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By L. W. Kempf, K. R. VanHorn

PLASTIC deformation of most commercial metals within a sufficiently low temperature range results in profound changes in structure and properties, of which the causes and effects are not completely understood. One of these effects is the presence of internal residual stresses and strains, which ordinarily do not appear to require specific consideration in most structural applications but which may be quite undesirable in particular instances. For example, in heavy sections that require considerable machining before assembly, residual stresses may be undesirable because of the distortion they cause when their balance is disturbed by machining or otherwise. In addition, the distribution of stresses may be such that it acts in the same direction as the applied load, thus bringing about premature failure or reducing the load-carrying capacity of the member. One source of residual stress in metal structures is the plastic deformation that may occur during rapid cooling from relatively elevated temperatures, as in the cooling of a casting in the mold or the quenching of a heavy section from elevated temperatures during heat-treatment. These residual stresses are usually undesirable because their direction of operation and magnitude cannot be controlled well enough to permit utilization of the changes in properties of the metal that they may bring about. The most convenient manner of controlling such residual stress is by proper selection of the cooling rate or by reheating to a temperature at which plastic flow can take place, resulting in relief of the residual stresses and strains. Both of these methods of control, however, may cause a reduction in the optimum properties obtainable from the previous operation compromise must be struck, and if it is to result in the best possible combinations of properties, specific information must be available regarding the magnitude of the stresses and the rate at which they are affected by variations in cooling rate or in reheating temperature. The complete quantitative estimation of residual stress in complicated metal shapes is exceedingly difficult, if not impossible. In simple sections, however, relatively quantitative analysis may be applied and useful estimations of stress distribution may be made. This paper is concerned largely with the rate of relief, upon reheating, of internal residual stress in simple aluminum-alloy structures. Since even with simple structures quantitative estimation of residual stresses is laborious and costly, an attempt was made to find other means of collecting data upon which commercial heat-treatments might be based. Incidentally, a few data were collected bearing on the problem of relaxation of aluminum alloys. DETERMINATION OF RESIDUAL STRESSES The magnitude and distribution of residual stresses in simple aluminum-alloy shapes rapidly cooled from elevated temperatures has been discussed in a previous paper.1 Fig. I reproduces some of the data

Jan 1, 1941

By S. E. Bronisz, J. O. Brittain

Experiments have been carried out to study the effect of an applied stress on strain aging in steel. It was found that the stress-induced strain aging reaction proceeds rapidly in the temperature range of 0° to 60°C. The variation of stress-induced strain aging with plastic strain, aging time, and temperatures is reported. The activation energy for the stress-induced strain aging was found to be 10,000 cal per mol for the steel used in this investigation. VARIOUS observations1-5 have been made of the influence of an applied stress upon the yielding of iron and steel. However, there have been only cursory studies of the effect of an applied tensile stress upon strain aging in iron and steel1,2 The following represents the results of a preliminary study of strain aging as influenced by the application of an external tensile load during the aging process. For the most part, previous experimental work on strain aging can be classified into two parts. First, the experimental technique involved a direct determination of mechanical properties of a suitable specimen that has been plastically deformed to a constant strain and aged generally at a temperature of the order of 200°C, with the aging times varying from about 1/10 to 2 hr.6-8 The second classification of strain aging experiments involves an indirect determination of strain aging by means of physical property such as electrical resistivity or internal friction as a function of the aging time at a constant temperature and strain.9-12 The latter results have

Jan 1, 1961

By D. K. Crampton

INTERNAL stress and season cracking in brass have been studied for many years and the technical literature contains many data on various phases of the subject. A résumé of the literature shows certain fairly well established points upon which various authors are mostly agreed: 1. Season cracking is primarily caused by the presence of relatively high internal stresses, or possibly in some cases by external stresses, or both. 2. A specific corrosion is also essential to season cracking: Certain agents, particularly mercurous salts, mercuric salts and ammonia salts; have such a specific corrosive effect. 3. The tendency to season crack under given conditions increases with increasing zinc content, brass containing less than 20 per cent zinc being relatively immune. 4. In alpha brass the season cracks are intercrystalline; in alphabeta brass they lie between the two constituents; and in beta brass they are transcrystalline. 5. The ordinary impurities or added elements in special brasses have little or no effect on the tendency to season crack. 6. Internal stresses can be eliminated, or at least reduced to a safe 'limit by annealing treatments at temperatures that do not produce visible microstructural changes or appreciable softening of the worked brasses. There are, however, some points in connection with the phenomenon of season cracking which have not been thoroughly investigated, or wherein different authors and investigators are not entirely in agreement. The investigations described in this paper were undertaken to determine: 1. The correlation between mercurous nitrate tests and actual season cracking on long-time atmospheric exposure. 2. The quantitative effect of type and degree of drawing operations on the intensity of internal stress and on the tendency to season crack in brass tubes. 3. The possibility of drawing high-brass tubes in such a manner as to prevent the occurrence of harmful stresses rather than to find a remedy for such stresses once having obtained them.

