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By J. L. Huisman, G. Schouten

After pyrometallurgy and hydrometallurgy, bio(hydro)metallurgy is the latest development in the ongoing search for efficient and economic metal winning processes. In addition to bioleaching, other biotechnology-based applications are getting more and more accepted. In this paper a number of proven and commercial processes will be presented that can be applied for nickel and cobalt recovery and refining. These processes are based on the ability of biomass to convert the redox state of sulphur compounds under ambient conditions. They can be applied to recover sulphate from effluents or SOx from off gases and convert it to H2S or dissolved sulphide that can be reused in production or effluent treatment. Not only does this minimize the costs on resources but it also reduces waste production and improves the quality of discharges even to the point where reuse becomes feasible.

Jan 1, 2005

By Emilie Williams

Introduction Mouska Mine, Doyon Division site Background and timeline Obstacles to standard paste delivery system Components of Mouska paste system Technical considerations Operational considerations Mouska Mine Underground gold mine 30 km east of Rouyn-Noranda, Quebec Part of Doyon Division, 100% owned by IAMGold Commercial production since 1991 Cumulative production over 850,000 oz Conventional mining until 2009 485 m shaft from surface 560 m internal shaft 500 tpd (ore and waste) Off-site milling Approximately 150 employees

Oct 1, 2010

By Wayne D. Goodfellow, William M. Luff, Steven J. Juras

Abstract-Brunswick No. 12 is a vent-proximal massive sulfide deposit that formed above a feeder pipe with associated hydrothermal alteration. Because of the replacement of bedded sulfides deposited above the hydrothermal vent, individual sulfide lenses show the following vertical and lateral zoning outward from the vent complex: massive pyrite-pyrrhotite-chalcopyrite core - interlayered pyrite-sphalerite-galena (Pb-Zn ore zone) - bedded pyrite. The feeder zone which underlies the Cu-rich core consists of an anastomosing network of pyrite-pyrrhotite-chalcopyrite­ quartz veins with variable and generally minor contents of ferroan carbonate, Fe-rich chlorite, sphalerite, galena and arsenopyrite. Hydrothermal alteration of felsic igneous rocks hosting and adjacent to the feeder pipe is represented by an inner zone (zone 1) characterized by sulfide stringers, Fe-rich chlorite, muscovite, quartz, and ferroan carbonate that formed at the expense of feldspars and what was probably glass; outer zones (Il and III) are represented by Mg-rich chlorite and muscovite formation, and the albitization and silicification of K-feldspar. Accompanying these alteration trends is a marked decrease of Na + Ca, and an increase in Fe + Mg + C03 in zone 1, and increases in Mg + Na in the outer zones. The classic zoning of metals within the sulfide lenses, the formation of a feeder pipe below the vent-proximal sulfide core, and the hydrothermal alteration of felsic volcanic rocks cut by the feeder pipe all support a vent-proximal origin for the Brunswick No. 12 deposit. Furthermore, restriction of sulfide stringer mineralization to the footwall sequence, the folding of the stringer zone by an F1 fold, and the difficulty of long distance mass transfer of metals from the sulfides into the host rocks all argue against a tectonic origin for the stringer zone. All of the evidence indicates that the feeder pipe formed during the ore forming hydrothermal event, but has been distorted and in some areas detached from the overlying massive sulfides during subsequent deformation.

