On the dynamics of mechanical milling in a vibratory mill

The dynamics of mechanical milling in a vibratory mill have been studied by means of mechanical vibration, shock measurements, computer simulation and microstructural evolution measurements. Two distinct modes of ball motion during milling, periodic and chaotic vibration, were observed. Mill operation in the regime of periodic vibration, in which each collision provides a constant energy input to milled powders, enabled a quantitative description of the effect of process parameters on system dynamics. An investigation of the effect of process parameters on microstructural development in an austenitic stainless steel showed that the impact force associated with collision events is an important process parameter for characterizing microstructural evolution. (C) 1997 Elsevier Science S.A.

Heat resistance of Bacillus spores when adhered to stainless steel and its relationship to spore hydrophobicity

Twenty-one strains of Bacillus (10 B. stearothermophilus, 3 B. cereus, and 8 B. licheniformis strains) were assayed for spore surface hydrophobicity on the basis of three measures: contact angle measurement (CAM), microbial adhesion to hydrocarbons (MATH), and hydrophobic interaction chromatography (HIC). On the basis of the spore surface characteristics obtained from these assays, along with data on the heat resistance of these spores in water, eight strains of Bacillus (three B. stearothermophilus, three B. cereus, and two B. licheniformis strains) either suspended in water or adhering to stainless steel were exposed to sublethal heat treatments at 90 to 110degreesC to determine heat resistance (D-value). Significant increases in heat resistance (ranging from 3 to 400%) were observed for the eight strains adhering to stainless steel. No significant correlation was found between these heat resistance increases and spore surface characteristics as determined by the three hydrophobicity assays. There was a significant positive correlation between the hydrophobicity data obtained by the MATH assay and those obtained by the HIC assay, but these data did not correlate with those obtained by the CAM assay.

Modelling comminution patterns within a pilot scale AG/SAG mill

The patterns of rock comminution within tumbling mills, as well as the nature of forces, are of significant practical importance. Discrete element modelling (DEM) has been used to analyse the pattern of specific energy applied to rock, in terms of spatial distribution within a pilot AG/SAG mill. We also analysed in some detail the nature of the forces, which may result in rock comminution. In order to examine the distribution of energy applied within the mill, the DEM models were compared with measured particle mass losses, in small scale AG and SAG mill experiments. The intensity of contact stresses was estimated using the Hertz theory of elastic contacts. The results indicate that in the case of the AG mill, the highest intensity stresses and strains are likely to occur deep within the charge, and close to the base. This effect is probably more pronounced for large AG mills. In the SAG mill case, the impacts of the steel balls on the surface of the charge are likely to be the most potent. In both cases, the spatial pattern of medium-to-high energy collisions is affected by the rotational speed of the mill. Based on an assumed damage threshold for rock, in terms of specific energy introduced per single collision, the spatial pattern of productive collisions within each charge was estimated and compared with rates of mass loss. We also investigated the nature of the comminution process within AG vs. SAG mill, in order to explain the observed differences in energy utilisation efficiency, between two types of milling. All experiments were performed using a laboratory scale mill of 1.19 m diameter and 0.31 m length, equipped with 14 square section lifters of height 40 mm. (C) 2006 Elsevier Ltd. All rights reserved.

Steel cladding to south-east corner, Sunshine Coast University Library, Maroochydore

View to south-east corner, clad in corrugated steel sheeting with colonnade below.

ESEM observations of SCC initiation for 4340 high strength steel in distilled water

The stress corrosion cracking (SCC) initiation process for 4340 high strength steel in distilled water at room temperature was studied using a new kind of instrument: an environmental scanning electron microscope (ESEM). It was found that the applied stress accelerated oxide film formation which has an important influence on the subsequent SCC initiation. SCC was observed to initiate in the following circumstances: (1) cracking of a thick oxide film leading to SCC initiation along metal grain boundaries, (2) the initiation of pits initiating SCC in the metal and (3) SCC initiating from the edge of the specimen. All these three SCC initiation circumstances are consistent with the following model which couples SCC initiation with cracking of a surface protective oxide. There is a dynamic interaction between oxide formation, the applied stress, oxide cracking, pitting and the initiation of SCC. An aspect of the dynamic interaction is cracks forming in a protective surface oxide because of the applied stress, exposing to the water bare metal at the oxide crack tip, and oxidation of the bare metal causing crack healing. Oxide crack healing would be competing with the initiation of intergranular SCC if an oxide crack meets the metal surface at a grain boundary. If the intergranular SCC penetration is sufficiently fast along the metal grain boundary, then the crack yaws open preventing healing of the oxide crack. If intergranular SCC penetration is not sufficiently fast, then the oxidation process could produce sufficient oxide to fill both the stress corrosion crack and the oxide crack; in this case there would be initiation of SCC but only limited propagation of SCC. Stress-induced cracks in very thin oxide can induce pits which initiate SCC, and under some conditions such stress induced cracks in a thin oxide can directly initiate SCC.

Linearly-increasing-stress testing of carbon steel in 4 N NaNO3 and in Bayer liquor

This paper reports the application of linearly increasing stress testing (LIST) to the study of stress corrosion cracking (SCC) of carbon steel in 4 N NaNO3 and in Bayer liquor. LIST is similar to the constant extension-rate testing (CERT) methodology with the essential difference that the LIST is load controlled whereas the CERT is displacement controlled. The main conclusion is that LIST is suitable for the study of the SCC of carbon steels in 4 N NaNO3 and in Bayer liquor. The low crack velocity in Bayer liquor and a measured maximum stress close to that of the reference specimen in air both indicate that a low applied stress rate is required to study SCC in this system. (C) 1998 Chapman & Hall.

