Academic literature on the topic 'Effect of Cemented Fill'

The principle scope of this research was to develop relationship between stope dimensions and cemented paste fill strength. Experiments in various fill thickness to span width ratios with cemented paste fill with different mechanical properties were conducted by using a constructed scaled-down open stope. Scaled-down laboratory experiments were used to understand the mechanism of fill failure when exposure is undertaken under a relatively fresh fill mass.

Difficult ground conditions negatively affect both mine production and the safety of underground workers. Underhand cut-and-fill mining is a potential solution to these issues. Discussions with mine sites revealed the use of sill beams in underhand cut-and-fill mining is not optimized. Optimization in ground support, development of in-situ strength test, and revisions of design standards are desired. Ultimately, the operations require the minimum cemented paste backfill (CPB) strength for a stable span. Operational concerns were addressed by a multi-prong approach investigating stability of CPB sill beams using observational, experimental and analytical techniques. A case study approach summarizing the design of five mines utilizing underhand cut-and-fill with CPB is presented for different ground conditions. A historical study of span widths and beam strengths for the Stillwater mine is presented. Laboratory testing determined the stress-strain behaviour of CPB. CPB follows a hyperbolic elastic loading path to peak stress followed by a strain-softening associated with the decay of the cohesion values. Additional testing found that cohesive and tensile strength values were on average 35 and 20 percent respectively of the unconfined compressive strength. This finding impacts sill beam design strengths as previous assumptions were conservative. Test database analyses from three mine sites found that sample size and location preparation has no effect on the strength of the sample. In-situ testing methods common in other industries were not practical with CPB; rather the in-situ strength can be represented by a site specific moisture content index relationship. Review of current design methodology noted closure stresses were absent from the majority; a method was developed to assess closure for sill beam stability. The potential for critical failures were determined through a Monte Carlo probabilistic model. Methods reducing the risk of failure based on the simulation are investigated. Analysis found ground support does not improve the structural stability of the sill beam. Ground support keeps the beam intact: beam equations govern stability. The stability of sill beam in a seismic environment was analyzed based on the strain-energy density of the beam. The research concludes with a design guideline for CPB sill beams.

The Renström mine, Boliden Mineral AB, uses, among other methods, the Transverse long hole stoping method with backfill. The mine uses a cement-stabilized hydraulic fill (CHF), which is a mixture of enrichment sand, cement and water. The most important factor in relation to strength is the water cement ratio. Today, only tests have been performed on the surface and in laboratory tests. The purpose of this work is thus to study the possibility of using other types of methods that can give a better understanding of the strength of the entire filling volume. Studies on backfill containing Portland cement and sulphur have shown that the UCS strength decreases with time, which can cause problems for the mine. A leaching method (MRM leaching test) used to evaluate potential sulphide soils has been used in this study on the backfill to investigate the sulphurs impact on the cement mixture. Electrical conductivity, pH, and redox potential were investigated and gave similar results, where the higher cement levels (8%, 10%, and 12%) were indistinguishable while the lower cement content (4%) differed significantly from the other levels. This probably indicates that the higher cement levels have a greater resistance to the influence of the sulphur. The most promising results were given when the method was used on enrichment sand alone. The linear lowering of the pH value of the enrichment sand, from pH 4.9 to about pH 3, point to that the enrichment sand contains large amounts of sulphur, as previously chemical analysis has shown. This suggests that the method can best be used in an early stage before the sand is mixed with cement. The strength results on the samples showed a strength after 7 days that was in line with the 90-day strength. However, all 90 day samples had decreased in strength during the time sequence, which may be an effect of the sulphur content, but should be further investigated to be determined. The smaller size of the samples was also experienced as a challenge during the temperature measurements due to small temperature variations and environmental effects. A maturity method for predicting the strength of concrete called "The maturity method" has been investigated in this study. To determine the strength maturity relationship, both the temperature related to time and the equivalent age must be evaluated. The study showed that the method cannot be used on the mine's backfill without first making adjustments related to the lower cement content used in the backfill compared with concrete constructions, since it is not possible to determine the strength growth in the early stage as the method requires.

Magnetic measurements are useful tools for quality control of cemented carbides. Previous work at Sandvik Mining and Rock Technology has shown that the coercivity increases with increased cooling rate during sintering for a specific grade.  This study aims to investigate why the coercivity changes with the cooling rate and if this is true for other cemented carbide grades as well. Three different cemented carbide grades were sintered with different cooling rates and evaluated with coercivity, Cobalt-magnetic saturation and hardness measurements, and with microscopy and Electron Backscatter Diffraction analysis. It was found that the coercivity increased with increasing cooling rates for the previously studied grade, but not for the two other grades. It was expected that the increased coercivity would indicate a decrease in WC grain size, but the results showed that the WC grain size of the fastest and slowest cooling rate were the same. However, a change in size of the Co areas between the WC grains was found. The fast cooled sample showed smaller Co areas than the slow cooled sample. These Co/WC grain boundaries increase the coercivity. An increased fraction of hcp-Co/fcc-Co was also found for the fast cooled material which also increases the coercivity. No relationship between the hardness and the coercivity or the cooling rate was found.   The contiguity for the different grades was also calculated.  No significant difference in contiguity between the different cooling rates of each material was found but the contiguity values between the different materials differed.  This is probably mainly dependent on the different binder contents of the materials.<br>Magnetiska egenskaper är en viktig del av kvalitetskontrollen av hårdmetaller.  Tidigare forskning hos Sandvik Mining and Rock Technology har visat att koerciviteten hos en hårdmetallsort ökar med ökad kylhastighet vid sintring.  Målet med den här studien är att undersöka varför koerciviteten ökar med kylhastigheten och om detta även gäller andra hårdmetallsorter.  Tre olika hårdmetallsorter sintrades med olika kylhastigheter undersöktes med mätningar av koercivitet, magnetisk mättnat i koboltfasen och hårdhet,  samt med mikroskopi och Electron Backscatter Diffraction analys. Det  visade  sig  att  koerciviteten  ökade  med  ökad  kylhastighet  för  hårdmetallsorten  som  studerats tidigare, men inte för de andra två sorterna.  En ökad koercivitet förväntas visa på en minskad WC-kornstorlek, men resultaten visar att det långsamt kylda och snabbkylda provet hade samma WC-kornstorlek.  Däremot upptäcktes en ändring av storleken på Co-områdena mellan WC-kornen.  Det snabbkylda provet visade en mindre storlek av Co-områdena jämfört med det långsamt kylda provet. Fler Co/WC-korngränser i det snabbkylda provet leder till en ökad koercivitet.  Fraktionen av hcp-Co/fcc-Co-korngränser ökade också för det snabbkylda provet vilket också ökar koerciviteten. Inget samband mellan hårdheten och koerciviteten eller kylhastigheten upptäcktes.  Beräkning av kontiguiteten för de olika sorterna genomfördes också. Ingen signifikant skillnad i koercivitet mellan de olika kylhastigheterna för the olika sorterna hittades,  men kontiguiteten mellan de olika sorterna varierade. Det beror mest troligt på att dom olika sorterna har olika mängd matrismaterial.

Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2011.<br>ENGLISH ABSTRACT: A 1.5 x 1.5 m2 counter-flow fill performance test facility is described in detail. