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By J. W. Freeman, J. P. Rowe, R. F. Decker

HEAT-to-heat variations in properties of an alloy of constant nominal chemical composition have been a perplexing problem to the metallurgist. These heat-to-heat differences have been especially baffling in high-temperature metallurgy. In order to establish fundamental reasons for these heat-to-heat variations, the National Advisory Committee for Aeronautics has sponsored and financially assisted an extended research program on heat-resistant alloys at the University of Michigan. As part of the program to find the contribution of processing variables, Frey, Freeman, and white' studied effects of heat treating on nickel-base alloys and Ewing and reeman' investigated effects of hot-working practice on N155 alloy. To extend the program to the study of effects of melting practice on high-temperature properties, a 55 Ni-20 Cr-15 Co-4 Mo-3 Ti-3 pct A1 composition was selected for experimentation. The objective of this program was to establish the melting-practice variables which influenced the hot-working characteristics and creep-rupture properties and, at the same time, establish the metallurgical mechanisms for the effects. During the course of the investigation of practices using vacuum melting, it became increasingly evident through chemical analyses supplied by industrial concerns that a major variable was melt reaction with the crucible. This paper is devoted to the results of this phase of the melting-practice study. EXPERIMENTAL PROCEDURES Experimental 10-lb heats were induction melted in the University of Michigan vacuum-melting unit with the melting practices outlined in Table I. Aim analysis for the basic alloy, in wt pct, for all heats was as follows: Cr Co Mo Ti Al 20.0 15.0 4.0 3.1 3.1 Mn Si C Ni 0.12 0.12 0.08-0.15 Bal. Small amounts of boron and zirconium were added to certain heats as listed in Table I. These additions

Jan 1, 1959

By Robert L. Marovelli

A recent reorganization placed the health and safety research activities of the Bureau of Mines under a director, Division of Minerals Health and Safety Technology. The new health and safety research organization and its position in the Bureau hierarchy is shown in Table 1.

Jan 11, 1979

By Dever Ashmead

ANTHRACITE was first mined in the Wyoming Valley and sold as an article of commerce in 1808. As some preparation has always been necessary to make it ready to burn, the preparation of anthracite must date back over a hundred years. Two vital factors have determined to a large extent the degree and method of anthracite preparation. These are, first, the character of the beds worked and the methods by which they were mined and, second, the equipment used and practices followed in the burning of the coal. It is not the intention here to go deeply into these phases of preparation as a paper of no mean length could be prepared on the history of either. Rather, the intention here is to point out the main considerations and to show the influence they have exerted on the preparation of anthracite. MINING METHODS AND THEIR RELATION TO PREPARATION In the beginning f the nineteenth century, the coal beds were virgin with the possible exception of some outcroppings that had been worked, to a slight extent, by the Indians. It is known that the American aborigines had a knowledge of the use of this fuel, because when the Wyoming Valley was purchased from them, in 1754, they mentioned the fact that, by selling the land, they would lose their coal.

Jan 9, 1921

By B. L. Sackett

LEAD smelting has been an important industry in Utah for many years. The first lead smelting was done, over 60 years ago, at the Rollins mine in Beaver County, by burning heaps consisting of alternate layers of wood and high-grade carbonate ore. The lead thus obtained was. molded into bullets. With the development of. the mines, the problem of cheaper handling of the ore became important. The only outlet for this ore was Swansea or the Atlantic Coast but to ship to either cost $150 per ton or more for treatment and handling. From 1864 to 1871, experimenting was done with blast, Scotch hearth, and reverberatory furnaces, with the blast furnace surviving as, the standard plant. The first crude furnaces were circular or hexagonal in shape, and were made of adobe and stone, which quickly burned out. They were small, about 2 1/2 ft. in diameter, and smelted from 3 to 10 tons. in 24 hr. The metal had to be tapped from the bottom of the crucible, necessitating a shut down of the furnace during this process. This pro¬cedure caused salamanders to form around the tap hole when the furnace was started again, which frequently resulted in freezing. The campaign lasted until a tap of bullion was made. The first successful plant of the crude stone type was operated in 1870. From 1870 to 1872, there was a smelter building craze in the state. During that period, about 20 furnaces were built, chiefly near the mines, and their operation was limited and sporadic. The work was then placed in the hands of trained metallurgists, who standardized on the rectangular form of furnace. In 1871, Daggett, at the Winnamuck mine in Bingham, installed water-jackets around the smelting zone of the furnaces. These furnaces were circular; the diameter at the tuyere line was 3 ft. 6 in. and at the charge floor 5 ft. 3 in. The height from tuyere line to charge floor was 14 ft., height of tuyere line above top of crucible was 3 ft. 8 in. Fur-

