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By T. S. Spicer

The relationship of coal characteristics to the principal types of firing equipment has been known to the coal combustion engineer, but is not as familiar a subject for purchasing agents, salesmen, consumers, and executives of coal-producing and consuming companies. This general survey of characteristics determined by standard laboratory tests, of major types of combustion techniques, and of the relationships between the two is directed toward the latter audience. It will also serve as a review for those actively engaged in the combustion of coal. Although the relationship of coal characteristics to the principal types of firing equipment is well known to the experienced coal combustion engineer, apparently there is need for a summary article on this subject. The author has received numerous requests for such a paper from purchasing agents, coal salesmen, coal customers and executives of coal-producing and consuming companies. Consequently, the scope of this paper will be directed to this audience, with the hope that it may serve also as a review to others actively engaged in the combustion of coal. The magnitude of this subject is so great that only a brief general treatise is possible. The author realizes that because there are so many special cases and exceptions to the generalities which follow, he is in jeopardy of contradicting himself. It is the hope, however, that the many references cited will prove valuable to those who wish to study the details excluded by necessity, due to space and time limitations. Hence, the characteristics of coals as determined by standard laboratory tests will be discussed; the major types of combustion techniques reviewed; and then the characteristics and firing will be related. CHARACTERISTICS OF UNITED STATES COALS The coals of the United States range from lignite to anthracite and each has its own general characteristics. The extensive coal fields of the U. S. are shown in Fig. 1 and the estimated reserve according to rank for each state is illustrated in Fig. 2. Coals may be classified according to rank as shown by Table I from the ASTM Standards on Coal and Coke, D-338-38.1 The basis of this classification is ac- cording to fixed carbon and heating value (Btu per pound) calculated to a mineral-matter-free basis. The high-rank coals are classified according to fixed carbon on the dry basis; and the low-rank coals according to Btu on the moist basis. Agglomerating and slacking (weathering) indices are used to differentiate between certain adjacent groups. While rank is not itself a characteristic it does signify certain characteristics that accompany a class of fuel. Anthracite, for example, immediately implies a hard, free-burning, smokeless coal of low volatile matter, usually having an ash of high fusibility. Coals may also be classified according to grade as described by ASTM Designation D-398-37.1 This quality classification is determined by size, calorific value, ash, ash-softening temperature, and sulfur. This type of classification is not used as extensively by the industry as the rank classification. Fig. 3 shows the heat value of different ranks compared to proximate analyses. Coals may also be classified by sizes, as shown in Tables IIA and IIB, and sizes can be on both top and bottom limits. If this is done, then the coal is called double screened; otherwise, either top or bottom sizes can be specified as a limit. Bituminous coal sizing varies from field to field and depends upon the market demand. The common sizes and their main uses are outlined in Table IIA. Anthracite is usually available in many sizes at the colliery, and Table IIB summarizes standard sizes and names. Although rank, grade, and size designations help identify and describe a coal in question, there still remain other characteristics such as indicated by moisture, free swelling index, grindability tests, etc. A bituminous coal information chart Table III) suggested for use in studying the available coals in a region, lists origin and chemical and physical characteristics. Even this more comprehensive list does not completely spell out all the characteristics of a heterogenous material like coal. For example,

Jan 1, 1961

By E. A. Anderson, M. L. Fuller

The copper-zinc phase equilibrium diagram has been the subject of many investigations. Until recently, however, the boundary of the terminal solid solution of copper in zinc (eta) has not been thoroughly investigated. This paper reports determinations of the solid solubility of copper in zinc at temperatures from 100' to 400' C., the course of the liquidus and solidus for the eta solid solution and determinations of the peritectic temperature and peritectic point for the reaction between epsilon and the melt to form eta. The liquidus of the eta phase was determined by thermal analysis and the solidus by the microscopical examination of specimens quenched from temperatures above and below the solidus. The temperature of the peritectic horizontal was obtained by thermal analysis and the composition at the peritectic point was determined by extrapolation of the solid solubility boundary of the eta phase to the peritectic horizontal. The solid solubility boundary of the eta solid solution was investigated very carefully. Particular care was used to achieve equilibrium in the alloys at each temperature selected. The X-ray, electrical conductivity and microscopical methods mere used in determining the solid solubility limits. The X-ray method measures the changes in the solvent lattice with increasing solute content and in this manner locates the composition of the alloy at which no further change in the solvent lattice takes place, the limit of solid solubility. The method of electrical conductivity measures the conductivity of the alloys of a graded series of compositions, whereby the solubility limit is indicated by a discontinuity in the conductivity-composition relationship. The microscopical method distinguishes, by direct inspection, between the homogeneous solid solution alloys and those having a secondary constituent in addition to the solid solution phase, and thus indicates from the examination of a series of alloys the solid solubility limit.