Measurement of grain boundary composition for X52 pipeline steel

Analytical electron microscopy was used to measure the composition of grain boundaries (GBs) and interconstituent boundaries (IBs) of X52 pipeline steel using specimens about 40-60 nm in thickness. All elements of interest were examined with the exception of carbon. With this caveat; there was no segregation at proeutectoid ferrite GBs. This indicated that the commonly expected species S and P are not responsible for preferential corrosion of GBs during intergranular stress corrosion cracking of pipeline steels. Manganese was the only species measured to segregate at the IBs. Manganese segregated to the IBs between proeutectoid ferrite and pearlitic cementite, and desegregated from IBs between proeutectoid ferrite and pearlitic ferrite. The pearlitic cementite was Mn rich. There was no Mn segregation at the IBs between pearlitic ferrite and pearlitic cementite. The pattern of Mn segregation could be explained in terms of diffusion in the process zone ahead of the pearlite during the austenite to pearlite transformation and diffusion in the IBs between the proeutectoid ferrite and pearlite. (C) 1998 Acta Metallurgica Inc. Published by Elsevier Science Ltd. All rights reserved.

Prediction of impact forces in a vibratory ball mill using an inverse technique

To understand the dynamic mechanisms of the mechanical milling process in a vibratory mill, it is necessary to determine the characteristics of the impact forces associated with the collision events. However, it is difficult to directly measure the impact force in an operating mill. This paper describes an inverse technique for the prediction of impact forces from acceleration measurements on a vibratory ball mill. The characteristics of the vibratory mill have been investigated by the modal testing technique, and its system modes have been identified. In the modelling of the system vibration response to the impact forces, two modal equations have been used to describe the modal responses. The superposition of the modal responses gives rise to the total response of the system. A method based on an optimisation approach has been developed to predict the impact forces by minimising the difference between the measured acceleration of the vibratory ball mill and the predicted acceleration from the solution of the modal equations. The predicted and measured impact forces are in good agreement. Copyright (C) 1996 Elsevier Science Ltd.

The secondary passive film for type 304 stainless steel in 0.5 M H2SO4

An examination has been carried out of the secondary passive film on Type 304 stainless steel in 0.5 M H2SO4. The characterization techniques used were electrochemical (potentiodynamic; potentiostatic, and film reduction experiments) and surface analytical. A bilayer model for the secondary passive film is proposed. It appears that next to the metal, there is a modified passive film which controls the electrochemical response; i.e., governs the current for any applied potential. On top of this modified passive film, the experimental data are consistent with a ''porous'' corrosion-product film which adds to the total film thickness but has little influence on the electrochemical response. The composition of the secondary passive film corresponds most probably to a mixed Fe/Cr oxide/hydroxide enriched in Cr3+, With a composition similar to a primary passive film.

Environmental assisted fracture for 4340 steel in water and air of various humidities

This paper reports on measurements of crack growth by environmental assisted fracture (EAF) for 4340 steel in water and in air at various relative humidities. Of most interest is the observation of slow crack propagation in dry air. Fractographic analysis leads to the strong suggestion that this slow crack propagation is due to hydrogen cracking caused by internal hydrogen in solid solution inside the sample material.

The influence of calcium on granular sludge in a full-scale UASB treating paper mill wastewater

Calcium precipitation can have a number of effects on the performance of high-rate anaerobic performance including cementing of the sludge bed, limiting diffusion, and diluting the active biomass. The aim of this study was to observe the influence of precipitation in a stable full-scale system fed with high-calcium paper factory wastewater. Granules were examined from an upflow anaerobic sludge blanket reactor (volume 1,805 m(3)) at a recycled paper mill with a loading rate of 5.7-6.6 kgCOD.m(-3).d(-1) and influent calcium concentration of 400-700 gCa(.)m(-3). The granules were relatively small (1 mm), with a 200-400 mum core of calcium precipitate as observed with energy dispersive X-ray spectroscopy. Compared to other granules, Methanomicrobiales not Methanobacteriales were the dominant hydrogen or formate utilisers, and putative acidogens were filamentous. The strength of the paper mill fed granules was very high when compared to granules from other full-scale reactors, and a partial linear correlation between granule strength and calcium concentration was identified.

Investigation of the effects of chrome ball charge on slurry rheology and milling performance

Ten surveys of the ball milling circuit at the Mt Isa Mines (MIM) Copper Concentrator were conducted aiming to identify any changes in slurry theology caused by the use of chrome balls charge, and the associated effect on grinding performance. Slurry theology was measured using an on-line viscometer. The data were mass balanced and analysed with statistical tools. Comparison of the rheogram demonstrated that slurry density and fines content affected slurry rheology significantly, while the effect of the chrome ball charge being negligible. Statistical analysis showed the effects of mill throughput and cyclone efficiency on the Grinding Index (a term describing the overall breakage). There was no difference in the Grinding Index between using the chrome ball charge and the ordinary steel ball charge. (C) 2002 Elsevier Science Ltd. All rights reserved.

Vibration instability in rolling mills: Modeling and experimental results

Models for the occurrence of the vibrational instability during rolling known as third octave chatter are presented and discussed. An analysis of rolling mill chatter was performed for the purpose of identifying characteristics of the vibrations and to determine any dependency on the rolling schedule. In particular, a stability criterion for the critical rolling speed is used to predict the maximum rolling speed without chatter instability on schedules from a 5 stand tandem mill rolling thin steel product. The results correlate well with measurements of critical speed occurring on the mill using a vibration monitor: This research provides significant insights into the chatter phenomena and has been used to investigate control methods for suppression of the instability.