Jan 1, 1992

By Francis Breton, Daniel Larouche, Pierre Heugue, Rémi Martinez

"Nowadays, in order to fit environmental restrictions, automotive markets are demanding cast aluminum alloys working at high temperature (180–300°C). New generations of alloys are required for higher strength components in engine downsizing or start-stop systems which lead to higher loading and higher specific power and stretch current materials to their limits. Recently, transition metals, such as zirconium and vanadium, have been added as alloying elements into an AlSi7Cu3.5Mg0.1 alloy to improve physical, mechanical, thermodynamic properties with the aim of increasing service life of parts. In such alloys, the best mechanical properties are associated with the formation of precipitates through an optimum heat treatment sequence, including: solutionizing, quenching and artificial aging. This study is focused on the modified AlSi7Cu3.5Mg0.1 cast alloy with Mn, Zr and V additions for high temperature application. The characterization of the cast alloy in this study, firstly, helps to evaluate and understand its performance both chemically and structurally according to their physical state: as-cast or as-quenched. Comparison of precipitation kinetics between a binary Al-3.5%wt.Cu alloy and the AlSi7Cu3.5Mg0.1 (Mn, Zr, V) alloy has been characterized by differential scanning calorimetry, TEM observations and micro-hardness testing. The Kissinger analysis was applied to extract activation energies from non-isothermal DSC runs conducted at different stationary heating rates. The study focuses on the impact of the chemical composition such as Si content on the kinetics parameters.INTRODUCTION Pure metal Aluminum shows poor mechanical properties and its malleability is high, that is why alloying elements are added to the mixture before casting to improve physical, mechanical and thermodynamic properties (Javidani, 2015); such as Silicon (Si) for casting properties (castability, cold crack capability, wear resistance, shrinkage behavior), Magnesium (Mg) and Copper (Cu) to generate precipitation hardening systems. Aluminum hypoeutectic alloys (<12% Silicon) with Cu, Mg additions used in the automotive industry for manufacturing mechanical parts (Larouche & Javidani, 2014) are mostly subject, after casting, to precipitation hardening heat treatment (Mohamed & Samuel, 2012) according to specifications and associated standards. The best mechanical properties are associated with the formation of precipitates through an optimum heat treatment sequence, generally including: solutionizing, water quenching and artificial aging (Manente & Timelli, 2011). Hypoeutectic aluminum-copper alloy with amount of Cu around 1 to 4.5wt% is an elementary case for precipitation in heat treatable aluminum alloys. Researchers essentially focused their work on the full precipitation sequence of binary Al-Cu alloy during aging which is presented below."

Jan 1, 2018

By M. G. Mena, M. S. Mena-Junio

Silver (Ag) filler is the most attractive choice among all the conductive fillers of die attach materials for the attachment of silicon devices because of its balanced properties and relatively low cost. However, a major problem of silver is that it electrochemically migrates in the presence of moisture and applied bias. In microelectronic devices, silver migration can occur between adjacent conductors/electrodes, which leads to the formation of dendrites and eventually results in short-circuit failure. In order to assess the reliability of these conductive fillers, an investigation for two types of Agfilled die attach materials was done using the water drop test at room temperature and using a 1000 hour temperature-humidity-bias (THB) test under 85 ºC and 85% RH conditions. Four different bias/voltages and six different electrode distance spacing were used. Both dendrite and cloud/lace-like growths were observed as a result of the electrochemical migration of silver, Water drop test results revealed that increasing the applied bias/voltage and decreasing electrode spacing causes migration to occur faster, thus resulting into shorter time to fail (TTF). It was also observed that the growth rate of the dendrites from the cathode increased linearly as the dendrite approached the anode, probably due to a combination of increased ion availability and electric field. A minimum applied bias of 3 volts was required for migration to occur in Epoxy A as compared to 2 volts for Epoxy C. The higher migration voltage requirement for Epoxy A was attributed to the higher volume resistivity of the said epoxy. In addition to the minimum voltage requirement, it was observed that a minimum electric field of about 1 volt/mm is required for migration to occur. The 1000 hour THB testing did not result into any failures. It is surmised that the presence of condensed moisture is another requirement for migration. Such condition is not present during the THB testing.

Jan 1, 2012

By B. Tiryaki, M. Ayhan, O. Z. Hekimoglu

"This paper discusses the aspects of tracking cutters related to the computer-aided design of shearer drums. A comprehensive computer analysis of drum dynamic parameters for multi-tracking tool arrangement is not presently available, as the current computer programs mainly consider the aspects of single tracking. Despite the fact that the single-tracking arrangement is recommended for efficient cutting, some major drum manufacturers have been seen to persistently adhere to multi-tracking, probably due to a lack of information. Further studies in this field are believed to contribute greatly to the current understanding of the computer-aided design of shearer drums.A number of laboratory simulation trials and long-term underground investigations were carried out in detail on tracking cutter arrangement, and an equation required for a computer program was derived. The results obtained from computer assessment of dynamic parameters for drums with multi-tracking arrangement were found to be in accordance with those of the underground trials, indicating the validity of the equations. The procedure adopted for the computer appraisal of the shearer drums designed with a multi-tracking concept, as described in this study, is therefore recommended to be considered in the currently employed computer programs."

Jan 1, 2003

By A. Lopez-Valdivieso

Particle size enlargement processes play an important role in solid/liquid separation, and in beneficiation unit operations. In the latter, not only the size of the formed aggregates but also their surface properties are very important. Oil agglomeration has a special place among such processes: it is a selective process in which hydrophobic particles are agglomerated into hydrophobic agglomerates which can be recovered by flotation. This explains the broad applications of oil-assisted beneficiation processes not only in the beneficiation of fine coal, but also in agglomerate flotation of many different types of ores, and in coal/gold agglomeration.

