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By G. S. Cole

By 2025, the U.S. automotive industry will have to average 54.5 mpg (4.3l/100km) Corporate Average Fuel Economy (CAFÉ). While new/improved powertrain technology (turbocharging, electrification, diesels, transmissions and stop/start) will be critical, it is estimated that 25-40% of the new CAFÉ standards will require significant mass reduction, and lightweight structural materials will be required. This presentation examines vehicle mass reduction based on new developments in manufacturing automotive structures and components using light metals (aluminum and magnesium), conventional heavy metals (iron and steel), polymers, and carbon-fiber reinforced polymer composites. Components that used to be sand cast or pressure die cast provided minimal fatigue strength and ductility. But greater mass reduction uses more light metals in structural applications. They require eliminating porosity and inclusions to improve ductility and fatigue strength. Improved casting processing, with vacuum die casting, counter pressure and squeeze casting, and new forging and extrusion applications are being developed for this purpose. New grades of ultra-high strength steels can be made thinner, and save over 1/3 the mass vs conventional mild steels. But more complex and expensive processing, such as hot stamping and in-mold quenching, is required. Most engine block structures have migrated from grey cast iron to aluminum over the past 40 years. But compacted graphite cast iron has higher strength at high combustion temperatures and pressures so that high powered engines can be smaller and even lighter than aluminum. Assembling a range of lightweight materials into vehicle structures requires specialized assembly techniques, including sophisticated structural adhesives that can mitigate vehicles’ unique corrosion environment. The presentation will conclude with discussing lightweighting strategies of Asian, American and, European marques and the materials, component designs and assembly techniques used to achieve 2025 CAFÉ.

Jan 1, 2016

By D. M. Hausen

"Refractoriness in Carlin-type gold ores results mostly from fine locking of gold in pyrite, locking in various gangue phases, notably quartz, and a ""preg robbing"" condition attributed to organic carbon. All three conditions may occur in any given deposit, including Newmont &apos;s Carlin and Gold Quarry deposits in Nevada, where types of ref ractoriness occur locally in minor amounts.Measurements of specific gravity, water absorption and screen size distributions of gold in alteration rock types from Gold Quarry show transitional changes from siliceous cherts through decreasingly silicified and increasingly argillized siltstones.Low permeability of siliceous ores contributes to ""size dependent"" refractoriness in cyanidation test work. Colligative physical and chemical measurements demonstrate that silicified cherty ores are difficult to grind, poorly permeable, and less amenable to cyanidation. Refractoriness in pad or column leaching of coarsely crushed siliceous siltstones and cherts is shown to correlate with interrelated measurable mineralogic and physical parameters.IntroductionMetallurgical treatment of variably amenable and refractory types of gold ore may be guided by both analytical and mineralogic data on the interlocking of gold (microscopic an d sub- microscopic) in assorted gangue/sulphide phases. Most oxidized ores from the Carlin gold mine, north of Carlin, Nevada, are amenable to direct cyanidation. The permeability of most oxidized ores from Carlin coupled with the fine size of the gold < 1.5 um) yields rapid extractions and high recovery without fine grinding.Small portions of the Carlin ore body, and also the nearby Maggie Creek and Gold Quarry orebodies, are less amenable to cyanidation, and are classified as refractory. Refractory conditions may be attributed mostly to the association or interlocking of gold with pyrite and /or microcrystalline quartz or chert, and also by the adsorption of leached gold by deleterious forms of carbon, termed ""preg-robbing"" carbon. Each of these conditions are described and defined, with emphasis on a form of silica-locking, which has been referred to as "" size dependent"" refractoriness."