Jan 8, 1925

By L. L. Wyman

SINCE the observations of Heyn,1 relative to the embrittlement of copper after having been heated in hydrogen, this subject has received considerable attention from later investigators. The published works of Archbutt2 and of Bengough and Hill3 give the reasons for this embrittlement-the formation of steam by the reaction between cuprous oxide and hydrogen. From Ruder,4 Pilling,5 Moore and Beckinsdale,6 Bassett and Bradley,7 and from Smith8 can be obtained quantitative data concerning the action of hydrogen and other reducing gases on copper samples having various oxygen contents. This problem has been discussed from a practical standpoint by Fuller9 who calls attention to some of the instances of this embrittlement encountered in the manufacturing field. The examples he cites may be considered typical cases of copper embrittlement which were incident to the process of manufacture. In many cases, such difficulties are overcome by changes in the manufacturing process.

Jan 1, 1931

By J. T. Burwell

The crystal orientation in silicon iron that has been given a particular treatment described by Goss,l has been studied by Goss, by Bozorth2 and by Sixtus,3 but their results do not agree and are almost entirely qualitative. The following pages give a description of the orientation of the crystals in the material as determined by means of X-rays and expressed graphically in a pole figure. The treatment consists of hot-rolling the material into strip and then giving it two cycles of cold reduction followed by recrystallization. This produces remarkably good properties in the rolling direction, the product having a maximum permeability in this direction of more than 25,000 and a permeability at 16,000 Gauss of more than 2200. It is now generally agreed that Goss's original conclusion1 that the crystals in the final product are randomly oriented was incorrect, since Bozorth2 and Sixtus,3 using different methods, have shown that there is a decided preference in orientation. Those writers, however, expressed their results only in terms of one or more ideal orientations with deviations therefrom. X-ray Data A strip of the material containing 3.1 per cent Si, prepared by Goss,† 1.2 by 0.0125 in., was etched rapidly in warm dilute hydrochloric acid until it was 0.005 in. thick, in order to eliminate the effect of the two surface layers. The specimen was then mounted in an integrating camera similar to one described in the literature.4 The purpose of this camera is to translate the specimen during exposure, so that a statistically large number of grains contribute to the pattern photographed. The camera also allows the plane of the specimen to make various angles with the X-ray beam. An area 5 by 1.2 in. was scanned by a beam of unfiltered radiation from a molybdenum target tube operating at 37 kv., and the measurements were made principally on the peak of the white radiation. X-ray photographs were taken at intervals of 15" in a plane

Jan 1, 1940

By J. T. Burwell

The crystal orientation in silicon iron that has been given a particular treatment described by Goss,l has been studied by Goss, by Bozorth2 and by Sixtus,3 but their results do not agree and are almost entirely qualitative. The following pages give a description of the orientation of the crystals in the material as determined by means of X-rays and expressed graphically in a pole figure. The treatment consists of hot-rolling the material into strip and then giving it two cycles of cold reduction followed by recrystallization. This produces remarkably good properties in the rolling direction, the product having a maximum permeability in this direction of more than 25,000 and a permeability at 16,000 Gauss of more than 2200. It is now generally agreed that Goss's original conclusion1 that the crystals in the final product are randomly oriented was incorrect, since Bozorth2 and Sixtus,3 using different methods, have shown that there is a decided preference in orientation. Those writers, however, expressed their results only in terms of one or more ideal orientations with deviations therefrom. X-ray Data A strip of the material containing 3.1 per cent Si, prepared by Goss,† 1.2 by 0.0125 in., was etched rapidly in warm dilute hydrochloric acid until it was 0.005 in. thick, in order to eliminate the effect of the two surface layers. The specimen was then mounted in an integrating camera similar to one described in the literature.4 The purpose of this camera is to translate the specimen during exposure, so that a statistically large number of grains contribute to the pattern photographed. The camera also allows the plane of the specimen to make various angles with the X-ray beam. An area 5 by 1.2 in. was scanned by a beam of unfiltered radiation from a molybdenum target tube operating at 37 kv., and the measurements were made principally on the peak of the white radiation. X-ray photographs were taken at intervals of 15" in a plane

