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By Robert S. Archer

THE proper material of construction for a given purpose is that material which meets the requirements satisfactorily at the lowest ultirnatc cost. It is consistent with this principle that most aluminum castings are made of an alloy containing about 8 per cent. copper. This alloy possesses mechanical properties satisfactory for general engineering purposes together with manufacturing characteristics leading to the production of finished castings at low cost. It is to the aluminum industry what gray iron is to the iron and steel industry. Just as some services require "semi-steel," malleable castings or steel castings instead of gray iron, there is a certain and growing demand for aluminum castings of superior strength or ductility, or both. Since the beginning of .the industry producers and others have sought to develop alloys or processes by which such castings could be made. Out of these efforts have emerged many alloy compositions and special processes, of which only a few have had sufficient merit to survive. It is the purpose of this paper to describe those which seem to the authors to offer the greatest promise for the production on a commercial scale of aluminum castings of superior mechanical properties, with special reference to heat-treated castings. The suitability of an alloy or process for actual manufacture is affected by so many factors that the problem of appraisal is not a simple one. Since this is such an important part of the whole subject it is proposed to discuss briefly some of the requirements. The final verdict is of course the result of commercial trial and experience. It will therefore, perhaps, be profitable to employ a somewhat historical method of treatment in discussing the subject of alloy development. The alloys or processes to be used in the production of aluminum castings are to be considered from the standpoint of their effects on both the utility and the cost of the finished casting. Specific gravity and mechanical properties come under the first head, while the properties

Jan 1, 1927

Jan 1, 1891

This is a most interesting paper and some data in it are corroborated by work I did at Watertown Arsenal some time ago with iron powder. I would like to ask Dr. Wulff to say just a little more about the compressive and tensile stresses on the surface of compacts. JOHN WULFF (author's reply).-Our work has not yet been completed; although enough data have been obtained with cylindrical compacts of iron to permit some conclusions. Briefly, in a compact 3/4 in. high and 1/2 in. in diameter pressed at 48 tons per sq. in., the residual stresses on the surface measured by X-ray diffraction techniques are as follows: The radial stresses on top center and bottom of compacts are practically zero; the longitudinal residual stresses on the side walls are near the top quarter of the compact about seven tenths that of the yield point of mild steel in tension; at the center surface of the compact they are in compression and in magnitude about 0.3 that of mild steel in tension; near the bottom, they are practically zero. F. V. LENEL.?- I was particularly interested in the work that Messrs. Wulff and Seelig reported on the influence of lubrication on the density of parts. In connection with the work of the American Society for Testing Materials on determining the green density of a compact, we ran into considerable difficulty in getting reproducible results of green density determinations. It was much easier to get a reproducible green density when the lubricant was mixed with the powder than when the lubricant was applied to the die walls; particularly when the die was not perfect-i.e., if it was somewhat rough or out of round. In this case, it was almost impossible to get reproducible green densities when the die walls were lubricated, while it was not too difficult to get reproducible

Jan 1, 1946

The income of the Institute is derived from dues, subscriptions to MINING AND METALLURGY and sale of publications. These sources are fortunately supplemented by the interest from invested funds now amounting to over $500,000, a considerable portion constituting endowments for especial purposes. Aside from the medal funds the principal endowments are the James Douglas Fund for support of the Library, the Rocky Mountain Fund and the Seeley W. Mudd Memorial Fund. The income from the two last named is available for the support of research and a variety of other purposes. It is allocated by the Board of Directors upon recommendation of standing committees in each case. An active effort is being made to increase the endowments of the Institute, it being felt that unusual opportunities exist for research and public and professional service through the organization and at a minimum of expense. J. V. W. Reynders is chairman of the Endowment Committee.