Jan 1, 1985

By James W. Cameron

DESPITE the fact that, after oxygen and silicon, aluminum is the most abundant and widely distributed element in the earth&apos;s crust, it is, commercially, a modern metal. Attempts were made by Sir Humphrey Davy and other chemists to decompose alumina, the oxide, into its elements, but with unsatisfactory results, and it was not until 1827 that Wohler succeeded for the first time in isolating the metal in pure form. Some thirty years later, commercial production of aluminum was started in a plant near Alais, France, using a process developed by Deville which was a modification of that of Wohler. It was not, however, until around 1886 that possibilities of low-cost production were realized. Hall and Heroult discovered, independently, the now famous process for extraction of aluminum by the electrolysis of alumina (Al,O,) dissolved in fused cryolite. This discovery, with its subsequent effect in reducing the price of the metal, was perhaps the greatest single factor contributing to the remarkable growth of the aluminum industry. But only in the years following the Great War did aluminum begin to attain equal importance in many fields with other non-ferrous metals. Numerous factors, political and economic, in the past decade have had a profound effect on the industrial history of the metal. At present, systematic substitution of aluminum for other base-metals is proceeding at a rapid rate in such countries as Germany and Italy with a view towards &apos;economic self-sufficiency&apos;. Quite naturally, ?the economic depression started extensive research and experiment in various industries in an attempt to improve efficiencies and lower costs. Partial answers have been found in the extended use of aluminum and its alloys. Even against the background of tremendous technological advance that has marked the past fifty years, the rise of the aluminum industry must necessarily stand out conspicuously.

Jan 1, 1939

By K. E. Waters, J. E. Nesset, F. Rosenblum, J. A. Finch, S. Moon

"Some materials when exposed to various conditions can exhibit a rise in temperature without requiring an external heat source. Generally referred to as pyrophoric or self-heating substances, they challenge the safety of materials handling, storage and transportation. Reliably assessing the self-heating potential of materials is thus essential. Over the years a number of test protocols have been developed. A widely accepted method is that recommended by the United Nations to certify the safety of shipping pyrophoric goods. Our test work on sulphide materials has shown that the U.N. test can give false negatives if the sample oxidation history is not considered. Depending on the degree of oxidation (“weathering”), the same sulphide material can exhibit self-heating ranging from safe to hazardous. For concentrates, oxidation can occur during storage and transport making the sample weathering history an important consideration in the test work. To make the U.N. test, and other single-stage self-heating procedures, more reliable in assessing self-heating potential when testing sulphide materials, it is suggested that a weathering step be incorporated in the test protocol. This test work for two sulphide samples, an ore and a concentrate, demonstrates the impact of incorporating a weathering stage in the test protocol. INTRODUCTIONSelf-heating occurs when exothermic reactions produce heat faster than can be dissipated to the surroundings. Numerous substances self-heat, ranging from wood chips and powdered milk to coal and sulphide minerals (Beever & Crowhurst, 1989; Hudak, 2002). Mixtures of sulphide minerals, most notably those containing the iron sulphide pyrrhotite (Fe(1-x)S), commonly encountered in the extraction of base metals (e.g., copper, zinc, lead, and nickel), are particularly prone to self-heating (Rosenblum, Nesset, & Spira, 2001; Payant, Rosenblum, Nesset, & Finch, 2012). In the mining and subsequent processing stages, the minerals are progressively liberated and finely ground, then separated, usually by flotation, with the resulting concentrates stored and transported to smelters for metal extraction. At most of these stages the sulphides are exposed to both moisture and oxygen, conditions that promote partial sulphide oxidation and the formation of elemental sulphur. Studies have shown that pyrrhotite, in particular, readily oxidizes to form elemental sulphur (Bernier & Li, 2003; Belzile, Chen, Cai, & Li, 2004; Somot & Finch, 2010). The elemental sulphur becomes fuel for further self-heating as the temperature of the mineral mixture increases above 100 oC (Rosenblum & Spira, 1995; Somot & Finch, 2010). It is believed the propensity of pyrrhotite to self-heat is a result of its iron-deficient, and hence somewhat unstable structure. It is worth noting that pure metal sulphides (with the exception of pyrrhotite) do not exhibit appreciable self-heating. A mixture of minerals sufficiently different in their electrochemical rest potential is required to initiate self-heating at ambient temperatures (Payant et al., 2012)."