Jan 1, 1940

By S. J. CRAIGHEAD

IN 1912 the United States Smelting Refining and Mining Company made a large investment in a number of coal properties in Utah and in 1915 a subsidiary, the United States Fuel Co., was organized to take over these properties. Operations started in 1916 and the Company soon became, and remains, one of the major coal producers of the State. It now produces approximately one million tons of coal annually, which is about 22 per cent of Utah's output. The U. S. Fuel Co. owns large reserves of good coal and is in a position to expand operations with the industrial growth now taking place in the West. Traveling through the Western States, one is struck by numerous advertising signs portraying the picture of jovial Old King Cole of nursery rhyme fame. His rotund figure and beaming countenance are the symbols of Utah King Coal, the product of the King mine of U. S. Fuel Co. King Coal is a by-word of quality coal throughout all the Western States.

Jan 1, 1948

By Robert Keeney

Before the outbreak of the war in 1914, the only electric-furnace smelting plant operating on a commercial basis west of the Mississippi River was an electric pig-iron plant in California; rare metal ores were not smelted, concentrates of molybdenum, tungsten, uranium, and vanadium ores being shipped east for reduction. Practically no- chrome ore was being mined, and only comparatively small amounts of manganese ore. Today there are two electric smelting plants in California, one in Washington, one in Iowa, and four in Colorado; two plants are under construction in California, and one in Montana. Ores of manganese, chromium, molybdenum and tungsten are now smelted in the West, and although uranium and vanadium concentrates are still shipped to the East, they will probably be treated in western plants in a short time. The four electric-furnace plants in Colorado are listed in Table 1. TABLE 1.-Electric Smelting Plants in Colorado Capacity, Company, Location Kilowatts Products . Tungsten Products Co Boulder 800 Ferrotungsten, ferromolybdentun. Boulder Tungsten Production Co. . Boulder 400 Ferrotungsten. Ferro Alloy Co Utah Junction 1200 Ferrochrome, ferrotung-sten. Iron Mountain Alloy Co Utah Junction 3000 Ferromanganese. Power for all of these plants is supplied by the Colorado Power Co.

Jan 8, 1918

By W. H. Blauvelt

The only way in which the difficult problems of classification of coal for the manufacture of by-product coke can be solved is to analyze them by the use of scientific data. It is very easy to adopt classifications for coal for the manufacture of by-product coke along certain lines; we can easily say that for a certain class of metallurgical operation coke made from bituminous coal must not contain more than so much sulfur or more than so much ash and should yield certain returns in the by-products, tar, ammonia, benzol, gas, etc. Those points we are fairly clear on and I think it is hardly worth while to discuss them because I presume that they are familiar to most of us who have any occasion either to make coke or to use it. But there is a field in the manufacture of coke which we know very little about. For example, we are operating a plant on a certain mixture of coal. Suddenly our blast-furnace man or the user of the coke tells us the coke is not as good as it was before. The coke is analyzed and the coal is analyzed. Everything seems to be about the same as it was— the ash is the same, there is no more sulfur, and so on—but the coke, for the use to which it is put, particularly in the blast furnace, is wrong. What happens? The management decide to try a slightly different coal mixture. They do not necessarily raise the total hydrocarbons, the volatile matter in the mixture, nor change the sulfur or the ash, but they do make a change which improves the value of the coke for metallurgical use. The reason for this difficulty, as I see it, is the " combustibility " of the coke—I hesitate to use the word, but it is the best one I have available. Combustibility of Coke We know now that the combustibility of coke is a very vital point in many metallurgical processes and I think one of the most notable instances of the proof of this is the experience of the Carnegie Steel Co. in the production of coke at its Clairton plant. The history of that