Jan 1, 1934

By H. G. Moulton

THE INCREASING scale of mining operations over the past decade, particularly in connection with the exploitation of large bodies of comparatively low-grade copper ores, has made necessary the study of the behavior of rock under failure. When extractions of as high as 40,000 tons a day are reached in steam-shovel operations and as high as 20,000 tons per day in underground mining operations, it is evident that excavations soon become of such size that the behavior of the rock will often be dependent on fundamental principles applicable to more or less homogeneous materials under stress, rather than on weathering or local planes of weakness. In the ordinary rock excavations encountered in civil-engineering practice, such as excavations for subways, highways, railroads, etc., rock faces are not carried to depths sufficient to develop any pressures, or consequently any failures, except those due to loose masses resulting from local planes of weakness. When, however, orebodies whose tonnage is measured by hundreds of thousands are to be extracted by steam-shovel operations in open pits, it is necessary to determine if possible in advance the slopes that the sides of the pits will assume, for these slopes influence the shape of the excavations and thereby the amount of ore that may be extracted by the open-pit method. When large orebodies are mined underground at depths of 300 to 500 ft. (91 to 152 m.) by caving methods, the surface subsiding as the ore is withdrawn, it is necessary to determine in advance the outermost limits of fracture in the subsiding surface, for on the delineation of these limits depends the location of surface improvements, mills, smelters, etc. and also the location of development work, such as hoisting shafts, main haulage levels, and all other underground openings that must remain undisturbed during the period of ore extraction. Heretofore, in civil-engineering practice, it has been assumed that earth and rock behave differently in failure. For the calculation of earth

Jan 2, 1920

By Douglas A. Sloan

Who would believe that young elementary school children could understand something as complex as the mining industry? The Challenge The challenge of accomplishing this is tremendous. An examination of Canadian school children indicated that they knew very little about the world of work in general, and hardly anything about the mineral resource industry in particular. It calls to mind the story about two youngsters who decided to play house. The little girl played her role well as she went about the house doing things she had watched her mother do every day. When it was the little boy's turn, he grabbed his lunch, waved goodbye to his "wife," jumped on his bicycle and pedalled furiously down to the end of the driveway-where he stopped. The youngster explained that he saw his dad go out of the driveway each morning, but he didn't know where he went, or what he did on the job. When you stop to consider the number of families today with two working parents, you can begin to appreciate the importance of the opportunities for role identity provided by this project. The Approach The challenge of teaching the school children of Canada about the world of work and, specifically, the mining industry is the challenge which the Canadian Institute of Mining and Metallurgy met with the Curriculum Development Research project. It started when a small, dedicated group of Vancouver members met Dr. Doreen Binnington. After this meeting, Dr. Binnington, an expert in curriculum development at the University of British Columbia, set herself to develop a curriculum program for the elementary shcools which accomplishes two main goals: It uses the "Identity Approach," developed by Dr. Binnington, an expert in curriculum development at the enable students to understand and appreciate the contribution of people, in this case, working with mineral resources. It has pupils enthusiastically exploring the importance of rocks, minerals, and the mining industry in their lives [(Fig. 1)]. Evolution of the Curriculum Development Research Project When the curriculum development research project was presented to the Vancouver Branch of the Canadian Institute of