Jan 1, 1923

Jan 1, 1943

Jan 1, 1943

By P. Duwez, L. Zwell

In recent years, the problem of pressing metal powder in a die has received much attention. The question has been the object of a Symposium held in New York in March 1947 under the sponsorship of the AIME; an excellent review of the subject may be found in Ref. 1. Various experimental techniques have been used to study the behavior of the powder in a die cavity. Two methods have been particularly successful; one consists of measuring the density distribution²,³ and the other makes use of a lead grid in the powder during pressing.4 In the present study, the pressure at various points on the bottom and the sides of a die 1.50 in. in diam was measured by means of small piston dynamometers and resistance sensitive strain gauges. In order to correlate the results with previous investigations, the pressure distribution inside the compact has also been determined by an indirect method based on density measurements. Strain Gauge Measurements of Pressure on Side and Bottom of Die A schematic drawing of the die used for measuring side pressures is shown in Fig 1. The pressure gauge consists of a 0.25-in. diam piston A which transmits the pressure to a dynamometer B, on which two Baldwin Southwark type 4-14 strain gauges are fastened 180" apart. Because the installation of several dynamometer assemblies along the side of the die would have been difficult, the pressure distribution was obtained in successive tests in which the distance from the gauge to the bottom of the compact was adjusted to different values by changing the length of the bottom piston. The dynamometer, disassembled from the die, was calibrated under compressive loads and showed a 1.00 ohm change of resistance for every 15,300 psi change of pressure (750 lb load change). All the strain gauge measurements were made with a null type Leeds and Northrup Wheatstone bridge. The sensitivity of the method was better than 1 pct and the accuracy was within 2 pct. These values were considered satisfactory in view of the rather large scatter in the measurements introduced by the random variation in packing the powder in the die. The stable ambient conditions and short time involved in the taking of observations made temperature compensation unnecessary-. The pressure distribution on the bot-

Jan 1, 1950

By Joseph Bernhardt

THE Cornwall Ore Mines, Division of the Bethlehem Steel Co., at Cornwall, Lebanon County, consists of two separate magnetite ore bodies, approximately one mile apart. The one ore body was an outcrop in which open-pit mining operations were begun in 1742 and continued without interruption. This mine is also served by a shaft for mining that portion of the ore body not recoverable by open-pit methods. The other property had no outcropping and is entirely an underground operation. This mine, cap-tioned No. 4 mine, is serviced by two shafts 220 ft apart. The No. 4 shaft is for hoisting rock and ore, and the No. 5 shaft is for handling men and ma- terials. The shafts are on a catenary curve, closely following the dip of the ore body. Slope of the shafts at the collar is 36", flattening to 26" at the bottom. The footwall at Cornwall is a traprock which varies structurally from solid to highly fractured. Grizzly stations at the top of each chute raise were reinforced by setting timber sills on concrete. Occasionally it was necessary to concrete the entire chute raise. Concreting was done by using 35-yd electric mixers set up in the breaking subs. Sand, stone, and cement were hoisted up through the chute raises to the breaking subs. Late in 1937 it was decided to eliminate chute raises and breaking subs in future development. Haulage levels are 50 ft apart vertically. When ore is below a 40 " dip, slushing drifts are driven normal to the haulages and on 40-ft centers. In a few areas, ore dips greater than 40" and slushing drifts are then placed parallel to the haulage drifts. Finger raises are opposite each other and on 20-ft centers making 20x20-ft draw areas (fig. 1). For loading

Jan 1, 1951

By Joseph Bernhardt

THE Cornwall Ore Mines, Division of the Bethlehem Steel Co., at Cornwall, Lebanon County, consists of two separate magnetite ore bodies, approximately one mile apart. The one ore body was an outcrop in which open-pit mining operations were begun in 1742 and continued without interruption. This mine is also served by a shaft for mining that portion of the ore body not recoverable by open-pit methods. The other property had no outcropping and is entirely an underground operation. This mine, cap-tioned No. 4 mine, is serviced by two shafts 220 ft apart. The No. 4 shaft is for hoisting rock and ore, and the No. 5 shaft is for handling men and ma- terials. The shafts are on a catenary curve, closely following the dip of the ore body. Slope of the shafts at the collar is 36", flattening to 26" at the bottom. The footwall at Cornwall is a traprock which varies structurally from solid to highly fractured. Grizzly stations at the top of each chute raise were reinforced by setting timber sills on concrete. Occasionally it was necessary to concrete the entire chute raise. Concreting was done by using 35-yd electric mixers set up in the breaking subs. Sand, stone, and cement were hoisted up through the chute raises to the breaking subs. Late in 1937 it was decided to eliminate chute raises and breaking subs in future development. Haulage levels are 50 ft apart vertically. When ore is below a 40 " dip, slushing drifts are driven normal to the haulages and on 40-ft centers. In a few areas, ore dips greater than 40" and slushing drifts are then placed parallel to the haulage drifts. Finger raises are opposite each other and on 20-ft centers making 20x20-ft draw areas (fig. 1). For loading