Jan 1, 2016

By Enrique Rubio

Several mining operations are currently evaluating the feasibility of changing their mining method to Block Caving. There will also be several deep low-grade ore bodies that will face the need to go underground in following their ore to depth. There are two main reasons why Block Caving is attractive: firstly, it offers the lowest operating costs amongst all the mining methods; and secondly, it is truly a massive mining method, offering the highest potential production capacity. Despite its longstanding popularity, there are still significant components of the method that are not clearly understood. Also, the lack of availability of key geomechanic information still presents a major obstacle to developing mine planning and production scheduling. There are several key issues in block caving that can make it feasible such as cavability, fragmentation, stresses will condition the way that a block caves and the way that material is drawn from the draw points. Consequently Block Cave mining method is a good example where the ore body has to be related to design and mine planning. The concepts of dilution, draw control as well as sequence definition are reviewed in this paper to illustrate the idea of integration. There have been some examples of mines where some of the components of mine planning have not been integrated causing a disaster in terms of economics or safety. Different layouts configurations might give a different result in the planning of the mine

May 1, 2002

By Hans Lundberg

The magnetometer which was developed during the war for detecting submarines has proven exceedingly valuable in outlining deep-seated structures in oil exploration, and will be useful also to geologists in outlining regional structural features in the Precambrian. Our magnetometer has been developed to outline local and detail structures. 1 am quite sure that all geophysicists and geologists would agree with me that, in ore prospecting, it is important to obtain as much detailed information as possible. We know that, as we ascend from the ground and get away from the magnetic ore-bearing structures and orebodies, the magnetic intensity decreases rapidly, but, worse than that, we lose the details even faster. Figure l shows two strong, very sharp, magnetic &apos;highs&apos; over two orebodies which, as our distance increases, rapidly merge into one fairly broad, moderately strong anomaly. If we drilled on this maximum, we would not encounter any of the orebodies. Therefore, we should fly the airborne magnetometer as close to the ground as possible in order to duplicate the results of the magnetic ground surveys. The first chance to accomplish this came with the helicopter, which is an exceedingly maneuverable aircraft. It can be landed in a cleared space not much more than fifty feet square. With floats, it can be landed anywhere, even in a swamp, on thin ice, or on soft snow. It can stand still in the air, hovering over a given point. It can ascend and descend vertically, fly sideways and even backwards, at the will of the pilot. It flies forward at any speed up to l00 miles an hour. The helicopter can be taken to any desired position at a given time. It can fly at any useful altitude from a few feet to several thousand feet above the ground. It can fly very close to the ground with safety. In bare areas, the survey flight may be performed a few feet above the ground. In forested areas, however, the flights, to clear the trees, must be made at l00 to 150 feet. To mark out a certain point, a small parachute-like marker may be draped over a tree or laid on the ground. This can be done from the helicopter without touching the ground.

Jan 1, 1947

By Denni Hoffmann

"Banded iron formation rocks associated with massive sulfide lenses in the Broken Hill Pb-Zn-Cu-Ag deposit in the Namaqualand Metamorphic Complex, South Africa, were investigated with respect to the geochemistry of manganiferous silicate-rich bands. Two common varieties of these are: amphibole- and garnet-rich iron formation bands. The results reveal that the former are enriched in Fe, Mg, Cu, Co and S. The garnet-rich bands are enriched in Mn, Ca, P, Pb and Ba with significant detrital contamination of Ti, AI, Zr, Cr, Y, V, Ni and Nd.The silicate-rich bands have compositions, in terms of, Si/AI, SilFe, FelMn, LalCe and Co/Zn, comparable to submarine chemical sediments which precipitated from hydrothermal fluids. The garnetand amphibole-rich bands are interpreted as ""evolved"" and ""immature"" hydrothermal sediments, respectively. The latter resulted from rapid precipitation after exhalation, whereas the former had a longer residence within sea water. The silicate-rich bands both exhibit increasing Mn/(Mn+Fe) fractions, which are consistent with a variation expected from proximal to distal depositional settings. The prevalence of garnet-rich bands over amphibole-rich bands is interpreted as the result of injection of hydrothermal fluids from a single vent situated along the northwest margin of the Broken Hill deposit."