Jan 1, 1981

By James Terry Duce

The symposium on production for the year 1940 contains few papers on the foreign situation. It is probable that the foreign part of next year's symposium will be even shorter. This is due to rigid censorship in various countries, as the question of the volume of petroleum supplies has become one of great strategic importance. This is even more true than in the last war, owing to greater mechanization of armies. 'It has always been the policy of officers in charge of the symposium to refrain from publishing information that might possibly injure national or private interests. At the close of the war we hope again to publish full and accurate records of production abroad. Excerpts from Circular to Authors In order to facilitate interpretation of the data in this chapter, we print the following excerpts from the Circular to Authors. The field is the unit in this tabulation. In cases of fields extending across State boundaries, such as Rodessa, it is suggested that each State author treat the section of the field in his State as a unit, and by a footnote indicate that the field extends into an adjacent State. Each space in Table I may represent one of four possibilities; either it is not applicable to the particular field, or the proper entry is not determinable, or the proper entry may be determinable but is not determinable from data available to the author, or the proper entry is determinable. When spaces are not applicable, leave blank; in spaces where the proper entries are determinable but not de-terminable frod data available to the author, please inserty; in spaces where the proper entries are determinable by the author, make such entries. y implies a hope that in some future year a definite figure will be available. The entry of a zero is a positive declaration, and an important declaration where it is in order. Inability to determine precisely the correct entry for a particular space should not lead the author to insert merely y. Contributions of great value may be made by the author in many cases where entries are not subject to precise determination. In sucli cases the author should use his good judgment and make the best entry possible under the circumstances. For many spaces the correct entries represent the opinion of the author (for example, "Area Proved') and in such cases the entry need not be hedged to such extent as when the quantities are definite yet can be ascertained only approximately by the author. In cases under definite headings but where figures are only approximate, the author may use x. It is thought that the nearest whole numbers are sufficiently accurate for our purposes except as to percentage of sulphur in oil. If an author desires to report any other figures to tenths, he may do so. The quantity of gas produced should include, where possible, gas sold or otherwise marketed, and gas blown into the air, burned as flares or otherwise wasted. Segregation of these figures would be interesting if the authors can make such segregation. In any event, the figures should represent as nearly as possible the total quantity of gas removed from the reservoir. Under the columns on "Depth," the average depth to the top of the productive zones and to the bottom of the productive wells, when

Jan 1, 1941

By T. S. Jr. Sligh

OF all the qualities that are essential in a good cigar tobacco none is quite so important as the burn. This term is general and includes many points, the most important of which are evenness of burn, color of ash, firmness and coherence of ash, and fire-holding capacity. The fire-holding capacity refers to the length of time the leaf or cigar will continue to, glow after ignition. Chlorides tend to prevent complete combustion and products are formed thereby that are injurious to the flavor and aroma. On the other hand, the carbonates of the alkalies, particularly of potassium, aid the combustion and increase the fire-holding capacity. Barth1 thought that the harmful effect of the chlorides was due to their fusing and coating the tobacco, thereby preventing complete combustion. Schlosing,2 Nessler,3 and Garner,4 suggested widely different theories to account for the favorable action of potassium salts. In order to study carefully the action of the various salts upon the course of combustion of the cigar a knowledge of the temperature of the burning cigar is necessary. Lehmann5 who seems to be the only investigator who has made any attempt to determine the temperature of a burning cigar gives 480° C. as the maximum temperature which he recorded. It is evident, however, that his measurements were in error, probably on account of the method and apparatus used, since the lowest visible red corresponds to a temperature of about 575° C.

Jan 9, 1919

By E. V. Daveler

THE milling plant of the Alaska-Gastineau Mining Co. is located at the town of Thane, Alaska, on Gastineau Channel, 4 mi. south of Juneau and directly across the channel from the Ready Bullion mine of the Treadwell mines on Douglas Island. Previous to the organization of the Alaska-Gastineau Mining Co., in 1912, the milling was done at the stamp mill of the Alaska Perseverance Co. located at the mine in Silver Bow Basin. But the contemplated increase in production made it necessary to locate the mill on Gastineau Channel, as not enough water was available at the mine during the winter months, nor was there room for taking care of the large tonnage of tailings that would ultimately be discarded from the mill. CHARACTER OF ORE The gold and silver values occur in quartz lenses associated with pyrrhotite, galena, arsenical pyrites, and zinc blende. These lenses occur in large bodies of slate, schist, and metagabbro, which also carry some valuable metallic contents. With the essential low cost of mining, it was necessary to mine large bodies of low-grade material containing the high-grade streaks. Of the minerals, pyrrhotite, the magnetic sulfide of iron, is predominant, and galena is the next sulfide present in quantity. The gold occurs free and coarse and associated with the iron sulfide in its finer state. The silver occurs with the lead or is alloyed with the gold. A chemical analysis of the ore shows Silver 0.10 oz. Magnesia 0.4 per cent. Silica 59.7 per cent. Sulfur 1.2 per cent. Iron 5.2 per cent. Lead 0.1 per cent. Alumina 21.4 per cent. Zinc 0.2 per cent. Lime 5.0 per cent.