Jan 1, 1951

By E. W. Henderson

Development work in the state of Utah in 1935 consisted of additional work done on wildcat tests started in previous years and on a number of new wildcat tests started during the year. No effort was made to extend areas or to discover deeper productive horizons in proven fields. Principal areas of development were in Daggett County, northeastern Utah; Grand and Emery counties, east-central Utah; and in Washington County, southwestern Utah. Daggett County Clay Basin.—The Mountain Fuel Supply Co. deepened Murphy No. 2, sec. 21, T.3N., R.24E., from 6030 to 6790 ft. for a test of the Sundance formation. Two sandstone members at 6520 to 6644 ft. and 6737 to 6790 ft. contained water. The hole was plugged back to 5860 ft. and left as a future gas supply for the Salt Lake City-Ogden pipe line. The failure of the Sundance formation to produce in this test, in view of the recent Sundance discoveries in Colorado arid Wyoming, was disappointing Emery County Last Chance.—-Thc wildcat test of the Rainsey Petroleum Corporn-tion, Well No. 1-X, sec. 18, T.26S., R.7E., completed plugging back from total depth of 3168 ft. to 2771 ft. and was shut in as a gas well. A gas sand at 2724 to 2771 ft. produced approximately 21 million cubic fert. A deep test of the structure will be started upon approval of a wit plan of development. Grand County Cisco.—-The wildcat test of the Utah Southern Oil Co., sec. 33, T.22S., R.22E., of which the total depth was 1720 ft. on Dec. 31, 1935, is the most interesting operation ill the state. Location of the test was deter-

Jan 1, 1936

By E. W. Henderson

Development work in the state of Utah in 1935 consisted of additional work done on wildcat tests started in previous years and on a number of new wildcat tests started during the year. No effort was made to extend areas or to discover deeper productive horizons in proven fields. Principal areas of development were in Daggett County, northeastern Utah; Grand and Emery counties, east-central Utah; and in Washington County, southwestern Utah. Daggett County Clay Basin.—The Mountain Fuel Supply Co. deepened Murphy No. 2, sec. 21, T.3N., R.24E., from 6030 to 6790 ft. for a test of the Sundance formation. Two sandstone members at 6520 to 6644 ft. and 6737 to 6790 ft. contained water. The hole was plugged back to 5860 ft. and left as a future gas supply for the Salt Lake City-Ogden pipe line. The failure of the Sundance formation to produce in this test, in view of the recent Sundance discoveries in Colorado arid Wyoming, was disappointing Emery County Last Chance.—-Thc wildcat test of the Rainsey Petroleum Corporn-tion, Well No. 1-X, sec. 18, T.26S., R.7E., completed plugging back from total depth of 3168 ft. to 2771 ft. and was shut in as a gas well. A gas sand at 2724 to 2771 ft. produced approximately 21 million cubic fert. A deep test of the structure will be started upon approval of a wit plan of development. Grand County Cisco.—-The wildcat test of the Utah Southern Oil Co., sec. 33, T.22S., R.22E., of which the total depth was 1720 ft. on Dec. 31, 1935, is the most interesting operation ill the state. Location of the test was deter-