Jan 1, 1930

By E. P. Klier, V. Weiss

IN studies of the X-ray diffraction line geometry of iron with chromium radiation using techniques aimed at minimizing the background intensity, Kp and Ka emission satellites* were resolved with three techniques. These satellite lines are present with sufficient intensity to lead potentially to erroneous structure analysis, if not properly interpreted. The techniques used were: 1) film technique with un-filtered radiation and polycrystalline specimen, 2) film technique with unfiltered radiation and single crystal, and 3) counter technique with unfiltered radiation and single crystal. An example of results obtained with technique 1 is given in Fig. 1.

Jan 1, 1958

By A. E. Brugger

SOME 2,000 years ago Pliny is supposed to have said, "Out of Africa always something new." It may perhaps even now be news to a great many that the Belgian Congo has in recent years been producing approximately a quarter of a ton of diamonds annually. For that is what the 1 1/4 million carats, the recovery from 40-odd operating mines, and about 20 or 25 per cent of the world's normal consumption, amounts to. In 1915, first exploitation operations produced less than 50,000 carats from two mines. The rapid expansion of operations following the Euro¬pean war meant a most rapid development of a virgin land. The interior is now reached by air in one day from the mouth of the Congo River, where steamers unload mail and passengers from Antwerp. This trip formerly consumed 4 to 6 weeks by a narrow-gage, wood-burning, railroad around the rapids of the lower Congo and Livingston Falls; by river boat to the heads of navigation, Djoko Punda on the Kasai or Luebo on the Lulua; and thence by caravan of native porters over narrow-trails to head¬quarters on the Tshikapa. Hundreds of miles of automobile roads have been constructed over veldt and through forest, bridging streams and ferrying rivers. The railway from Capetown to the Katanga copper district to the East, once two months away by trail is now reached in 2 or 3 days over fair automobile highway. Native "boys" who a few short years ago wore little more than a smile and a string of beads and to whom a wheelbarrow was a complicated piece of machinery, are today driving Fords, tending boilers and engines and operating electrical equipment, or are capable mine workmen, machinists and artisans, and dressed in all manner of cast-off white man's clothing. Even as late as 1920, due to difficulties of securing and transporting machinery during and just after the war, the crudest hand operations were the rule for the excavation, sizing, and concentration of the diamondiferous gravel. All washing and concentration is now mechanized, using steam or electric power, and where operations are sufficiently large to permit competition with native labor costs, excavation and transportation are also accomplished by machinery.