Jan 1, 1920

By Sidney Cornell

THE technical- advantages of adding oxygen to air and producer gas, or using it as a reactive agent, producing 400 B.t.u. gas instead of. the present 150 B.t.u., with higher flame temperatures and a reducing flame possible, with a smaller volume of gases passing through a furnace, will result in quicker melting, sharp working, and the production of a higher quality steel. Probably electric-furnace quality steel can be produced in an open-hearth furnace using oxygen. A modern, standard, 100-ton open-hearth furnace, with all equipment, costs from $350,000 to $500,000; there are about 1000 open-hearth furnaces in this country. When considering the use of oxygen in the open-hearth furnace, it is necessary to study: (1) The use of oxygen in the present furnaces, such that modification of existing furnaces and equipment cost the minimum, although the full advantages of oxygen are not thus obtainable. (2) The use of oxygen in a furnace designed for its use, producing quality and quantity steel at the lowest possible cost. This entails the junking of approximately one-half the value in existing equipment-writing off $250,000,000. The basis of such an estimate is the present cost of manufacturing open-hearth steel. Objection may be taken to some of the unit prices here given, but while some companies obtain their ores for much less, the prices quoted are -market price. They are used to show the maximum economy obtained by oxygen at that point.

Jan 11, 1924

THE book covers principally the assaying of silver and gold and the determination of these values in ores, sweepings, and base metal. It seems to have been written more for the goldsmith and jeweler than for the primary producer of metals. There were approximately sixty different substances needed in the operations described and not over a dozen different types of raw material (ore, matte, crude or alloyed metal) are mentioned. The methods of separation used were essentially simple and reasonably reliable, though the processes were not sufficiently understood to permit the selection of the simplest effective ingredients, and there was a great tendency to employ complicated fluxes, with unnecessary repetition of long-continued heatings indicative of a leisurely pace of life. Practically all the processes described are based on a few chemical facts: the inability of gold to combine with sulphur, while silver and the base metals form easily fusible sulphides; the ready oxidation of base metals; and the ii- solubility of gold in nitric acid. Fluxes serve to make earthy impurities fusible, and to carry oxidizing or sulphurizing ingredients. Many of the processes of assaying had changed little up to the beginning of the present century. Even as late as 1924, when the writer took a University course in fire assaying, the crucibles, cupels, scorifiers, molds, and tongs were identical with those of the sixteenth century, though the wind furnace had a stack on it and the muffle for cupelling was gas-fired.* The fluxes were purer, but of the same essential composition. That this branch- or twig-of metallurgy had not advanced in any funda-

Jan 1, 1949

By B. S. Norris, Charles R. Austin

The stresses which initiate deformation processes in metals are fundamentally important in the study of the mechanical properties of metals. A point of inflection in the load-elongation curves obtained for single crystals' has been rather too readily interpreted as a true yield point, and the critical resolved shearing stress on the plane of slip taken as a material constant. Even early work showed that the stress at this point varies with rate of loading, but it has not been generally appreciated that creep tests under static loads alone are suited for determining the existence or nonexistence of a yield point.* It has now been shown by Miller that single crystals of zinc3 when loaded statically begin to yield at loads too small to measure; as a result there is no case now known, apart from that cited in the present paper, in which a true critical stress for yielding has been demonstrated for single crystals of metals. The case of iron has especial interest: the existence of an upper and lower yield point and of an elongation at the yield point in ordinary iron and steel marks this substance as unusual, though the effects have been found to a very minor degree in other metals and alloys. $ Most alloys do not show such marked phenomena when appreciable yielding begins, and accordingly modern practice is to speak of the yield strength of such materials, a stress read from the load-elongation curve after elongation has begun, rather than yield point. The special behavior of iron suggests that it is more likely that single crystals of iron should have a true yield point than other metals. The study of the mechanical properties of metals and alloys requires a determination of the crystallographic mechanism of deformation, wlletller deformation proceeds by slip, twinning, or cleavage, or a combination of these, and a determination of the stresses that induce these modes of deformation. With this information, a study of the rates of work-

Jan 1, 1938

By B. S. Norris, Charles R. Austin

The stresses which initiate deformation processes in metals are fundamentally important in the study of the mechanical properties of metals. A point of inflection in the load-elongation curves obtained for single crystals' has been rather too readily interpreted as a true yield point, and the critical resolved shearing stress on the plane of slip taken as a material constant. Even early work showed that the stress at this point varies with rate of loading, but it has not been generally appreciated that creep tests under static loads alone are suited for determining the existence or nonexistence of a yield point.* It has now been shown by Miller that single crystals of zinc3 when loaded statically begin to yield at loads too small to measure; as a result there is no case now known, apart from that cited in the present paper, in which a true critical stress for yielding has been demonstrated for single crystals of metals. The case of iron has especial interest: the existence of an upper and lower yield point and of an elongation at the yield point in ordinary iron and steel marks this substance as unusual, though the effects have been found to a very minor degree in other metals and alloys. $ Most alloys do not show such marked phenomena when appreciable yielding begins, and accordingly modern practice is to speak of the yield strength of such materials, a stress read from the load-elongation curve after elongation has begun, rather than yield point. The special behavior of iron suggests that it is more likely that single crystals of iron should have a true yield point than other metals. The study of the mechanical properties of metals and alloys requires a determination of the crystallographic mechanism of deformation, wlletller deformation proceeds by slip, twinning, or cleavage, or a combination of these, and a determination of the stresses that induce these modes of deformation. With this information, a study of the rates of work-