Jan 1, 2004

By F. Hassani, D. O’Donnell, M. Momayez, P. Guevremont

Shotcrete is a practical and economical support system in many Canadian underground mines. Although shotcrete technology has gained acceptance in the mining industry, there are some problems that have emerged with respect to quality assessment and thickness measurement of the liner. This paper presents recent tests performed with miniature seismic reflection technology (MSR) developed and patented at McGill University primarily for thickness measurement of this heterogeneous liner. MSR is also capable of providing information regarding the quality of shotcrete in terms of its mechanical properties such as modulus of elasticity and Poisson’s ratio. Work was performed on site in an underground mine in Ontario, Canada. This paper also presents the results from laboratory tests performed on fiber-reinforced and non-reinforced shotcrete panels that were used to assess the P-wave velocity in both materials. The results of these tests were used in a second site investigation. The NDT thickness measurements showed good agreement with direct thickness measurement such as coring. In addition, the MSR technology has the advantage of being more accurate and more affordable compared to other non-destructive testing (NDT) systems in the market.

Jan 1, 2002

By K. C. Corin, Z. G. Song, J. G. Wiese

In the present study the effect of using different grinding media, viz, ceramic balls, forged steel balls, 15% Cr steel balls, stainless steel and mixture of stainless steel and 15% Cr steel balls (50:50) on the flotation performance of a Platinum Group Mineral (PGM) UG2 ore was investigated. Test work was conducted using a laboratory scale horizontal tumbling mill and a batch flotation cell. Power draw to achieve a specific P80 was determined for each media type. Changes in flotation behaviour were evaluated in terms of particle size distribution, water recovery, solid recovery and valuable mineral recovery. pH, Eh and DO levels were also measured. Grinding products of five different media produced similar solids and water recovery, which is indicative of the froth characteristics, but the grades and recoveries of PGE and chromite were different. The product obtained when using ceramic media showed the best flotation performance, producing the highest PGE recovery and the lowest Cr2O3 recovery. The products obtained when using stainless steel balls (SS) produced the lowest PGE recovery and highest Cr2O3 grade and recovery. The paper proposes possible reasons to explain these observations which may have significant importance for the operation of a PGM concentrator.

Jan 1, 2015

By R. K. Netolitzky

The Weedy Lake, Tower Lake, and Wedge Lake gold deposits illustrate contrasting styles and different ages of mineralization within the same district. The discovery of these deposits was the result of systematic exploration of gold occurrences noted during research of assessment files. The Weedy Lake and Tower Lake depo its reflect a late-stage gold mineralizing event. The e deposits developed along the same major structural break, and also display simi lar mineralogy and alteration patterns. Mineralization is developed in all the lithologies present. The Wedge Lake property, while having occurrences similar to the Weedy and Tower deposits. has the more important Twin Zone which best fits a volcanogenic exhalative model. The Twin Zone has a complex structural history without a recognizable alteration halo. The setting may be proximal to a hydrothermal vent. Mineralization is hosted within a mixed ulphide/oxide/silicate facies iron formation breccia. and the gold is intimately associated with arsenopyrite. The origin and age of the brecciation is key to understanding the mineralizing event. Traditional prospecting procedures in conjunction with conventional B-horizon soil geochemistry were instrumental in the Twin Zone and Weedy lake disco,•eries. Tower Lake was a prospecting discovery partially defined by previous drill programs. This deposit was also identified by B-horizon oil sampling.