Jan 1, 1930

By R. P. Carreker, J. C. Fisher

Cheep tests are normally constant load tests. Such tests approximate some types of service conditions and therefore are justified from the engineering point of view. Coupled with this consideration is the advantage of simplicity inherent in constant load tests, as contrasted with the comparatively complex requirements of a constant stress test. It is not surprising that the vast majority of creep tests reported are of the constant load type. Despite the enormous amount of accumulated creep test data, plastic flow is by no means completely understood. The widespread use of constant load tests is at least partly responsible for this lack of understanding. Any attempt to analyze deformation must involve the more fundamental quantity stress, rather than load. It is possible to predict constant load behavior from known constant stress data, but the reverse is much more difficult. When a metal specimen elongates, as in a creep test, the cross section decreases, maintaining constant volume. Thus For a constant stress test the force on the specimen must be decreased as the cross section decreases, that is, this force must be inversely proportional to the elongation of the specimen. An-drade has described three methods of obtaining the constant stress condition,l-3 each of which is relatively complex. The most recent proposal,³ suggests a major simplification which maintains the simplicity of the constant load test while approximating quite closely the desirable condition of constant stress. Andrade's device is admittedly more accurate but the method described below has definite advantages Consider a specimen in the form of a "V" supported at its ends. If a weight be applied at the vertex of the angle, the stress in each leg of the "V" If this stress causes an elongation ?1 in each leg of the "V," the angle decreases from a. to a smaller angle a1. The quantity sec — thus decreases with specimen elongation while the quantity 1/A increases. By selecting proper initial conditions it should be possible to hold S/So very nearly constant at unity. The proper initial conditions are realized when a0 is made equal to approximately 90°. Fig 1 compares the ratios of S/S0 for a0 = 85, 90, 95, 100°, with a0 = 0, that is, a straight speci- men, for true strains up to e = 0.10. It may prove convenient to measure X, the movement of the vertex, rather than the true elongation 1. Contour lines of X/lo are also plotted in Fig 1. The method for obtaining constant stress described above is especially suited to the testing of small wires, but may easily be extended to rods of any diameter through the use of a suitable grip which serves as the vertex joining two identical rods forming the legs of the "V." References 1. E. N. da C. Andrade: On the Viscous Flow in Metals, and Allied Phenomena. Proc. Roy. Soc., A, 84, 1, (1910-11). 2. E. N. da C. Andrade and B. Chalmers: The Resistivity of Polycrystalline Wires in Relation to Plastic Deformation, and the Mechanism of Plastic Flow. Proc. Roy. Soc., A, 138, 348, (1932). 3. E. N. da C. Andrade: A New Device for Maintaining Constant Stress in a Rod Undergoing Plastic Extension. Proc. Phys. Soc., 60, (3). 304, (March, 1948).

Jan 1, 1950

By Gerald Edmunds, R. K. Waring, E. A. Anderson

Brass is liable to failure under the combined influence of stress, certain corrosion media, and time, a phenomenon commonly termed season cracking or stress-corrosion cracking. The consequences of this are serious in applications of brass generally, including the important field of cartridge cases. Cartridge cases (70 Cu: 30 Zn) that fail from this cause may allow the escape of gas from the gun breech, a hazard to the shooter, and may not eject, thus temporarily putting the gun out of action. In loaded cartridge cases, the stress present is partly residual from the, drawing and necking operations and partly applied by the insertion of the projectile. Ammonia, present as a decomposition product of smokeless powder, air and moisture constitute corrosive media. The prevalence of season cracking has been reduced considerably, but not eliminated, during the past quarter of a century by low-temperature annealing to relieve stresses residual from fabrication, a method suggested by Diegel 38 yr. ago(I).2

Jan 1, 1945

By Fun-Den, Wang

An open pit rock structure usually contains geological planes of weakness. They are formed by joints, faults, bedding planes, fractures, and cleavages. Rock slope failures often occur in the form of sliding of rock blocks along a plane or several planes. Such a rock block has three- dimensional geometry, and consequently a vector method of analysis has been found useful in evaluating its stability. Rock blocks of a tetrahedral shape with one free surface have been analyzed by Londe. Rock blocks formed by sets of parallel joints have been analyzed by Wittke. The present chapter presents the analysis of rock blocks formed by planes of weakness of arbitrary orientation, and of three-dimensional geometry.