Jan 1, 1994

By Andrew Bamber

A fast and objective spreadsheet-based model for the financial evaluation of innovative mining and processing strategies such as pre-concentration vs. a conventional base case is presented. The size and grade of the deposit must be chosen, from which a mining rate is selected. Expected operational data for the deposit as well as any mill testwork and results from the pre-concentration testwork are entered as input variables on the sheet, and cost and revenue impacts are calculated in the ?Output? sheet. A capital sum and operating costs for the initial mine and mill development as well as the pre-concentration facility are calculated. The net changes in capital and operating costs are calculated, and impacts on revenue through changes in metal recovery are also calculated. These outputs are used to calculate the overall impact on the cutoff grade and thus the size of the mineral reserve using a generic grade-tonnage model. The NPV and NPV profile of the two scenarios is calculated, with variations in basic parameters such as operating cost, capital requirements, metal price or grade as well as discount rate. Cost and revenue impacts are evaluated and compared to the baseline to establish a positive or negative impact overall. Different scenarios of grade, tonnage, mining rate, process performance, capital and operating cost structure can be explored using the model. Outcomes projected by the model for case studies conducted thus far have been calibrated against internal estimates by the sponsoring organizations and found to be accurate to within 30%, confirming the utility of the model in practice.

Oct 1, 2009

By J. J. Jonas, G. R. Stewart, A. M. Elwazri

Two important parameters for dynamic recrystallization can be derived from the changes in the strain hardening rate: the critical strain for initiation of dynamic recrystallization and the point of maximum softening. In this work, these values are determined from the flow stress-strain data obtained in continuous compression testing in the range 900-1100°C. The resulting strains are used to calculate a kinetic model of dynamic recrystallization for two materials: 304 austenitic stainless steel and a hypereutectoid plain carbon steel. The mechanical parameters used to define the proposed model are confirmed with quantitative metallographic analysis of the recrystallized microstructure.

Jan 1, 2004

Between 1993 and 2003, a series of AG and SAG mill pilot plant trials were conducted using Hardinge Ical pilot plant scale SAG mills on numerous ore samples and ranging across a wide variety of operating conditions. The data from these tests were used to evaluate the design of SAG and AG mill circuits for over a dozen projects, of which about half were eventually constructed and commissioned. The data were also used in the development of SAG mill modelling, scale-up and simulation procedures by several consultants who had access to part of the data set. Recently, we have had the opportunity to bring this data together and further analyse the consolidated dataset. This paper reports on the outcomes of this analysis that has identified the impacts of different AG/SAG circuit flowsheets and operating conditions on energy efficiency and operating cost.

Jan 1, 2012

By Richard W. Hutchinson, Christopher Osterman

The Selebi-Phikwe deposits are hosted by amphibolite to granulite facies gneisses of the Limpopo belt. The sulfide orebodies are generally stratiform and conformable to the foliation of the wallrock gneiss. Sulfide remobilization has occurred during metamorphism and has produced discordant sulfide veins, called piercement structures, which project into the hanging wall and footwall gneisses. These piercement structures are compositionally similar to the stratiform sulfides, consisting mainly of pyrrhotite, pentlandite and chalcopyrite. However, texturally the piercement sulfides are coarse grained and inclusion-free, whereas the stratiform sulfides are fIne grained and packed with tectonically produced wallrock inclusions. The piercement structure sulfides and adjacent stratabound sulfides were sampled and analyzed for major base metals and PGE&apos;s for comparative purposes. Most of the piercement structures were enriched in Cu, Ag and Au, whereas they were generally depleted in Ni, Co, Fe and PGE&apos;s. Changing elemental associations were observed from the stratabound sulfides and along the length of the piercement structures. This and the degree of depletion or enrichment of various major and minor elements in the sulfide piercement structures may reflect the relative mobilities of metals under metamorphic conditions. The similarities between sulfIde piercement structures and the footwall Cu-PGE veins in some Sudbury deposits are reviewed.

Jan 1, 1994

By M. S. Badollet

"IntroductionAsbestos as received by the manufacturer of asbestos products is •in the •form of either crudes or milled fibres processed to different degrees of texture. Frequently, the manufacturer finds that l:ihe fibres as he buys them are not adaptable to his plant processes, and, therefore, it is necessary for him either to contact the mine supplying the material and request a specific texture for the :fibre or to reprocess the fibre in his own plant.When the mine or mill manager is requested to change his milling equipment to produce a special grade of fibre with a specific texture, he would like to comply. However, if he began to make special fibre grades for each customer, he would be in the position of constantly rearranging his milling technique, adding more equipment, or building a new mill. In the end, his mill would he producing hundreds of different fibre grades of varying degrees of texture, which is a difficult accomplishment if he desires to maintain any quantity of production."