Jan 1, 1986

By Paul L. Broughton

"IntroductionThe coal deposits, all of lignite rank, of economic interest in Saskatchewan are associated with the Ravenscrag Formation (Paleocene). Several Cretaceous formations have less significant lignite accumulations (Broughton, Irvine and W'hitaker, 1974). The Swan River Group (lower Cretaceous) and Judith River Formation (upper Cretaceous) have the only coalbearing strata in the shallow subsurface of central Saskatchewan. The Swan River Group coalfield is relatively small and underlies only 15 sq km of the surface approximately 40 km south of La Ronge, Saskatchewan. An estimated 36 billion short tons are within 45 m of the surface. No reserve estimates are known to have been calculated for the coal-bearing Judith River Formation exposed at the surface in the vicinity of the South Saskatchewan River valley in west-central Saskatchewan. Although no coalfields have been delineated, lignite beds up to 1.8 m thick have been intersected in test holes. The coal-bearing upper Cretaceous and lower Tertiary strata of the northern Williston Basin extends the full width of southern Saskatchewan for 650 km, and from the United States border 120 km north to 50° latitude (Fig. 1). Only the coalfields of the Ravenscrag Formation, because of their economic interest, will be considered further. There are four major coalfields. They are, from east to west: Estevan, Willow Bunch, Wood Mountain and Shaunavon (Cypress) coalfields. Cumulative lignite seam thickness for each basin is 10 -15 m (Figs. 2 and 3). The origin of each coal basin, resource calculations, seam stratigraphy, and mining activity are discussed. Regional Setting The Williston Basin is an ellipsoidal depression in the Precambrian basement, centered in western North Dakota and marginal to the exposed craton of northern Saskatchewan and central Manitoba (Fig. 1). The sediments of the basin range from Cambrian to Pleistocene in age and have a maximum known thickness of 4614 min western North Dakota. A maximum of 3200 m is recorded in southern Saskatchewan. Most structural deformation is late Cretaceous to early Tertiary (Paleocene) in age, coinciding with the Laramide Orogeny. The pre-Laramide Williston Basin, with a depocenter near Williston, North Dakota, began developing during the middle Ordovician, or possibly earlier."

Jan 1, 1985

By C. Boudreault, M. Fortier, S. Fafard

In the forging industry, the increasing trend is to use DC cast billets as forging stock to replace extruded stock. However, there is little technical information available in open literature. In order to gain a better understanding of the behaviour of cast stock during deformation, a study was initiated to evaluate the impact of an homogenisation treatment on the billet prior to cold forging. Axisymmetric upsettings of cylindrical samples machined from DC billets were achieved in order to evaluate and compare flow stresses, crack initiation and propagation. Results show a 30% decrease in flow stress after homogenisation. Observations of the deformed samples show major cracking for the as-cast material. Optical microscopy and SEM observations have related the crack initiation to decohesion around ß -AlFeSi particles and subsequent growth along the constituent path. Homogenisation effectively breaks up and transforms the ß phase, present as platelets in the cast product, into smaller spherodised a-AlFeSi particles. This has the effect of preventing crack growth in the forged product. The homogenisation treatment also resulted in the reduction of Mg and Si in solid solution. The softer matrix generated 29% less die wear when compared to the as-cast structure. Based on the results of this study, it is thus recommended to homogenise cast billets prior to cold forging.

Jan 1, 2006

By S. G. Luckey, N. R. Harrison, F. Nadeau, U. Brüx

"The adoption of tailored-rolled or tailor-welded blanks (i.e. TRB/TWB) in the automotive industry has been known to offer great potential for the optimization of weight, function, cost and complexity. Vehicle light weighting can further be achieved by using high strength aluminum alloys like the 7xxx-series. 7xxx-series alloys are capable of delivering specific strengths equal to or greater than high strength steels. However, room temperature formability of this aluminum class is limited, so one approach to forming 7xxx-series alloys is by hot stamping. Hot stamping utilizes an elevated temperature blank and the high pressure stamping contact of the forming die to simultaneously quench and form the sheet. This paper explores the initial feasibility of tailored thickness material for body-in-white applications when processed under hot stamping conditions.INTRODUCTION Steel tailor-rolled blanks (TRB) or tailor-welded blanks (TWB) have been used within the automotive industry as a method of reducing weight, expanding material utilization, and decreasing overall part/assembly cost (Ganeasan et al., 2015; Merklein et al., 2014; Hirt et al., 2005; Kridli et al., 2000). The production of such tailored thickness materials has resulted in over $2.5 billion (2016) in combined industry sales (Mubea, 2018). As automakers begin to adopt the manufacturing practices traditionally reserved for steel such as tailor rolling/welding with greater enthusiasm for vehicle light weighting, there exist an opportunity to expand the material database to extend beyond the traditional aluminum alloys found in current production. High strength aluminum alloys, i.e. 7xxx-series, are ideal for structural automotive applications due to their high specific strength; however, they have limited room temperature formability. Hot stamping, another manufacturing practice used by the steel industry, can be used to form these high strength materials. The combination of tailoring the thickness of a sheet material and hot stamping provides an opportunity for significant weight saving within an existing manufacturing footprint. This paper explores the potential and challenges of this approach when applied to structural body-in-white components. The methods for tailor rolling, tailor welding and hot stamping are described and applied to the production of a 7075 aluminum alloy B-pillar. The results are discussed in terms of feasibility and weight savings."

