquid's Froude, Reynolds and Weber numbers, reflecting the ratios of gravity, viscous and surface tension forces to the jet's inertial, or momentum, forces. Good agreement between the mathematical model and experiment was obtained in terms of predicted and observed depths of penetration. Further efforts have been made to study jet penetration into liquid metals. The effects of mean liquid density of slag/metal mixtures and a wide range of gas flow rates on the penetration depth were investigated theoretically. The results show that the penetration depth can be increased with increasing gas flow rate and decreased bath density.

Jan 1, 2004

By P. Su

Friction stir spot welding of a range of Mg-alloys is investigated (AZ91, AZ31, AM50 and AM60). The peak temperatures during friction stir spot welding of all Mg-alloys are close to their solidus temperatures. Also, the apparent material viscosity of Mg-alloy sheet is lower than that when Al-alloy sheet material is spot welded. This is important since it means that the widths of the stir zones forming during spot welding of Mg-alloy sheet are smaller than those when Al-alloy sheet is welded (when identical welding parameter settings are applied). These lower apparent viscosity values must be taken into account during numerical modeling of the Mg-alloy spot welding process. The efficiency of energy utilization is very low when Mg-alloy sheet is spot welded and is of the same order as that when fabricating Al-alloy sheet. The energy generation contributions of the rotating pin and the tool shoulder are investigated. When the spot welding operation is carried out without the application of a dwell period, the contribution made by the rotating pin vis-à-vis energy generation is around 66%. The contribution made by the tool shoulder increases to about 65% when a dwell period of four seconds is incorporated during the spot welding operation. This increase results from a longer contact time between the tool shoulder and material within the stir zone, The failure load during overlap shear testing increases when the bonded area and the energy input increase during spot welding. Sample failure initiates from unbonded regions and from discontinuities at the edge of the stir zone. The formation tendency of discontinuities is increased when Mg-Alloy sheet is spot welded because of the limited deformation characteristics of the base material at lower temperatures.

Jan 1, 2006