Jan 1, 1936

By P. W. Ramsey, G. L. Werley

THERE have been numerous examples in recent years of the similarity between aging behavior and diffusion behavior, where a plot of the logarithm of the aging rate versus the reciprocal of the absolute temperature yields an approximate straight line, analogous to a similar plot of the diffusion coefficient D (log D vs. 1/T). Austin and Rickettl have pointed out that this linear relationship holds empirically for the de- composition of austenite into pearlite and bainite in carbon steels, and Robertson' has shown similar trends in the aging of 24S-type aluminum alloys. Jenkins and Bucknall³ have also demonstrated the association between aging and diffusion rates for nickel-silicon-copper alloys. Jetter and Mehl,4 however, have shown that the maximum rate of dilation of a series of aluminum-silicon alloys does not show this linear relation and Mehl5 has pointed out that careful study of available knowledge indicates that "aging rates increase with temperature approximately exponentially, whereas D increases precisely exponentially." He further notes that "the rate of aging at a given temperature is the greater the lower the melting point of the alloy, which is also true for D." This paper describes the aging changes occurring in a zinc-25 pct manganese-15 pct copper-0.1 pct aluminum die casting alloy. It was found that this alloy does show this linear relationship and use was made of this relationship to estimate aging rates at low temperatures from data acquired at elevated temperatures. It should be noted that the aging reaction is being studied only indirectly, using changes in certain properties as criteria of the progress of the phenomenon. This alloy is purely an experimental one and is not available commercially. Zinc-Manganese-Copper System: The zinc-rich portion of the zinc-manganese-copper diagram which is of significance in the present work is quite uncertain. X ray examination of the alloy as die cast shows a phase similar to the epsilon phase (hexagonal close packed) of the copper-zinc system. All of the data accumulated indicate that the epsilon phase of the zinc-manganese-copper alloy is stable at high temperatures; that is, 500°C or above. Below this temperature a new phase is precipitated on annealing, and a decrease in specific volume occurs. At elevated temperatures this phase change occurs quite rapidly, while at room temperature the alloy has shown no change after several years. According to X ray data, this precipitated phase resembles the gamma phase (cubic) of the copper-zinc system, a hard and brittle structure. From examination of the microstructure and from X ray examination of the alloys annealed at

Jan 1, 1951

By C. C. Wright, R. J. Day

Although data on the exact tonnage of recoverable coal silt are not known, the quantity produced in 1943 was estimated to be over five million tons for the anthracite region of Pennsylvania alone. Since that time the recovery of the No. 5 buckwheat size previously included in silt estimates has increased greatly thus reducing the total silt tonnage. As a compensating factor, however, the methods of recovering silt previously escaping into the rivers and streams have been markedly improved so that the net figure may not have changed materially. Comparable estimates for bituminous coal are lacking, but undoubtedly the silt represents a significant tonnage. With the trend toward increased wet cleaning of the smaller sizes of bituminous coal, it is to be expected that even greater quantities of silt will be available in the future. The raw silt from anthracite collieries usually contains a high mineral matter content, but technological developments in fine coal cleaning have been making rapid advances and it appears probable that more extensive use of these methods will be employed in the near future. Bituminous coal silt in many instances contains a similar high mineral matter content. As with anthracite silt, however, the cleaning of this material, where necessary, appears both technologically and economically feasible. With a view to upgrading the size and value of silt, considerable laboratory and pilot plant work has been conducted by a number of organizations on what is commonly known as pelletization. Actually the process is one of extrusion in which the moist silt is extruded from a die in the form of rods, which usually break into relatively short lengths—a few inches long—as they fall from the die. Fig I is a photograph of some extruded 3/8-in. diam pellets and of the anthracite silt from which they were produced This technique of producing larger sized material from fines is by no means new, having been used extensively by the industrial carbon and clay industries for years.' The application of the process to coal silt appears, however, to be relatively new. The first major program of investigation dates back only to July 1945, when a group of engineers representing the Anthracite Institute, The Pennsylvania State College and the J. F. Pritchard and Co. conducted preliminary tests on the extrusion of anthracite silt at the Floridin Co. plant at Warren, Pa. Since that time these three organiza-tions—individually, together, and in cooperation with other interested groups— have actively pursued work on various phases of the problem. Much of the early history and details of the laboratory and pilot plant work by the Anthracite Institute, has been reported by Mulcey and Eckerd.2 It is the purpose of this paper to report additional information on the process, especially with respect to the factors influencing the quality and use properties of the product, and the current develop-