Jan 1, 1950

By A. Bendada, P. Servais, X. P. Maldague, C. Ibarra-Castanedo, C. Mohr

Infrared (IR) thermography is a nondestructive, non-contact and non-intrusive technique that allows the fast inspection of large and complex structures with limited accessibility. Pulsed thermography is particularly interesting for the inspection of aerospace materials such as composites given that, after submitting the specimen surface to a thermal front, the most common types of subsurface discontinuities (e.g. porosity, de laminations, dis bonds, fiber breakage and inclusions) can be detected with an IR camera as regions showing abnormal temperature patterns. We present first the case of an aircraft door with water ingress and surface repairs on its honey comb structure. We also highlight the advantages and limitations of thermography for the inspection of aircraft composite parts, such as edge flaps, rotor blades and speed breaks. Finally, we expose some results from a Kevlar® non-planar specimen with Teflon® inclusions at different depths and locations.

Jan 1, 2006

By P. H. Riordon

ONE OF the major sources of the world's supply of asbestos lies in a belt of ultrabasic rocks stretching through the Eastern Townships of Quebec where chrysotile asbestos has been mined continuously since 1878. The productive portion of the belt extends from the town of Asbestos in Shipton town-ship northeastward some 60 miles to the eastern edge of Broughton town-ship. (See map). Twelve mines, currently treating an aggregate of over 60,000 tons of rock daily, produce more than one million tons of asbestos :annually. An equal number of mines are now dormant, having for the most part exhausted their reserves. It is evident from the past and present activity, in this belt that it can look forward to at least half a century or more of large scale production. The host rock to the asbestos de-posits is essentially a peridotite which originally contained I 0 to 15 per •cent pyroxene. The peridotite, associated with dunite, pyroxenite

Jan 1, 1962

By C R. Evans

Whole-rock and muscovite potassium-argon dates from selected low-grade metamorphic rocks of Precambrian age in the Canadian Rocky Mountains near Jasper, Alberta, were obtained to ascertain the age of the source terrain and the age of the metamorphism. Ten argillites gave whole-rock dates ranging from 270 to 485 million years, dates which are apparently inter-mediate between the age of the source material and that of the metamorphism. "Up-dating" increases with the degree of orientation of muscovite in the cleavage plane, and with the ratio of the muscovite in the cleavage plane to that in the plane of the bedding. Detrital muscovite from four arenaceous rocks gave dates ranging from 1,050 to 1,780 million years. "Updating" increases with decreasing grain size, so that, within the range investigated, the cube of the median diameter (¢) of the muscovite is apparently proportional to the radiometric date.

Jan 1, 1964

By A. Dahi Taleghani, A. Shojaei

Continuum damage mechanics (CDM) of rocks is studied together with their elastic and plastic behaviors to develop simulation tools for hydraulic fracturing jobs in naturally fractured formations. The model is constituted based upon pressure sensitive inelastic deformation of porous rocks and their damage mechanisms in the cases of drained and undrained conditions. The CDM model is formulated within Fracture mechanics framework. The performance of the developed elastoplastic and CDM models are compared with the available test data of a specific shale play. The hydraulic fractures growth in the reservoir scale is then simulated; in which the effect of fluid viscosity, natural fractures characteristics and differential stresses on induced fracture network is studied. The simulation results are compared with the available solutions in the literature. The developed CDM model outperforms the traditional fracture mechanics approaches by removing stress singularities at the fracture tips and simulation of progressive fractures without any essential need for remeshing.