Jan 1, 1972

By Å. Sterten, R. Tunold, J. Brun, K. Dalatun

c axis compression behavior of beryllium single crystals at three purity levels under hydrostatic pressures up to 27 kbars was determined. Extensive non-basal slip, observed by two-surface trace analysis and transmission electron microscopy, occurred under a hydrostatic pressure of about 12 kbars (175 ksi) for the high-purity (twelve-zone pass) material and at about 19 kbar (275 ksi) for the lower-purity (zone-leveled) material. Prismatic loops with a (c + a) Burgers vector were observed in association with second-phase parti- A principal factor limiting the use of beryllium is its brittle behavior when tested at the usual strain rates (E = 10-4 sec- 1) at temperatures below about 200°C and under impact conditions at temperatures in excess of 200°C. It has been proposed' that the brittle-ness of beryllium is associated with the lack of a sufficient number of independent slip modes and the absence of a slip mode with a Burgers vector out of the basal plane [presumably (c + a) pyramidal slip mode] and to the ease with which beryllium cleaves on the basal and second-order prism planes. The absence of pyramidal slip has been attributed to a high Peierls-Nabarro stress associated with the motion of dislocations with a (c + a) vector and the ease with which cleavage occurs on the basal and second-order prism planes. The experimental evidence in support of the proposed explanation for the brittleness of beryllium is far from complete; for example, that the ductile-to-brittle transition in polycrystalline beryllium is associated with the operation of profuse (C + a) slip has not been unequivocally established. The occurrence of (c + a) slip ({1122}(1123)) has been experimentally established2-5 under conditions where basal and prism cleavage are restricted in a c axis compression test. In these investigations (C +a) slip was found in high-purity beryllium single crystals tested in c axis compression* at 200°C and in Be-4.4 pct Cu and Be-5.2 pct cles in the lower-purity materials tested. The loops were related to surface "extrusions" observed on many of these same specimens. Nonbasal dislocations operating on (1122) planes with a (c + a) Burgers vector were observed. The presence of c and a dislocations together with (c + a) dislocations suggests that the (c + a) dislocations dissociate presumably on unloading or after failure of the test crystals to c and a dislocations. terial, (c + a) slip has only been observed near the the fracture4 surface in room-temperature c axis compression tests. Fracture in these tests occurs without measurable plastic flow, as determined with a strain sensitivity of 10"6. Since it has been shown for many metals that the application of hydrostatic pressure suppresses fracture,?-' it was felt that studying the behavior of unalloyed beryllium single crystals stressed in c axis compression under a hydrostatic pressure would reveal whether (c + a) can occur if fracture was prevented, and that it might elucidate the role of (c + a) slip in the ductile to brittle transition. Evidence that (C + a) slip is associated with increased ductility in a high-pressure environment has been found in stress-strain tests on poly crystalline beryllium.10 The present paper describes a study on the influence of a hydrostatic pressure environment on the occurrence of (c + a) slip in beryllium single crystals. Material of two purity levels was tested in c axis compression over the pressure range ambient to about 27.5 kbars.* 1) MATERIAL PREPARATION AND CHARACTERIZATION Two lots of low-purity single-crystal beryllium were used. The first lot was "ingot secondary refined grade" and designated lot A. The second lot (lot B) was produced by a two floating zone pass zone-leveling operation in an argon-filled sealed quartz apparatus on a 1-in.-diam by 12-in.-long bar of Pechiney secondary refined-grade vacuum-cast and hot-extruded material. The high-purity material (lot C) was made by traversing twelve floating zone passes through a similar bar of Pechiney secondary refined-grade vacuum-cast and hot-extruded material. In a series of spark cutting and lapping procedures,11 single-. crystal specimens some 0.12 in. sq by 0.30 in. high were made with the sides Parallel to the first- and second-order prism planes and the basal plane within 3' of arc of the top and bottom surfaces of the specimen. Such an accurate orientation is necessary because of the large difference in resolved shear stress

Jan 1, 1970

By H. Kenworthy, M. M. Fine

The progress made to date in the mineral dressing of complex Arkansas titanium ores is reported in this paper. Concentrates of rutile, a dioxide of titanium, were produced by treating a submarginal ore from the Magnet Cove Rutile Co., Inc., Magnet, Ark. The rutile recovery at present is 45 to 50 pct of the total TiO2 with the possibility of increased recovery with additional research. The work reported herein is part of a general study which will later include results of investigation of other titanium ore bodies in the Magnet, Ark., area. The fragile character of the rutile minerals, the softness of the gangue, the occurrence of pyrite and leucoxene, and the considerable proportion of extremely small size rutile in the presence of montmorillonite- and illite- type clays in the Magnet Cove open-pit mine are the important factors in the mineral dressing of this submarginal rutile ore.

Jan 1, 1949

By Clinton H. Crane

IN October, 1925, J. R. Finlay delivered an address entitled, "The Future Price of Lead." Lead was then selling at 8.85c. and Mr. Finlay and most of the rest of us were concerned about the shortage. Now, a little more than six years after, lead is selling for 3.55c., and nobody is worrying about the difficulty of getting plenty of it. For 1931 the U. S. G. S. reports United States produc¬tion as 390,000 tons of recoverable lead in ore. Our estimate is slightly higher than this; nearer 400,000 tons. This is the smallest production since 1911 and 1912, but in spite of this, stocks for the year-have increased nearly 50,000 tons. Our estimate for the production outside the United States is 1,120,000 tons, or more than double the production of either 1920 or 1921, and 30 per cent more than in 1913. Stocks abroad probably have not increased more than stocks in the United States. In other words, foreign consumption is double what it was in 1.920-21, whereas domestic consumption is substantially less. It looks as if Mr. Krueger, president of the Swedish match trust, was right when he said that "This country had better stop worrying about Europe and think a little bit more about its own affairs."