Jan 1, 1949

Jan 1, 1966

By A. H. Bell

Continued low prices and restricted markets for crude oil discouraged drilling activity in Illinois oil fields during 1933. Only 36 wells were completed in the state, the smallest number since 1904, and of these the majority were scattered wildcat wells, only 10 having been drilled in producing fields (Table 2). Production was curtailed approximately 40 per cent for the first half of the year. During July, August, and the early part of September there was no restriction on production. On Sept. 8, under the "code of fair competition for the petroleum industry," the quota of allowable production for Illinois was fixed at 12,000 bbl. per day. The state's production in 1933 was 9 per cent less than in 1932. What it would have been had there been no curtailment of production and if economic conditions had permitted a normal amount of cleaning out and repairs to wells, it is not possible to estimate, but it would no doubt have been considerably more than the actual figure. No new pools or new producing horizons were discovered in 1933, but the deepening of a Robinson sand well in Crawford County to the McClosky "sand" horizon (St. Genevieve limestone of the Lower Mississippian) resulted in a production of 3 bbl. per day (Fred Patchel, Savilla Shipman No. 5, NE. 1/4, SW. 1/4, sec. 26, T.6N., R.l3W., deepened from 1122 to 1388 ft., to be tested to the McClosky horizon, and, owing to the rapid variations in porosity within short distances, as shown in the Lawrence County field to the south, one test may not be considered as proving or condemning any large area. The average price of Illinois crude oil in 1933, calculated from the posted prices as published in the Oil and Gas Journal and Oil Weekly, was $0.862 per barrel. This compares with a calculated average price of $1.032 in 1932 and 0.852 in 1931. The total value of Illinois crude oil produced in 1933 obtained by multiplying the average price (0.862) by the total production (4,227,000 bbl.) was $3,643,674. Of the 26 wildcat wells drilled in 1933, only one was drilled on known favorable structure. This was the Walmar Oil Company's William Pepple well No. 1, sec. 12, T.4N., R.12W., Hancock County, which tested

Jan 1, 1934

By B. C. Craft

Oil and gas development in Mississippi during the year 1933 was rather active and a number of important wildcat wells were drilled throughout the state. Mississippi showed an increase in drilling operations during 1933. There were 58 completions from 22 counties during this period, compared with 53 completions in 10 counties during 1932. The Jackson gas field in Hinds and Rankin counties continued to be the most active area with 26 completions, resulting in 17 gas wells, 2 oil wells, and 7 dry holes, compared with 38 gas wells, 1 oil well and 5 dry holes during 1932. A further attempt to extend the producing limits of the Amory gas field resulted in a dry hole. Extensive exploration in south Mississippi has proved the existence of ample source beds and presence of an extensive sandbody near the top of Cockfield. Core tests, supplemented by extensive geophysical work, have been carried on in Jackson, George, Harrison, Pearl River and Stone counties. Exploration will be continued in 1934. The most important deep test drilled in 1933, and the deepest well ever drilled in a southeastern state, was the Eastman Gardner et al., Bank of Seminary No. 1, sec. 26-8N.-15W., Covington County. This well went through about 1300 ft. of Selma chalk, and was abandoned in the Eutaw at 8004 ft. Another interesting operation during the past year was the Foster Creek Oil Corporation's Foster Creek Lumber Co. No. 1, sec. 14-2N.-2W., in the "Eastern Conroe Trend." This test is shut down at 3687 ft. in the Catahoula sandstone and has not encountered any important shows of oil or gas. A total of 107 of the 117 gas wells completed in the Jackson gas field since its discovery in 1930 are still producing, and have a combined open flow of approximately 3,724,896,000 cu. ft. It is reasonable to assume that this area will be rather inactive during 1934 as the maximum daily production during 1933 was 3,476,000 cu. ft. The 10 wells that have gone dead were edge wells. The water level is now between the sub-sea depths of 2190 and 2195 ft. The Gulf Refining Company's Rainey No. 1, sec. 13-5N.-lE., one of the early wells in the field, had gas and water at —2225 ft. That the field is under hydraulic control is