Jan 1, 1938

By Carl Samans

THE attention of physicists and metallurgists has been directed toward the study and explanation of the deformation textures in metals for the past 15 years. In 1920 N. Uspenski and S. Konobejewski1 were first able to show that the symmetrical X-ray diffraction effects that had been previously reported by E. Hupka2 and others in metal foils were caused by a directed arrangement of the crystallites. Since then, the systematic study of textures resulting from the application of the pure forces of tension or compression to polycrystalline materials hag been supple-mented by many investigations on deformed single crystals, which have greatly added to our knowledge of deformation. However, despite the valuable information secured from these comparative studies only four investigations upon cold-rolled single crystals of any of the face-centered cubic metals have been reported in the literature. This lack of quantita-tive data is especially unfortunate because of the much greater practical significance of rolling textures and their effects in both cold-rolled and annealed materials. This investigation was undertaken for the purpose of specifying the deformation of rolled single crystals in the hope that such information might later facilitate the explanation of polycrystal-line textures.

Jan 1, 1934

By Frank W. Osterwald

Violent, spontaneous destruction of coal faces and ribs during, what are commonly called, bumps endangers and at times destroys life and property in mines of the Book Cliffs coalfield, Carbon County, Utah. Because these mines supply much of the coking coal for the West Coast steel industries, mining is necessary, although costs are high and operating conditions are very difficult at times. As operations continue, mining will go to greater depths, and the difficulties will increase. Whether or not mining can be continued successfully depends in part on whether or not incidence of bumps can be controlled successfully. For this reason, the U.S. Geological Survey, at the request of and in cooperation with the U.S. Bureau of Mines, undertook a study of the Sunnyside No. 1 mine to determine what geologic factors were related to the incidence of bumps. This report presents the preliminary results of that study and indicates that some observable geologic features in the mine may be related directly or indirectly to bumps, and that other features may be used to infer stress distribution around workings that will aid in design of roof support measures. Coal is mined in the Sunnyside No. 1 mine from depths as great as 2500 ft by room-and-pillar methods. The surface topography is rugged with many steep cliffs and deep canyons, hence the load on the coal varies greatly within short distances. Much of the Sunnyside coal is under high stress, and while being mined, it shatters continuously' and falls from the face. Continuous shattering (bumping) makes mining easy, but if the shattering is interrupted, greater stress is built up and violent bumps may result when the coal is mined.

Jan 4, 1962

By P. R. Kalischer

IN the production of alloys by powder metallurgical processes it is often necessary or desirable to include one or more components that tend to form very stable oxides Included in this group of metals are aluminum, manganese, magnesium, silicon, and a few others In many cases it is not necessary for the sintered compact to have full density and the other physical characteristics of a cast alloy and in that event no undue precautions need be taken If, however, it s required that the sintered part be entirely homogeneous, and have maximum density and physical properties, some method must be found to reduce the surface films of oxide, which are always present on the metals, and for the metals mentioned above this is always extremely difficult, if not impossible Since the production of high-density alloys is of particular interest to powder metallurgists, some experiments were undertaken to devise methods of reducing the refractory oxides For this work, alloys of iron, nickel, and aluminum were chosen because aluminum oxide is one of the most stable oxides and because these alloys in the right compositions form excellent permanent magnets All of the pertinent properties of the magnets could be accurately and delicately measured by density measurements and magnetic tests of sufficient scope to give a complete demagnetization curve From such a curve the maximum coercive force, residual magnetism, and energy products could be obtained and compared with the same properties for a cast material Any lack of homogeneity, density, or solid diffusion would be immediately apparent as a decrease in the magnetic properties NATURE AND REMOVAL OF SURFACE BARRIERS The early work of the present investigation was based upon published processes In the published information it was claimed that by intimately mixing iron, nickel, and iron-aluminum alloy (50 per cent Fe, 50 per cent Al) powders, compressing such a mixture into the desired shape and size, and then sintering (heating to a temperature below the melting point of the component metals) in hydrogen at 1200ºC or higher, a sound, homogeneous article could be made having the desired physical size, shape, and strength, and good magnetic characteristics However, this early work showed clearly that something in the powder compress was inhibiting diffusion and the process was almost entirely unworkable In the initial phase of the investigation samples of iron powder, nickel powder, and iron-aluminum alloy powder were pressed into separate bars and sintered in hydrogen Both the iron and nickel powders sintered