Jan 1, 1932

By A. Brown

RAPIDLY rising world demand for mineral products has accelerated depletion of the more readily accessible ores, particularly those of premium grade. Operations must proceed at a faster rate to deeper horizons, where there are problems of ground control that restrict economic recovery of the mineral and introduce new hazards to mine personnel. For some of the new Canadian mining fields severe problems of ground stress are still in the future, but much of Canada's mineral output comes from well established mines that have reached considerable depths. It must also be anticipated that the depletion of premium grade ores will eventually necessitate mining low grade material at competitive cost, and unsolved problems of ground control can materially increase costs. Studies of ground stress phenomena in underground workings are therefore considered a present-day necessity, especially since these investigations must be a long-term effort owing to the highly complex nature of the problem and the difficulty of making full-scale observations. In recent years the Mines Branch of the Department of Mines and Technical Surveys in Canada has conducted such an investigation. This report of the work is primarily concerned with stress problems in some Canadian coal mines and, in particular, with mine bumps. Mines Branch investigations of this and related problems are carried out by a small team of mining engineers and physicists who, with assistance from geologists, pool their special skills in an integrated program. These Canadian investigations combine a field and laboratory approach. Since data obtained under contrasting mining conditions allow useful comparisons of ground behavior under stress, this article will present data gathered under a wide range of Canadian coal mining conditions. Two contrasting longwalls in eastern Canada will be discussed and two dissimilar pillar extraction operations in western Canada. Locale of Observations In eastern Canada observations are being made in the collieries at Springhill, Nova Scotia. The district's No. 2 mine, which has a history of bump occurrences dating back to 1917, is currently being worked at a depth of 4200 ft. The mining method is longwall retreating along the strike and the practice is to retreat three walls in line, each about 350 ft long. There is no machine cutting or shooting—the coal is hand-picked and hand-loaded onto face conveyors. There are three rows of hardwood chock block supports parallel to the coal face. These supports are built during the two daily coal loading shifts, and the rear line is withdrawn during the midnight shift. The goaves are partially packed by stone midwalls 12 ft wide which are built forward daily in step with the face advance. The seam dips at 15° and averages 9 ft of strong, well cleated bituminous coal enclosed in competent beds of shales, sandy shales, and sandstones of Carboniferous age. The bumps rarely disturb the retreating longwall faces but manifest themselves as violent upthrusts of pavement in the levels leading to the walls. Observations have also been made in Springhill's No. 6 mine, which operated in a 5-ft seam of coal at a depth of about 2500 ft. Although No. 6 mine was

Jan 1, 1959

By George J. Young

(Cleveland Meeting, October, 1912.) I. GENERAL. THE recurrence of mine-fires in Nevada during the past decade is not only a matter of interest, but also one of considerable concern to engineers and mine-managers. The more important fires may he enumerated as follows: Forman Shaft fire., Gold Hill, April 21, 1903 ; shaft-house, machinery, and shaft, destroyed; loss estimated at $50,000.; Cause Unknown. Union Shaft fire, Virginia City, July 14, 1904; shaft-house, machinery, and shaft in part destroyed; loss estimated it $100,000; cause of fire stated as the careless throwing of a match in the rope-house. Sutro Tunnel fire, Virginia City, Jan. 27, 1909 ; 700 ft. of tunnel-timbering destroyed, and direct damage of $10,000; cause ' probably electric wires." Belcher Shaft fire, Gold Hill, Aug. 9, 1910; shaft-house destroyed, machinery ruined, and upper part of shaft damaged; damage, $25,000; no cause given. Belmont Mine fire, Tonopah, Feb. 23, 1911; fire started in winze ; 17 men killed. Giroux Mine fire, Kimberly, Aug. 23, 1911 ; fire originated iii shaft-station from unknown cause; 7 men killed, and $34,¬521 damage caused. (NOTE 1.-On June 11, 1912, some time after the present paper was written, a fire broke out in the pump-room on the 2475 station of the Ward shaft, Virginia City. This fire was caused by the short-circuiting and exploding of the starting-switch on No. 5 pump. The oil in the switch was scattered about and set fire to the timbers and laming of the pump-room. The pump-roan in charge notified the surface, and the * Professor of Mining and Metallurgy, Mackay School of Mines.

Oct 1, 1912

By Shosei Serata

Conventional roof bolting may be giving ground to a new technique that utilizes only the ground itself to stabilize mine openings. This newly developed stress control technique (SCT) has initially been used in sedimentary ore bodies that are both overlain and underlain by weak strata. The technique is also suited to the design of production panels and main entry systems, and is readily adaptable to room and pillar as well as total- extraction mining, including both shortwall and longwall coal mining. In applications where the technique has been used, the requirements for roof bolting and floor renewal were virtually eliminated. The SCT comprises three basic methods and covers a wide range of problems associated with failing roofs and heaving floors in underground mines (see Table 1).

