The use of lubricants in iron powder metallurgy

This investigation has been concerned with the behaviour of solid internal lubricant during mixing, compaction, ejection, dewaxing and sintering of iron powder compacts. Zinc stearate (0.01%-4.0%) was added to irregular iron powder by admixing or precipitation from solution. Pressure/density relationships, determined by continuous compaction, and loose packed densities were used to show that small additions of zinc stearate reduced interparticle friction during loose packing and at low compaction pressures. Large additions decreased particle/die-wall friction during compaction and ejection but also caused compaction inhibition. Transverse rupture strengths were determined on compacts containing various stearate based lubricants and it was found that green strength was reduced by the interposition of a thin lubricant layer within inter~particle contacts. Only materials much finer than the iron powder respectively) were able to form such layers. Investigations were undertaken to determine the effect of the decomposition of these lubricants on the development of mechanical properties in dewaxed or sintered compacts. Physical and chemical influences on tensile strength were observed. Decomposition of lubricants was associated with reductions of strength caused by the physical effects of pressure increases and removal of lubricant from interparticle contacts. There were also chemical effects associated with the influence of gaseous decomposition products and solid residues on sintering mechanisms. Thermogravimetry was used to study the decomposition behaviour of various lubricants as free compounds and within compacts. The influence of process variables such as atmosphere type, flow-rate and compact density were investigated. In a reducing atmosphere the decomposition of these lubricants was characterised by two stages. The first involved the rapid decomposition of the hydrocarbon radical. The second, higher temperature, reactions depended on lubricant type and involved solid residues. The removal of lubricant could also markedly affect dimensional change.

Physical metallurgy of Zn-Al based alloys

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Development of An Enhanced Oil Sands Fluid Tailings Generation Model

Bitumen extraction from surface-mined oil sands results in the production of large volumes of Fluid Fine Tailings (FFT). Through Directive 085, the Province of Alberta has signaled that oil sands operators must improve and accelerate the methods by which they deal with FFT production, storage and treatment. This thesis aims to develop an enhanced method to forecast FFT production based on specific ore characteristics. A mass relationship and mathematical model to modify the Forecasting Tailings Model (FTM) by using fines and clay boundaries, as the two main indicators in FFT accumulation, has been developed. The modified FTM has been applied on representative block model data from an operating oil sands mining venture. An attempt has been made to identify order-of-magnitude associated tailings treatment costs, and to improve financial performance by not processing materials that have ultimate ore processing and tailings storage and treatment costs in excess of the value of bitumen they produce. The results on the real case study show that there is a 53% reduction in total tailings accumulations over the mine life by selectively processing only lower tailings generating materials through eliminating 15% of total mined ore materials with higher potential of fluid fines inventory. This significant result will assess the impact of Directive 082 on mining project economic and environmental performance towards the sustainable development of mining projects.

Influence of smectite suspension structure on sheet orientation in dry sediments : XRD and AFM applications

The structure-building phenomena within clay aggregates are governed by forces acting between clay particles. Measurements of such forces are important to understand in order to manipulate the aggregate structure for applications such as dewatering of mineral processing tailings. A parallel particle orientation is required when conducting XRD investigation on the oriented samples and conduct force measurements acting between basal planes of clay mineral platelets using at. force microscopy (AFM). To investigate how smectite clay platelets were oriented on silicon wafer substrate when dried from suspension range of methods like SEM, XRD and AFM were employed. From these investigations, we conclude that high clay concns. and larger particle diams. (up to 5 μm) in suspension result in random orientation of platelets in the substrate. The best possible laminar orientation in the clay dry film, represented in the XRD 0 0 1/0 2 0 intensity ratio of 47 was obtained by drying thin layers from 0.02 wt.% clay suspensions of the natural pH. Conducted AFM investigations show that smectite studied in water based electrolytes show very long-range repulsive forces lower in strength than electrostatic forces from double-layer repulsion. It was suggested that these forces may have structural nature. Smectite surface layers rehydrate in water environment forms surface gel with spongy and cellular texture which cushion approaching AFM probe. This structural effect can be measured in distances larger than 1000 nm from substrate surface and when probe penetrate this gel layer, structural linkages are forming between substrate and clay covered probe. These linkages prevent subsequently smooth detachments of AFM probe on way back when retrieval. This effect of tearing new formed structure apart involves larger adhesion-like forces measured in retrieval. It is also suggested that these effect may be enhanced by the nano-clay particles interaction.