Jan 1, 1941

By J. T. Norton, N. J. Grant, I. S., Servi

Coarse grained high purity aluminum was tested in creep at temperatures of 400° to 1200°F to develop subgrain structures. Measurements of subgrain size, distribution, and rotation were made from X-ray diffraction patterns. Subgrain size and distribution were checked metallographically and the size was compared with average slip band spacing. The slip family was determined for several specimens. THE interest and research recently evident abroad in the role of subgrain formation and polygon-ization as a contribution to the creep of metals at elevated temperatures is deserving of greater attention in this country. Such metallic subgrains can be defined as macroblocks existing within the grains. The general observation has been that the macro-blocks which belong to the same grain have a maximum difference in orientation of a few degrees. In spite of the considerable amount of work that has been done since Jenkins and Mellorl observed the "division of existing crystals into smaller units when deformation occurs at an annealing temperature," the subject of subgrain formation is only now receiving truly active discussion and investigation. The existence of subgrains has been revealed by metallographic methods, as in the work of Jenkins and Mellor,1 and by X-ray methods, first applied to this problem by Homes.' Hirst3 and Calnan and Burns4 applied the back-reflection Laue technique to the study of coarse grained specimens. Wood et al.5 and Greenough and Smith' examined the ring obtained with a back-reflection camera for the study of fine grained specimens. In addition to the above, the transmission technique was used by Wood.6 A special technique was developed by Guinier and Tennevin8 in order to improve the resolution. Metallographically, the subgrains have been observed directly on the surface of deformed specimens by Wood et al.,3 or have been made evident on repolished surfaces by applying a suitable etching reagent. The latter technique, first suggested by Lacombe and Beaujard,9 was then improved by Wyon and Crussard.10 Subgrains can be formed in single crystals after small amounts of bending followed by heating after this cold work, or during deformation at elevated temperatures. The first phenomenon was analyzed by Cahn11 for the simple case of pure bending followed by annealing. Cahn suggested a mechanism of subgrain formation based on the dislocation theory and called this phenomenon "polygonization." He extended this mechanism to the more complex case of local bending, such as the bending which may occur when a polycrystalline specimen is deformed in tension. Cahn's suggestion was later found quite consistent with the results obtained by Dunn and Daniels." An explanation has been presented recently regarding the formation of subgrains during deformation at elevated temperatures by Chang and Grant.'" In general, there are two schools of thought on the subject. One, according to Wood et al.,5 is that subgrain formation is a mechanism of deformation which is operative under certain conditions in the same way that the slip process is the mechanism of deformation which is operative under other conditions. The boundaries between the subgrains undergo a viscous flow which contributes substantially to the deformation of the material. The second, according to Cahn,13 Wyon and Crussard,10 and Chang and Grant,18 is that subgrain formation is the effect of simultaneous deformation and annealing and is,