Jan 5, 1976

By C. E. Sims, C. A. Zapffe

MANY hundreds of publications have appeared during the past 78 years that treat the subject of hydrogen in iron and steel,105 but conclusions regarding the functions of hydrogen in causing some important defects in steel are still unsatisfactory to many; and other hydrogen-caused phenomena yet remain to be identified with this gas. The most widely discussed of these defects is hydrogen embrittlement, but the conception, perhaps the popular one, that embrittlement is due to hydride formation does not conform to the known facts.104 The true identity of hydrogen embrittlement seems instead to lie in a mosaic nature of metal crystals, which is a concept not yet accepted by most metallurgists. A study of hydrogen embrittlement therefore provides new viewpoints in regard to the crystalline substructure of steel. A second widely discussed hydrogen-caused defect is the "flake" or "shatter crack." Although it is generally agreed that the presence of hydrogen is a prerequisite for their appearance, it is also realized that internal stress plays a decisive part. The relationship of hydrogen to internal stress has not been explained very clearly; nor is it always clear what the relationship is between a "flake" and a "snowflake," or between a "fish eye" and a "shatter crack." More importantly, the relationships among hydrogen embrittlement, hydrogen-caused fissures such as "flakes" and the ultramicroscopic structure of steel have scarcely been recognized. The present investigation attempts to provide an explanation for the embrittlement of steel by hydrogen by showing cause for accepting the "block" concept of metal crystals, and then to show how the numerous hydrogen-caused defects are interrelated in the light of this concept. EVIDENCE OF SUBSTRUCTURE IN METAL CRYSTALS It appears that the concept of a crystal as an aggregate of smaller multi-atom units must be accepted in some form if the behavior of metals is to be understood. The abundant literature on the evidence of an ultramicroscopic "mosaic" structure in metals and other crystalline substances suggests that the physicist has provided the metallurgist with an invaluable new insight. The exact picturization that any one physicist provides may be open to question, but the fact that there is some such fundamental substructure seems undeniable. The present work makes no pretense of comprehensively treating the imperfection structure theories. Nor will conclusions be drawn here regarding the exact nature of the substructure of crystals. However, the acceptance of some imperfection theory of fundamental attributes seems so necessary to an understanding of the behavior of hydrogen in steel that the following brief

Jan 1, 1941

By Charles E. Heinrichs

IN the last decade one of our oldest and largest non-metallic metallic mineral industries has been the subject of persistent technical research, the results of which are another example of the benefits following the systematic application of scientific principles. The consequent improvement in the technique of phosphate recovery represents the greatest material advance in the industry since the discovery of phosphate in Florida in 1881. Moreover, these successes have stimulated interest and development in numerous other nonmetallic industries. Strange as it may seem, and despite the fact that the phosphate deposits of Giles County, Tennessee, together with those of Polk and Hillsborough Counties, Florida, have yielded more than 50,000,000 long tons in the last twenty years, the mineralogy of phosphates has been given scarcely any space in our technical literature. For many years it was the general consensus that these so-called phosphate rocks represented a physical mixture composed principally of tri-calcium phosphate, together with smaller quantities of calcium carbonate, calcium fluoride, iron phosphate, aluminum phosphate and other less important constituents. More recent investigations, however, led to the conclusion that these phosphates really represent a complex mineral in which calcium, iron, aluminum, phosphorus pentoxide, carbon dioxide, and fluorine all form a definite part of the molecule. Colony, after a careful study, utilizing chemical, microscopic, and X-ray diffraction methods, reported that American phosphates consist principally of calcium-carbono-phosphate of the staffalite type.

Jan 1, 1933

By J. K. Edgar

For a number of years the production and use of super-purity aluminum (better than 99.99 pct) has been steadily increasing. High-grade lots of. such aluminum show certain outstanding characteristics not found in lower grades containing principally silicon, iron and copper as impurities. One such characteristic is the so-called "self annealing," that is, the re-crystallization of the heavily cold worked metal at room temperature.' Interest therefore is aroused as to the effects of the impurities. It is well known that the amounts of silicon and copper which occur in aluminum of better than 99.95 pct are completely soluble, at least at elevated temperatures (above 200°C). Iron, on the other hand, is known to be fairly insoluble in solid aluminum. Thus, a knowledge of the limits of this solubility would he of considerable use in studying the characteristics of the high purity metal. All investigators have agreed that iron has very low solubility in solid aluminum. Rosenhain, Archbutt and Hanson2 reported traces of an aluminum-iron phase in the "purest samples of aluminum obtainable." Gwyer and Phillips3 reported that an iron constituent was visible under the microscope in metal containing ".0088 per cent iron." Roth4 found that in the solid state the solubility of iron in high purity aluminum was 0.01, 0.01, 0.017 and 0.022 pct at 225, 320, 500 and 600°C respectively. Dix5 working with alloys containing less than 0.03 pct impurities, concluded from microscopic and chemical analyses of eutectic areas that the eutectic composition was close to 1.7 pct iron. Dix placed the eutectic temperature at 65s°C. Archer and Fink,6 using high purity aluminum-iron alloys, found that the hypoeutectic liquidus intersects the eutec-tic horizontal at 1.7 pct. This is in fair agreement with the investigation of the aluminum-iron system by Gwyer and Phillips who placed the eutectic at 1.89 pct iron with a freezing point of 653'C. Preparation and Chemical Analysis oP Alloys Electrolytically refined aluminum (99.991 pct aluminum) and a high purity alumi-num-iron alloy (11.45 Pet iron) were used in the preparation of the alloys for this investigation. To aid in controlling the iron content of the experimental alloys, an alloy of lower iron content was prepared first from these materials. The high purity aluminum was melted and heated to about 700°C in a plumbago crucible coated with alundum cement and the aluminum-iron alloy was then added. The alloy was thoroughly stirred, fluxed and skimmed and then chill-cast into notch bars. The aIlalyses of the three materials are given in Table I. The alloys for the determination of the solid solubility of iron in aluminum were prepared by melting 600 g total of the aluminum plus the required quantity of the aluminum-iron alloy (No. 92531). These