Jan 1, 2018

By Magnus Evertsson, Johannes Quist

HPGRs have since introduced in the 1980s (Kellerwessel, 1993; Schönert, 1988), now become integral comminution units at several minerals processing plants around the world. Even though a lot of the initial issues concerning performance, availability and wear have been addressed and solved there are still phenomena and aspects which can be improved and understood further. Schönert and Sander (2002) presented experimental results and a mechanistic model including the internal force dynamics between the rollers and the compacted bed. They derived expressions for the pressure distribution involving most of the influencing terms and effects. However, in order to solve the differential equations several of the terms vanish by assumptions. The Schönert and Sander model reflects the experimental data in many aspects but the predicted shear force distinctly deviates from the experimental results at the angular position of the peak pressure level. This finding suggests that the particle to particle interaction and breakage process in the different zones seen in Figure 1 are complex and difficult to model using analytical models. A numerical modelling approach using DEM does not require the same amount of assumptions and simplifications of boundary conditions. Hence such modelling may provide further knowledge and vital understanding. In this paper the breakage process is simulated in order to investigate the shear slip behaviour and how it relates to different operating variables. A laboratory scale HPGR corresponding to the experimental setup used by Schönert (2002) have been modelled in EDEM (DEM-Solutions). The bonded particle model (BPM) is used for modelling quartz particles (Potyondy, 2004). The breakage model strength parameters are calibrated against interparticle breakage experiments in an Instron 400RD compression device. The contact model parameters are calibrated using calibration methods developed by Quist (2015). The floating roller dynamics are modelled using a spring-damper system. Results present insights regarding the interparticle slip behaviour as well as the frictional tangential force distribution on the rollers. The simulated roller pressure distribution shows good correspondence with previously reported findings in the literature.

Jan 1, 2016

By R. M. BUCHANAN

The segment of Canadian industry based on smelting of alum in um and manufacture of consumer products is based entirely on imported alumina and bauxite. In the absence of Canadian bauxite deposits, consideration of anorthosite, a less desirable aluminous rock, is being undertaken as one alternative in maintaining assurance of supply. Anorthosites in Canada cover many thousands of square kilometres of the Precambrian Shield. Although compositions vary widely among Canadian anorthosites, many appear to exceed the specified minimum of 25% A I 20 3 in bodies containing more than the required JOO million tonnes. A lthough most Canadian anorthosites are of Precambrian age, one located in British Columbia has been identified as being Middle _Cretaceous.

Jan 1, 1984

By D. B. Dreisinger, M. Rasouli

"Developing technology to address the environmental hazards associated with selenium in mine-impacted waters has been a serious challenge. Ion exchange (IX) has been identified as a potential treatment technology. This paper begins with a review on selenium adsorption with commercially-available basic anionic exchangers (BAS). It then looks at the use of resins for selenium removal via modification with the addition of -O, -N, or -S-containing chelating ligands and chelating polymeric ion exchangers pre-loaded with immobilized metal cations. The synthesis of chelating exchangers requires a final product with a highly stable metal in the ligand-metal complex. The nature, oxidation state, size, and affinity of the metal for the target oxyanions and the size, degree of protonation and space configuration of the oxyanion are among critical factors affecting the oxyanion uptake. There is a limited number of studies on the critical parameters affecting the selenium affinity for chelating exchangers. Such a study could fill in the gaps of our understanding of selenium-metal-chelating ligand interactions and assist in developing a new ion exchanger. In addition to commercial IX resins, layered double hydroxide materials (LDH) have received attention for oxyanion removal from waste water. The adsorption capacity of the LDHs are affected by the crystallinity of LDH, the nature of metal components, the ratio of metals, charge and type of anion, and the space between the layers. In particular, the Friedel phase (FP), a member of the LDH family, showed high adsorption capacity for selenate removal from synthetic solution. A study is currently underway at the University of British Columbia to investigate the effect of different synthesis methods and aging on the suitability of FP for selenium removal from mine waste water."

Jan 1, 2017

By M. W. Wadsley

"Physical and chemical property models are widely used in process engineering. There exist, in the published literature, completely empirical models of &apos;&apos;thermodynamic properties"", that is, property models that are not consistent with the laws of thermodynamics. There also exist property models that purport to be thermodynamically consistent but are flawed in their implementation. There are also published property models that are consistent with the laws of thermodynamics but that do not reproduce property values with an acceptable accuracy. A practicing engineer might be asked to assess very different property models for which there are a variety of claims. This paper discusses features of thermodynamic and empirical property models that may assist in their practical evaluation and implementation."