Jan 1, 1953

By J. E. Steiner, J. M. Hodge, M. A. Orehoski

Ingots of four steels (1045, 1080, Ni-Mo-V, and Ni-Cr-Mo-V) were cast at pressures varying from about 1 to 760 mm of mercury, so as to obtain a range of hydrogen contents in each steel. The susceptibility of these steels to flaking was evaluated by cooling hot-rolled blooms at a range of cooling rates, varying from water quenching to slag cooling, and studying the occurrence of flaking as a function of cooling rate. The steels exhibited differences in susceptibility to flaking, and a tlzreshold value for hydrogen content for each steel was found, below which the susceptibility was very low and above which the susceptibility increased markedly with increasing hydrogen content. Mechanical property evaluations, metallogvaplzic exantinations, and X-my diffraction determinations o,t retained austenite were made on samples from the blooms. A mechanism of flaking which is consistent with the observed behaviors, the effects of hvdrogen content, and the differences in susceptibility among the steels investigated is postulated, based on the results of mechanical property evaluations and metallographic and X-ray diffraction studies. ThE important role of hydrogen as a factor in the occurrence of "flakes" or "hair-line cracks" in steel has now been established by many investigations. These have included investigations by steel producers and forging manufacturers, to whom the prevention of flaking is a very real and serious problem, and many research studies aimed primarily at establishing the mechanism of this behavior Several investigators3 have reported that steels cast at reduced pressures (absolute pressures of about 1 mm) not only are low in hydrogen content but are essentially insensitive to the formation of flakes. These investigations have shown that a general relationship exists between hydrogen content and susceptibility to flaking. The difficulty of obtaining suitable samples of steels of a given composition with the desired range of hydrogen contents, particularly in the relatively large sections in which flaking most commonly occurs, has been the principal obstacle to quantitative evaluations of these relationships. Steels with intermediate hydrogen contents between 1 ppm, and the 4ppm or higher of air-cast steels are generally not available in commercially produced steels. Laboratory procedures, in which the hydrogen is introduced into solid steel samples by heating in a hydrogen atmosphere under pressure, generally involve a limitation in the size of the sample which can be treated, and thus are not representative of the behaviors in large sections. The availability of a facility at the South Chicago Works of U.S. Steel, in which several ingots could be cast from a single heat of steel at total air pressures ranging from 0.25 to 760 mm of Hg, has made it possible to overcome this obstacle and to obtain ingots of a given steel covering the intermediate range of hydrogen contents desired. These ingots, furthermore, are of a size suitable for the production of product with section sizes large enough to be representative of the products in which flaking most commonly occurs in commercial production. In these experiments, this facility was used to study the relationships between hydrogen content and the susceptibility to flaking of four steels, two plain carbon steels at 0.45 and 0.80 pct C and two low-carbon alloy steels representing a medium and a rather high hardenability level. These flaking studies were supplemented by evaluations of mechanical properties and by metallographic studies on samples from the blooms, in order to obtain pertinent information on the factors other than hydrogen content which influence the susceptibilities of these steels to flaking. Based on the results of these tests, a mechanism for the initiation and propagation of the flaking cracks, which is consistent with the observed behaviors, is postulated. MATERIALS AND EXPERIMENTAL WORK Steelmaking and Conversion. To provide material for the investigation, five 29- by 35-in., hot-topped, big-end-up ingots were cast from each of four 80-ton, basic electric-furnace heats of four different steels (a 1045 steel, a 1080 steel, a Ni-Mo-V steel, and a Ni-Cr-Mo-V steel). A double-slag practice was used on all steels and the two plain carbon steels were Si-A1 deoxidized with an addition of 2 lb of A1 per ton, while the Ni-Mo-V and Ni-Cr-Mo-V steels were deoxidized only with silicon and

Jan 1, 1964

By A. Coskun, J. F. Elliott

The activity of aluminum in liquid Al-Fe alloys .has been measured by an improved version of the transportation method in which the metallic vapor has been collected by its solution in a metallic condenser. The results can be represented by the equation: log yAl = -3.0(1 - xAl2) (0.6 < XAl < 1.0) This equation applies at 1315°C. MORRIS and zellarsl adapted the transportation method for measuring the vapor pressure of a com- ponent of an alloy at high temperature. We have modified their technique further2 for use with metals that are strong oxide formers. In the present case the method has been applied to the Al- Fe system to obtain the activity of aluminum in the liquid region at 1315°C. Dried ultrahigh-purity hydrogen (Matheson) is the carrier gas. The operations, Fig. 1, of deoxidizing the gas, equilibrating the gas with the sample at 1315";, and then collecting the aluminum vapor are all accomplished within a single, continuous alumina tube to avoid contamination of the system by leaks. De-oxidation to a very low level of PO2 (<10-25 atm) is Obtained by passing the hydrogen through a tightly packed bed of aluminum powder. The temperature of this bed increases to approximately 550°C in the direction of the gas flow. The boat containing three pellets of the alloy is supported on the end of a