Jan 1, 1934

By W. L. Dumoulin

A RATHER detailed description of the entire plant and leaching process was given in a paper recently presented to the Institute,1 so this paper will cover briefly only the crushing practice of the New Cornelia Copper Co. for the year, 1918. The ore, which is mined by steam shovels and loaded in side-dump cars, passes through two crushing plants. These crushing plants were constructed to crush the ore required by a leaching plant of 5000 tons daily, capacity, during a crushing period of 16 hours. The primary plant reduces to less than 3 in. (76 mm.) and the secondary plant, to ¼ in. (6.35 mm.), which is sufficiently fine for satisfactory percolation of solution through the ore in the leaching tanks, and to give good extraction. The ore is then conveyed to the leaching tanks by a system of 28-in.. (71-cm.) belt conveyors. On the way to the leaching tanks, it passes through an automatic sampling plant, where a 1-per cent. sample is taken. From the primary crushing plant, the ore is conveyed by two 36-in. (91-cm.) belt conveyors to a 10,000-ton steel storage bin, with a reinforced-concrete flat bottom. The ore discharges from the bottom of this bin onto four 20-in. belt conveyors, which deliver it to the four units of crushers in the secondary crushing plant. There is no storage bin between the mine and the primary crushing plant. The ore breaks very coarse, is very hard, and contains a great many boulders, some as large as 4 ½ by 4 1/2 by 10 ft. (1.3 by 1.3 by 3 m.). Jams form in the bowl of the coarse crusher in the primary crushing plant, as a consequence, and are freed by means of an immense steel hook operated from a 40-ton electric traveling crane.

Jan 8, 1919

By A. M. Gaudin

This year the American Institute of Mining, Metallurgical and Petroleum Engineers has chosen to give me its Robert H. Richards Award, a distinction which is widely regarded as the highest honor in the field of mineral engineering. I am deeply moved by this tribute, which suggests not only regard for my service to the profession but also the affectionate esteem of my fellow mineral engineers. You have made me happy at the prospect of the permanent association of my name with that of Robert Hallowell Richards and of the distinguished recipients of the award, Arthur Fay Taggart, Frank R. Milliken, John F. Myers, Edward William Englemann, C. Harry Benedict, Edward W. Davis and Arthur W. Fahrenwald. I wish to thank you all for an honor so generously bestowed. Professor Richards is known to us all as a legendary figure, and we can read about him in the Richards Memorial Volume of our Transactions. Some of us have even had the good fortune of knowing him. I count myself among those lucky few. In its intangible attributes the Award recalls those things for which Professor Richards stood: for Science in Art, for thoroughness, for meticulous accuracy, for bold imaginativeness, most of all for professional integrity. Now, as in his day, these attributes are central to an engineer's creed. They are appropriately needed in a formulation of a definition of the mineral engineering profession.

Jan 6, 1957

By H. F. Moore

DURING the last six years, there have been many extensive investigations of the fatigue of metals. The major work of 'these investigations has been the determination of constants for fatigue strength of wrought ferrous metals; but during the past year or two there have become available considerable test data on the fatigue strength of certain nonrferrous metals, including copper, brass, bronze, nickel, copper-nickel alloys, aluminum and aluminum alloys, magnesium and magnesium alloys. It is not proposed to give here extensive quantitative tables of test results; for such tables, reference is made to the published data of various laboratories. The following general conclusions, however, seem to be fairly well established: 1. The phenomenon known as "fatigue" of metal really a progressive fracture of metals. A minute (probably submicroscopic) crack is formed in the metal, the internat stress, is intensified at the ends' of the crack, and under successive applications of load the crack spreads like a minute hacksaw cut until there is not enough sound metal left in the cross-section of the piece to stand the load. applied, and then failure occurs suddenly. 2. For wrought ferrous metals, there is .a limiting intensity of stress (as computed by the ordinary formulas of mechanics of materials) below which, a metal is able to withstand an indefinitely large number of repetitions of stress without failure. This limiting stress is known as the "endurance limit or the fatigue limit.? For reversed flexure, the endurance limit for. wrought ferrous metals is usually not far from 50 per cent. of the ultimate tensile strength.

Jan 1, 1925