Jan 1, 2015

By J. Day, Matthew X. Yao, Lijue Xue

Hardfacing overlays are commonly applied on the shroud Z-section of turbine blades for enhanced wear resistance. Among various processes that are used to apply the hardfacing overlays, the plasma transferred arc (PTA) welding process offers several advantages including lower heat input, less base material dilution, rapid process time, and reduced operating cost associated with the capability to apply materials in the powder form. The development of a robust PTA process is crucial for overlay performance and repeatability, particularly in the aerospace industry where a quality intensive manufacturing environment prevails. For this reason, the Taguchi method of experimental design was selected to develop a test plan. A 4-factor 3-level (L9) orthogonal array (OA) was used in the experiment. The L9 OA allows for a more detailed (3 level) investigation of critical process parameters, namely plasma gas flow rate, traverse speed, powder feed rate, and arc current. Two hardfacing materials, Stellite 694 and Tribaloy T-800, both Co-based wear resistant alloys, were investigated by deposition onto a cast IN738 Ni-based superalloy substrate. Performance measurements of the hardfacing deposits included deposit hardness, substrate hardness, deposit density (porosity), degree of cracking/inclusions, and a quantified visual inspection. The procedure resulted in optimized PTA hardfacing parameters for both Stellite 694 and Tribaloy T-800 on IN738 turbine blade material.

Jan 1, 2004

By M. Bigdeli Karimi

In this study, the effect of strain level and holding time in semisolid temperature range via SIMA process on AS21 Mg alloy was investigated. Some cylindrical samples of this alloy with 1cm in height and 2.5cm in diameter (H/D=0.4) were compressed to 10%, 20%, 30% and 40% at 300-C. Then, the samples were reheated in semisolid temperature range at 614°C for various times. The results of optical microscopy and image analysis showed that with increasing of strain and holding time, dendritic structure changed to equi-axed structure, gradually. Also, the best conditions to obtain good globular structure were achieved. Furthermore, it was seen that after compression and reheating, Mg2Si intermetallics with Chinese script morphology converted to dispersed-fine particles which were distributed into the ci-Mg grains.

Jan 1, 2007

By L. I. Kiss, S. Perron, S. Poncsák, A. Perron

Aluminium industry has an increasing interest in the diminution of the energy consumption of the Hall-Heroult process by the reduction of the anode bottom covering with gas. Electrically isolating carbon-dioxide bubbles, produced at the anode, increase the ohmic resistance of the cell. As the gas production rate is determined by the applied current density, anode covering can be decreased only by a faster evacuation of the gas from the inter-electrode space. Among others, the inclination and curvature of the anode bottom promotes the release of the bubbles and thus decreases the mean value of the covering. Indeed, anode, insert in the molten cryolite bath has a square shape with horizontal bottom. However, inhomogeneous anode consumption, electro-erosion, bath circulation and the inclination of the bath-metal interface modify this shape gradually during electrolysis. Anode bottoms become inclined with rounded comers. This concentrates the gas generation to the center zone of the anode. As the bubble layer cannot be observed directly because of the hostile environment and the opacity of the bath, real scale air-water systems are used to study the impact of the anode geometry on the anode covering and the bubble induced flow. However, the physical properties of such a system are different than that we can found in the real cells. A simulator using the Lagrangian description of the bubble layer has been built and presented in earlier papers. This tool was used to investigate the effect of the anode inclination on gas covering and bath velocity, for both C02-cryolite and air-water system. Results obtained for the second system were compared to experimental data .

Jan 1, 2006

By M. D. Quinn

THE sand and gravel used for backfilling at the Hollinger mine is obtained from deposits in a low range of hills some three miles north of the mine, where the Company owns a number of claims. The material is transported to the mine by aerial tram. Shipments from these deposits to the Hollinger mine commenced in June, 1927, and since May, 1936, sand has been supplied also to the McIntyre mine. During 1942, Hollinger requirements were 1,700 tons per day, and 900 tons per day was delivered to McIntyre. For the past seven years production has averaged 900,000 tons annually, and total deliveries to the end of 1942 were 13,129,022 tons, of which 11,075,339 tons went to Hollinger and 2,053,683 tons to McIntyre. Some years ago, when the original pit was approaching exhaustion, new workings were opened on claims east and south of the tramway terminal. It soon became apparent that the sand varies considerably in character from place to place. The weight per cubic foot was found to range from 85 to 130 lb., and the water percolation rate from 2 to 50 inches per hour. As the mine requirement is a sand with percolation rate of 6 inches or better per hour, it was evident that in certain parts of the deposits the material was not suitable for use as backfill. As a consequence, it was decided to carry out a programme of systematic sampling of the claims in order to select the areas containing suitable material for back-fill and at the same time estimate the tonnage available.

Jan 1, 1944