Jan 1, 1969

By E. J. Ripling

TUBES may be produced by a large number of forming processes, the most common of which will be discussed analytically in this paper. In no case will the stress analysis for any given tube producing process be derived formally for where such analyses are available, they may be referred to readily. Rather, emphasis will be placed on the interpretation of the theory of the different processes, few of which are developed to a state that will allow rigorous mathematical analyses, in an attempt to give a rational description of the effects of the different variables involved in each method. Tube producing methods can be divided into two groups: Those used to form shells, and those used to further work these shells into a shape more suitable for their final use. Among the first group are included roll piercing, extrusion and cupping for seamless shells, and bending with welding for welded tubes. The re-forming processes include sinking, drawing with a plug, and drawing with a rod. Only the plastic forming operations will be discussed here; other forming processes such as casting shells will not be considered. PRODUCTION OF SHELLS Shells for Seamless Tubing Piercing: The extremely important process of forming an axial hole in a billet by oblique rolling never has been analyzed satisfactorily, although a certain amount of experimental work relating to this process has been conducted. There are a number of factors that make piercing difficult to analyze; one of these is the fact that piercing is not a problem in plasticity, but one in fracturing, and the laws of fracturing are even less well understood than those of plasticity. If, however, it is assumed that fracturing occurs on a surface as a result of tensile stresses acting normal to this surface, piercing can be analyzed qualitatively by examining the stresses established in the oblique rolling process. To determine the origin of the tensile stresses that are thought to effect piercing, it will be necessary to know the angular relationships between the maximum stresses that are established in piercing. These angles quite frequently can be determined in a plastic deformation process by an examination of the deformed product. For example, consider the stresses established when a tensile test is conducted on a rectangular cross-sectional specimen of pearlitic steel. When stretched, this material first flows plastically, exhibiting the well-known yield jog on a stress-strain curve. The formation of the slip areas that give rise to the yield jog can be detected during the straining, since these flowed areas cause depressions on the specimen surfaces which can be seen if the surfaces are polished highly. The plastically strained areas also can be found after the specimen has been stretched to a strain not exceeding the yield jog, by sectioning the test piece and. etching these sections with Fry&apos;s etch. With this etchant, it is possible to dis-

Jan 1, 1951

By Cyril Stanley Smith

The method of thermal analysis, so important in the development of metallographie science, has of recent years been falling into disuse owing to the development of other physical methods which give result&apos;s easier of interpretation and which can be used for the study of either equilibrium or transitional conditions because they do not require a continuously changing temperature. Nevertheless thermal analysis remains useful in the study of reactions that take place rapidly, and the simplicity of the experimental technique and the general availability of the apparatus involved are point&apos;s in its favor. Theoretically, thermal analysis is capable of giving specific and latent hat measurements and therefore should permit the study of reactions on a more fundamental basis than any other method. It is, however,difficult or impossible to obtain quantitative heat measurements from cooling curves obtained in the usual way. Even if the furnace containing the sample is cooled or heated at a linear rate, or if a gradient furnaec is employed to maintain a constant rate over a large range of temperature, the heat flow from or to the specimen depends on its previous history, for the difference of temperature between the specimen and its surroundings varies. The emissivity of the specimen surface, moreover, is unlikely to be constant. The able mathematical analysis by Russrll,1 although it prevent,s misinterpretat,ion of data, has an effect rather the reverse of that intended, and leaves the reader doubtful of the possibility of ever obtaining quantitative results from thermal curves. Nothing can be done to apply thermal analysis t&apos;o the study of equilibrium conditions of reactions that arc not completed at rates of temperature change above about 1° C;. per minute, and this unfortunatetly excludes most solid transformations in alloys.† For the determination of liquidus

Jan 1, 1940

By Cyril Stanley Smith

The method of thermal analysis, so important in the development of metallographie science, has of recent years been falling into disuse owing to the development of other physical methods which give result&apos;s easier of interpretation and which can be used for the study of either equilibrium or transitional conditions because they do not require a continuously changing temperature. Nevertheless thermal analysis remains useful in the study of reactions that take place rapidly, and the simplicity of the experimental technique and the general availability of the apparatus involved are point&apos;s in its favor. Theoretically, thermal analysis is capable of giving specific and latent hat measurements and therefore should permit the study of reactions on a more fundamental basis than any other method. It is, however,difficult or impossible to obtain quantitative heat measurements from cooling curves obtained in the usual way. Even if the furnace containing the sample is cooled or heated at a linear rate, or if a gradient furnaec is employed to maintain a constant rate over a large range of temperature, the heat flow from or to the specimen depends on its previous history, for the difference of temperature between the specimen and its surroundings varies. The emissivity of the specimen surface, moreover, is unlikely to be constant. The able mathematical analysis by Russrll,1 although it prevent,s misinterpretat,ion of data, has an effect rather the reverse of that intended, and leaves the reader doubtful of the possibility of ever obtaining quantitative results from thermal curves. Nothing can be done to apply thermal analysis t&apos;o the study of equilibrium conditions of reactions that arc not completed at rates of temperature change above about 1° C;. per minute, and this unfortunatetly excludes most solid transformations in alloys.† For the determination of liquidus

Jan 1, 1940