Jan 1, 1949

By W. G. Bearden, G. C. Howard, J. W. Spurlock

An investigation of the factors af-fec.ting the inter-zonal flow of fluids in the casing-wellbore annrc1rt.s of an oil or gas ivell is presented Laborntory tests revealed that failure of the caring-cement bond allows communi-cation of fluid at pressure differentials near 1.000 psi. Perforating with a 11011011: carrier gun does not shatter or crack the cement sufficiently to allow communication through these cracks and does not seriously affect the casing-cement bond failure pressure. The pressure to cause communication at the casing-cement bond can he increared to 3,000 psi by. limiting pipe deformation during cementing and subsequent operations. Communication can be prevented, however. up to pressures sufficient to cause the cement to fail or the casing to col-lapse, by attaching to the casing a seal ring of deformable ruhber molded between two steel flanges. When installed, one flange is attached rigidlv to the casing to serve as back-up for the gasket While tile other flange is movable. To date, these gasket seal rings have been field-tested in 27 Wells. Althotrgh communication has been noted in two wells, inter-zonal flow has been prevented in other wells in the same area by installing more seal rings between the communicaring zones. INTRODUCTION The inter-zonal flow of fluids behind casing cemented in oil wells during normal production or stimulation operations is a major operating problem. If it cccurs during production operations. it can seriously limit the pressure to which a reservoir may be depleted without harmful invasion of unwanted fluids. If it occurs during stimulation operations, it may preclude the possibility of stimulating the desired zone. This communication can be caused by failure of the bond between the casing and cement, failure of the bond between the cement and formation, or failure of the cement itself. This paper presents the results of an investigation of factors affecting com-munication at the casing-cement bond and methods which aid in preventing it. LABORATORY INVESTIGATIONS The laboratory tests performed in this study were divided into three phases. The first phase consisted of tests to determine if perforating would shatter and crack the cement sheath so severely that communication would occur through the cement itself. The second phase consisted of tests to determine more precisely the cause for the casing-cement bond failure. The third phase consisted of tests to evaluate the effectiveness of various de-formable seals attached to the casing in preventing communication. EFFECT OF PERFORATING, The effect of perforating was invest~gated in tests performed with apparatus shown on Fig. 1. Cement was poured into the annulur space hetween 5%-in. casing and 8%-in. casing and allowed to cure for 72 hours. The apparatus was then perforated with a hollow carrier gun containing eight duPont 26-A shaped charges. Bull plugs were placed over the perforations in the 8 5/8-in. casing and hydraulic pressure was applied inside the 5 1/2i-in. casing. The pressure to cause fluid communication past the cement sheath was observed and termed the "bond failure pressure". Several different cement compositions were included in these tests, the results of which are shown in Table 1. In Tests 1 through 4 of Table 1, bond failure occurred at- the inter- .

Jan 1, 1966

By Paul H. Lu, Fred D. Wright

Numerous laboratory tests and field measurements conducted by different persons have indicated that most mine rocks behave viscoelastically rather than elastically. Hence, for an accurate and realistic design of underground structure, the time factor should be taken into account, and the theory of viscoelasticity can be used. By considering the time factor, the time-safe-strength may be used for economical design instead of liberal safety factors with design based on the elasticity theory. The deflection and moment distributions on an elastic roof slab resting on elastic pillars have already been studied.l In this chapter, the stress- strain analysis for a viscoelastic mine roof resting on pillars of the same material or on supports of different material is first considered theoretically. Viscoelastic solutions for deflections, moments, and shears are de- rived from the elastic plate theory on the basis of the elastic-viscoelastic correspondence principle. The Laplace transformation technique is employed as the operational method in the mathematical treatment. The roof slab materials are represented by four different rheological models and four different loading histories are considered. The method of finite difference equations is employed for solving the partial differential equations, using FORTRAN programs to calculate roof deflections, moments, and shears. Numerical examples are given for one of the four models under two of the four loading histories with regular and staggered pillar patterns. The results are discussed in terms of the variance with time of deflections, moments, and shears as well as their variation in space due to the dimensions and configuration of the structure system. A viscoelastic slab resting on viscoelastic pillars or on elastic supports