Jan 1, 1932

By H. l. Burghoff, E. C. Bohlen

The work reported in this paper was carried out to supplement the existing information concerning directional properties and recrystallization textures of annealed brass sheet and strip. These characteristics are of direct interest when the forming and drawing properties of such material are being considered. Among those who have made contributions in this field are Bass and G1ocker;l Bauer, Göler and Sachs;2 Phillips and Samans;3 Pratt;4 Price;5 Cook;6 Richards;7 Brick;8 and Brick and Williamson.9 These investigators have found, in general, that in brass strip that shows directional variations in properties, tensile strength has a minimum value and elongation has a maximum value at 45' to the rolling direction. The most pronounced directional properties have been found in material given the greatest reductions in rolling followed by high annealing temperatures. Recrystallization texture of brass has been variously reported as (II3)[II2], (ooi)[ioo], and a combination of (II0)[II5] and traces of the primary rolling texture, (110)[112]. The directional studies have been very informative, but actual tests appear to have been confined to material in its final condition. Tests at intermediate stages have received little attention although previous history of some materials has been partly considered. Perhaps the most comprehensive investigation was made by Cook,' who studied the directional properties of 70-30 brass strip for which the final and penultimate, or next to the last, anneals and the final reductions were varied. He found that, for any given combination of penultimate anneal and final reduction, the tendency toward the development of directional properties was reduced as the temperature of the final anneal was decreased. In addition to drawing cups and making tensile tests of the finished material at various angles to the rolling direction, he measured the frequency and the angles of twins in grains for several specimens. Plots of his twin counts showed directionality for the materials that produced eared cups. Test Materials and Equipment For this investigation, one commercial heat of 68-32 brass was cast in the form of bars for cold-rolling, I31/2 in wide and I1/2 in. thick. The analysis was as follows: 68.83 per cent copper, 0.04 per cent lead, 0.01 per cent iron, 31.12 per cent zinc (by difference). The bars were so processed to the final thickness, 0.020 in., as to obtain on this thickness all possible combinations of the variables listed below except those involving the sequence of 84 per cent penultimate reduction and 84 per cent final reduction: I. Penultimate reductions of 37 per cent, 50 per cent and 84 per cent; 2. Penultimate anneals at 800°, 900°, 1050° and 1200°F.; 3. Final reductions of 37 per cent, 50 per cent, 69 per cent and 84 per cent;

Jan 1, 1942

By E. C. Bohlen, H. l. Burghoff

The work reported in this paper was carried out to supplement the existing information concerning directional properties and recrystallization textures of annealed brass sheet and strip. These characteristics are of direct interest when the forming and drawing properties of such material are being considered. Among those who have made contributions in this field are Bass and G1ocker;l Bauer, Göler and Sachs;2 Phillips and Samans;3 Pratt;4 Price;5 Cook;6 Richards;7 Brick;8 and Brick and Williamson.9 These investigators have found, in general, that in brass strip that shows directional variations in properties, tensile strength has a minimum value and elongation has a maximum value at 45' to the rolling direction. The most pronounced directional properties have been found in material given the greatest reductions in rolling followed by high annealing temperatures. Recrystallization texture of brass has been variously reported as (II3)[II2], (ooi)[ioo], and a combination of (II0)[II5] and traces of the primary rolling texture, (110)[112]. The directional studies have been very informative, but actual tests appear to have been confined to material in its final condition. Tests at intermediate stages have received little attention although previous history of some materials has been partly considered. Perhaps the most comprehensive investigation was made by Cook,' who studied the directional properties of 70-30 brass strip for which the final and penultimate, or next to the last, anneals and the final reductions were varied. He found that, for any given combination of penultimate anneal and final reduction, the tendency toward the development of directional properties was reduced as the temperature of the final anneal was decreased. In addition to drawing cups and making tensile tests of the finished material at various angles to the rolling direction, he measured the frequency and the angles of twins in grains for several specimens. Plots of his twin counts showed directionality for the materials that produced eared cups. Test Materials and Equipment For this investigation, one commercial heat of 68-32 brass was cast in the form of bars for cold-rolling, I31/2 in wide and I1/2 in. thick. The analysis was as follows: 68.83 per cent copper, 0.04 per cent lead, 0.01 per cent iron, 31.12 per cent zinc (by difference). The bars were so processed to the final thickness, 0.020 in., as to obtain on this thickness all possible combinations of the variables listed below except those involving the sequence of 84 per cent penultimate reduction and 84 per cent final reduction: I. Penultimate reductions of 37 per cent, 50 per cent and 84 per cent; 2. Penultimate anneals at 800°, 900°, 1050° and 1200°F.; 3. Final reductions of 37 per cent, 50 per cent, 69 per cent and 84 per cent;