Jan 1, 2005

By Jianglan Duan, Steve L. Cockcroft, Andre B. Phillion, Carl Reilly, Daan M. Maijer

"In the aluminum alloy wheel casting process, careful design of the cooling system in the die and its operation (cooling channel timing) are critical to achieve quality and productivity goals. The problem is challenging owing to the cyclic nature of the process and the relatively large thermal mass of the die in comparison to the wheel. For a given die geometry, a set of constraints have been defined to ensure directional solidification and an objective function, based on cooling rate during solidification, has been defined to reach a target secondary dendrite arm spacing. The methodology presented in this study employs the commercial finite element package, ABAQUSTM, and an optimization module based on the open source library, Scipy. The developed methodology has been applied to a series of geometries and cooling system configurations, including a 2-D axisymmetric wheel and die assembly generated from a prototype die. Preliminary testing has shown that careful selection of the objective and constraint functions have made it possible to reach desired solidification pattern.TM- Dassault Systèmes Corp."

Jan 1, 2014

By M. O. Pekguleryuz, D. S. Aydin

The high temperature oxidation and ignition resistance of Mg-(0-6) wt% Nd alloys have been investigated via isothermal and continuous heating experiments conducted in air atmosphere. Alloy composition is observed to be effective in low levels (~ 0.5 %) in the ignition temperature (Ti) of the alloys; the Ti of pure Mg increased from 630 °C to 770 °C with 0.5 wt% Nd addition. However, no noteworthy improvement was achieved with further additions up to 6 wt% Nd. The initial microstructure was observed to determine the oxide structure on the surface due to the differing oxidation behavior of the phases (a-Mg + Mg12Nd intermetallics). It has been found that the formation of a Nd-depleted region at the subsurface due to extensive Nd oxidation at the oxide/intermetallic interface lowers the protective ability of the oxide scale.

Jan 1, 2015

By D. M. Maijer, S. L. Cockcroft, A. B. Phillion, P. Fan, C. Reilly

"A numerical model has been developed to study macrosegregation associated with liquid feeding in the Low Pressure Die Casting of A356 aluminum alloy wheels. The model of the wheel casting process has been implemented within the commercial CFD software package, FLUENT, using a User Defined Function (subroutine) to account for Si rejection based on the Scheil approximation. The model has been validated against temperature and microstructural data taken from a commercially cast wheel. The amount of segregation in the wheel has been shown to be significant in a couple of key areas. The implications of accounting for segregation include an improved ability to predict shrinkage porosity, fatigue performance and potentially also hydrogen porosity.INTRODUCTION The aluminum alloy A356 is widely used in the automotive and aerospace industries for various components. Examples include automotive wheels, automotive suspension components and airframe castings. Focusing on automotive wheels, Low-Pressure Die Cast (LPDC) A356 wheels offer significant design freedom and are far more aesthetically appealing to consumers than conventional stamped steel wheels. A356 wheels now dominate the market, appearing in all but the entry level offerings of the OEM manufacturers. However, they are typically over-designed to allow for the various casting related defects that degrade their mechanical performance. Thus, their potential to save weight has not been fully realized. Wheel manufacturers are under constant pressure to ensure their products meet strict mechanical requirements (ductility, fatigue, vibration), tight geometric tolerances and high aesthetic quality. The mechanical properties of the final product are determined by the microstructure – e.g. SDAS – and the defect population (porosity and oxides). Depending on their size and location, both porosity and oxides, can act as crack initiation sites reducing fatigue life (Caton, 2001; Jordan, 2010; Wu, 2015). There are a number of examples appearing in the literature (Atwood, 2000; Carlson, 2007; Lee, 2001; Yao, 2011) of numerical models that have focused on hydrogen-based pore formation that have demonstrated an ability to predict porosity formation and pore size distributions in geometrically simple castings. These models assume that the local gas species diffusion through the liquid metal to the pores is the rate-controlling factor of pore growth. Another common source of porosity is liquid encapsulation (Dantzig, 2009). As the pressure within the isolated liquid drops, pores form first due to the pressure dropping below the equilibrium partial pressure of hydrogen in solution and then second grow substantially as the pressure continues to drop falling below the vapour pressure of Al. One factor that can affect both mechanisms of pore formation is species macrosegregation, which has received comparatively little attention in die-casting."

Jan 1, 2017