Jan 1, 1972

By D. S. Tomalin, D. F. Stein

The effect of reducing oxygen to low concentrations on the fracture of high-purity iron single crystals has been examined at 78° and 20°K. It is found that iron single crystals grown by the strain-anneal method usually contain a few occluded grain boundaries which may become embittled in the presence of oxygen, thereby nucleating cleavage fractures. High purity with respect to interstitial elements was found to inhibit twinning and evidence is presented for an orientation dependence of the resolved yield stress. Deformation occurred by slip rather than twinning at both temperatures of testing with elongations of as much as 9 pct at 20°K. THE fracture properties of iron single crystals have been observedl-3 to be a function of temperature, orientation, and purity. Allen, Hopkins, and McLennan1 demonstrated that at 78°K iron single crystals became increasingly brittle as the tensile axis approached the (001) pole of the stereographic unit triangle. Iron crystals with the tension axis near a (001) pole were completely brittle and orientations near the (011)-(111) boundary were very ductile, achieving a 100 pct reduction in area prior to fracture. Later work of Biggs and pratt2 and of Edmondson3 demonstrated that by reducing the carbon content of the single crystals the transition between brittle and ductile failure at 78°K could be shifted to orientations nearer the (001) pole. Ed-mondson went further and pointed out that any mechanism which tended to increase the yield strength of the iron (i.e., carbon addition, pre-strain) also increased the tendency for brittle behavior at 78°K. Thus by a reduction of carbon content Biggs and Pratt were able to obtain ductile behavior to within 20 deg of the (001) pole, and Ed-mondson was able to obtain ductile behavior to within 26 deg of the (001) pole. Edmondson's material had a total interstitial content (carbon, oxygen, and nitrogen) of approximately 60 ppm and, although Biggs and Pratt reported no analysis, indications were that their iron contained comparable impurities. Stein, Low, and seybolt4 purified iron single crystals to a total carbon, oxygen, and nitrogen content of approximately 20 ppm. They observed a lowering of the yield stress with this increased purity, and thus one might have expected an observation of increased ductility. Although they tested specimens of orientations which the previous workers had indicated should be ductile, the crystals failed at a 78°K in a brittle manner with little elongation. Stein noted,' however, that about 90 pet of the failures could be traced in origin to occluded grains. Allen et al.1 and Edmondson3 do not report examination of their cleavage surfaces, but Biggs and pratt2 reported that microscopic examination of the cleavage surfaces of many of their specimens revealed the presence of small occluded grains. Honda and cohen6 and Keh7 have also observed the initiation of fracture at occluded grains in iron single crystals. Therefore, the additional complication of occluded grains must be considered in studying the properties of iron single crystals and the origin of fractures determined if the ductility exhibited by the crystals is to be considered meaningful. Various investigators8-12 have studied the effects of impurities on grain boundaries in high-purity polycrystalline iron. Rees and Hopkins10 showed that the addition of oxygen to low-carbon (0.002 pet) iron weakened the grain boundaries, causing a shift from transcrystalline to intercrystalline fracture and a progressive decrease on the brittle-fracture stress with increasing oxygen content. In addition, it has been shown by Low and Feustel11 that the addition of carbon to polycrystalline iron containing oxygen eliminated grain boundary brittleness. Thus, oxygen can embrittle grain boundaries in high-purity polycrystalline iron, but the addition of an appropriate amount of carbon can eliminate the oxygen-induced brittleness. The oxygen content (19 ppm) of the iron "single crystals" employed by Stein el al. was large enough to suspect impurity effects at the occluded grain boundaries. Allen et al.1 Biggs and pratt,2 and Edmondson3 may have masked any occluded grain problem in their specimens considering the relatively high carbon levels they employed. stein13 demonstrated that the addition of as little as 0.9 ppm C to previously purified (less than 5 x 10-3 ppm C) "single crystals" would increase the elongation from a few percent to more than 20 pet at 78°K and the fracture was not associated with grade boundary initiation.