Jan 1, 1942

By Fred Bond

THE process of comminution by grinding is properly classified as an art, rather than as a science. Like most other operations concerned in ore dressing, or in the treat-ment of nonmetallic minerals, the mathe-matical relationships of rock breaking are still obscure, and much disputed. If some basic formula exists, comparable for in-stance to E = RI in electricity, it has not yet been placed in common use. The absence of such a comprehensive mathe-matical background undoubtedly is the cause of many inefficient designs and installations, as well as of much poorly oriented experimental work. On the other hand, the mathematical immaturity of the process constitutes an opportunity for a real contribution on the part of those who enjoy mental pioneering. Some of the statements made in any such exploratory work may be little more than opinions, and it is to be expected that some will later be proved untrue; but such an evolutionary development is necessary if we are ever to arrive at the fundamental laws, the discovery of which can change the empirical art into a mathematically exact science. The most significant principle of com-minution that we possess is probably Rittinger's law, which states that the work done in crushing or grinding is proportional to the area of the new surface produced. There is an alternative theory, known as Kick's law, which formerly was preferred to Rittinger's but which now is rather dis-credited. According to Kick, the work done in comminution is proportional to the volume, or weight, of the pieces broken, or to the cube of their diameters, while accord-ing to Rittinger it is proportional to the square of the diameters.

Jan 1, 1940

By T. Egleston

THE materials containing copper which are refined in the United States, are, for the most part, the native, coppers of Lake Superior. Until quite recently but little pig copper was made for sale, and that came principally from the pure sulphurous ores of New England and the South, and was generally sold to refineries not far from the ore furnaces. A small amount found its way into the market which was produced either as the by-product of the treatment of gold and silver ores, or as the result of the treatment of impure copper ores; but both these grades, on account of the impurities they contained, were looked on with suspicion, and were not sought for. All the grapes of pig copper are sold by the unit of copper contents, a great reduction being made in the price when impurities are present. There are at the present time only three works which treat native copper, the two of the Detroit and Lake Superior Copper Company, and the works of C. G. Hussey & Co., in Pittsburgh. There are a few works which smelt sulphurous ores and refine their pig; besides these there are a few small works where pig copper is refined only. Some of these purchase black copper, refine scrap, or simply refine such grades of ingot copper as are found in the market, but mostly that from Lake; Superior, for the purpose of getting it into such shapes that can be handled commercially to advantage, such as in making large plates or high grades of wire for electrical purposes. A number of such works are situated in the Naugatuek Valley and elsewhere in New England. The recent discovery, of valuable ores in Arizona makes it probable that within a few years the refining of copper in the United States will make great developments. Up to the time of the discovery of the mines on Lake Superior, only a very small quantity of native copper had ever been found, not sufficient to justify the erection of works for its special treatment. It had, besides, never been found in very Large masses, so that the discovery of great-blocks of it presented serious difficulties, not only in mining it,† but in bringing it into a merchantable condition. It seemed a very simple process to melt these large masses, * Road at the Lake Superior Meeting, August, 1880. †Transactions American Institute Mining Engineers, vol. vi, page 2S2.

Jan 1, 1881

By J. J. Brown

Wilkes-Barre Meeting, Julie, runs., THE ore-hearth was the earliest type of furnace used in smelting Mississippi Valley lead-ores, which are very pure, and low in silver-content. The first smelters made no attempts to recover lead from the smoke; and since about 15 per cent. of the lead -in the charge escaped in this manner, early practice with the hearth was decidedly wasteful. At most of the large smelting-plants blast-furnaces with auxiliary roasters were substituted for the hearths long ago. But, upon the introduction of the Lewis and Bartlett bag-process for collecting fume, the ore-hearth was used by companies engaged in the manufacture -of pigments, simply on account of the large percentage of fume made by it. In fact, the extraction of lead was kept down by the use of hot blast and other devices. During recent years, however, several smelting companies have realized that the preliminary roasting of galena for the blast-furnace is not economical, and have, therefore, replaced the roasting-furnace with a modification. of the old Scotch hearth, in which a large percentage of the lead in a charge is recovered directly as pig-lead, while the remainder passes partly into fume and partly into slag low enough in sulphur to be charged into the blast-furnace without further treatment. The results obtained have proved so satisfactory, both As to recovery and operating-expense, that one eminent metallurgist has predicted the universal use of the ore-hearth on non-argentiferous ores. The-ore-hearth, thus employed as an adjunct to a blast-furnace plant, is rather a desulphurizer than a smelting-furnace proper,-the chief object being to make a blue slag suitable for the cupola-furnace. Hence, no special care is taken to obtain from it a large lead-extraction. * Head of Department of Ore Dressing and Metallurgy, Oklahoma School of Mines and Metallurgy, Wilburton, Okla.

May 1, 1911

By B. F. Peters, J. Gordon Parr, E. R. Macgregor

A SERIES of seven hypoeutectoid alloys, up to 18.2 atomic pct Mn, was made by the levitation melting technique. The loss of weight on melting was considered to be entirely due to volatilization of manganese, and compositions were computed on this basis. Filed samples (—200 Tyler mesh) were helium quenched from 1000°C after soaking for 5 min by a technique already described.' Quenched Alloys -Assessments of the amounts of a phase produced and the hardness of the quenched alloys are summarized in Fig. 1. The experimental techniques and calculations involved have been described previously. The amount of a decreases as manganese content increases, until at 10.6 pct Mn only a trace of a' is observed. Previous

Jan 1, 1957

Executive SIDNEY J. JENNINGS, Chairman GEORGE D.-BARRON J. E. JOHNSON, JR. EDWIN LUDLOW ROBERT M. RAYMOND Membership KARL EILERS, Chairman LEWIS W. FRANCIS J. E. JOHNSON, JR. LOUIS D. HUNTOON ARTHUR L. WALKER Finance GEORGE D. BARRON, Chairman. CHARLES F. RAND BENJAMIN B. THAYER Library E. GYBBON SPILSBURY,1 Chairman ALEX C. HUMPHREYS3 GEORGE C. STONE2 J. H. JANEWAY4 BRADLEY STOUGHTON Papers and Publications BRADLEY STOUGHTON, Chairman

Jan 9, 1918

By C. D. Ramsden

DURING the war years of 1941 to 1945, maintenance of mine locomotives and other mine equipment took the form of rebuilding rather than of renewing. Pur¬chase of new parts became increasingly difficult and mine operators found it necessary to maintain equipment by sal¬vaging old parts. Mine-locomotive wheels, although not representing a high cost per pound of material, contain a con¬siderable amount of steel and without rebuilding would have to be scrapped long before even a moderate percentage of the steel in the wheel is actually consumed. Many mine operators have been re¬building locomotive wheels for several years with automatic open arc-welding equipment. In 1927, the Pittsburgh Coal Co. started such a program, using a single Westinghouse automatic welding head. Since that time, many refinements have been added, until in 1944 the setup was operating very efficiently. A desire to increase wheel life and to hold down rising costs led the company in 1944 to investigate the possibilities of the under¬flux arc-welding process for wheel rebuild¬ing, although at that time, little or no work had been done on multiple pass or "build-up" welding with the underflux arc. Work with this process had been confined largely to welding together flat plates in a "down hand" position. Possibilities for savings were intensified by the fact that the company has 300 locomotives in operation, using actively or as spares 1200 sets of wheels. During 1942 and 1943, about 500 sets of wheels were sent each year to the company's maintenance shop at Library, Pa., for rebuilding. Based on having 800 sets in service (many of the company's heavy locomotives have three- sets of trucks), the average life of a set of wheels was approximately 19 months. Anything that could be done to increase wheel life promised sizable annual savings. OPEN ARC WELDING With the open arc process, a set of wheels could be rebuilt for about 40 pct of the cost of new wheels. Underflux arc welding gave promise of greatly increased welding speeds, more homogeneous, dense deposits and the chance for use of a wider range in welding-wire compositions. Against this was ranged the higher cost of materials and the cost of developing the process from the theory to a practical reality. Since 1927, when a single open arc head was placed in operation, fixed welding procedures had been gradually developed, a positioner for handling a set of wheels was built, and a second head was placed in operation in order to weld two wheels simultaneously. The fixture, or posi¬tioner, which was built to position and turn the wheels under the two welding heads, included a motor drive, controlled by a rheostat, which rotated the wheels through a double set of speed reducers and a removable jaw coupling attached to one end of the axle of the wheel truck.

Jan 1, 1946