Jan 1, 1965

By J. C. Swartz

Measurements of the effect of precipitation stresses on the solubility of cementite (Fe3C) precipitates in a iron are reported. Solubilities were determined from measurements of the Snoek relaxation due to interstitial carbon after quenching from various equilibrium treatments. Stress-free precipitates were obtained by a spheroidizing treatment of vacuum-melted Fe 0.06 wt pet C. Subsequent equilibration treatments were designed to suppress nucleation of other precipitates. The results for stress-free cementite give a heat of solution of 14.8 i 0.2 keal per mole and an entropy change of 1.1 i 0.2 eu in the temperature range 400" to 715°C. Comparison with previous data indicates that the heat of solution increases about 6 keal per mole as temperature increases from 700" to 1000°C. Data on self-stressed cementite in quench-aged specimens of Fe 0.013 wt pet C indicate 1) an apparent heat of solution of 12.1 i 0.4 keal per mole in the range 280" to 690°C, 2) a strain energy of- 1.1 keal per mole Fe3C accompanying precipitation at 280°C, and 3') a gradual decrease in the strain energy of precipitation with increasing equilibration temperature. In com-parison with 2 and 3 the strain energy calculated for an isotropic model is 1.7 keal per mole Fe3C. The lower values obtained from the experiment indicated substantial stress velaxation by dislocation motion. WHEN a supersaturated solution of carbon in a iron is aged at temperatures in the range 200o to 700oC, the carbon clusters by interstitial diffusion and forms cementite (Fe3C) precipitate particles. Unstressed cementite has a volume per iron atom 9 pet higher than that of a iron;' hence, cementite precipitate particles are usually under pressure from the iron matrix. The pressure would tend to increase the solubility of cementite in iron.' This report describes anelastic measurements of the solubilities of self-stressed and stress-free cementite in a iron. Previous determinations of the cementite solubility are summarized in Table I. The method of cementite formation for each reference was studied to ascertain the state of stress of the cementite. The results judged to be for stress-free and stressed cementite are distinguished in the table. In the next section an estimate of the stress effect is obtained which is clearly too small to account for the large difference between the previous results in parts A and B of the table. THEORETICAL Let AGO be the standard free-energy change of the reaction Fe3C (eem.) = 3Fe (a) + C (in a) [1] in the absence of stresses. Since cementite precipitates appear to be rather pure10 and the carbon is so dilute in the iron,8 the cementite and iron of Eq. [ I] for the stress-free case have essentially unit activities and the activity of carbon equals its atom fraction xoC Then the stress-free equilibrium is expressed by RT In XoC = -?GO 121 To first approximation the change in the chemical potential of carbon due to the precipitation stresses equals the elastic strain energy W accompanying precipitation of a mole of cementite.2 Hence, in the presence of the precipitation stresses the equilibrium is described by RT In x sq = -?G° + W [3] where xsC is the mole fraction of dissolved carbon in the stressed case. An approximate value of W can be obtained from analysis of the inclusion problem in elasticity theory. The inclusion is a small portion of the matrix phase which has suffered a transformation while still imbedded in the matrix. In the absence of the constraint of the matrix the transformation would be equivalent to a uniform dilational strain eT. Both the matrix (a) phase and inclusion (0) phase are assumed to be homogeneous, isotropic materials. When the a and 0 phases have the same elastic moduli, which is approximately true for iron and cementite,11 the total strain energy per mole ß is12 2µVß(eT)2(3 +4 µx)-I [4]

Jan 1, 1968

By Claiborne C. Van Zandt

THE heavy postwar demand for Portland Cement has created shortages that are gradually being overcome by increases in plant capacity. In the post-war period, the Lone Star Cement Corp. has expanded several of its existing 15 plants and has built 2 new plants, now in operation, with a third new plant under construction in Brazil, of design somewhat different from that of the two preceding ones. The new domestic plants are located at Lone Star, Va., near Roanoke, and at Maryneal, Tex., near Sweetwater, and went into operation during 1951. Each plant is equipped with two rotary kilns and has an initial capacity of 1,500,000 bbl per year, or 6,000,000 sacks. The total cost of each plant was about $10,500,000, and on this basis $7.00 in 1951 money are required per bbl of annual capacity; at 376 lb per bbl, this corresponds to $37.00 per ton of output. The investment corresponds to approximately $80,000 per hourly-wage earner employed. The purpose of this paper is to describe the most interesting design features of the two new and almost identical Lone Star plants. Why the Dry Process Was Chosen The two new domestic Lone Star mills employ the dry process because: 1-The raw materials at both properties are particularly suitable and can be dried very, readily. 2-The Maryneal, Tex., plant does not have water available for slurry. 3-Very substantial kiln fuel savings can be obtained. 4-Dry raw grinding reduces ball and liner wear and- general maintenance, without any sacrifice in power. Operating costs to date have more than justified the choice of the dry process for these two plants. Raw Materials The chemical composition of Portland Cement raw material after crushing, grinding, and mixing, but before burning, is about as follows: [ ] sometimes tailings from an iron ore concentrating plant. Certain objectionable materials occur in raw mix: magnesia, limited in cement to 5 pct, in excessive amounts; alkalies, as sodium and potassium; phosphorous; and sulphur, generally present in coal and oil. The Roanoke raw, materials are dense limestone and shale. The Maryneal materials are soft limestone and a hard brittle clay that can be handled much like shale. Sand and iron ore are required in small quantities. General Plant Layout and Construction The two plants are so similar that one joint description will cover both, with such exceptions as will be especially indicated. The crushing plant is located in the quarry, and raw material is conveyed by belt to the storage building, where all materials are stored and handled. Fig. 1 identifies the various structures of the Roanoke plant. The large storage building is used for the storing and handling of all materials, including limestone, shale, sand, iron ore, coal, clinker, and gypsum. Directly adjoining the storage building is a structure under a similar arched roof, containing the raw and clinker grinding departments and the electrical substation. The discharge ends of kilns and coolers, and coal or gas burning equipment are also placed at one end of the mill building. The 340ft long kilns extend away from the main buildings to form the long leg of an L, at the end of which is the feeding and kiln dust collecting equipment, and the raw blending silos are conveniently located adjacent to the feed end of the kilns. The machine shop, storeroom, electrical shop, foremen's office, service rooms, and meeting hall are combined in one structure in the center of the plant, and the office and laboratory are close by. The cement silos and packhouse do not have to be tied directly into the manufacturing process and are therefore located at a point convenient to the railroad tracks.

Jan 1, 1952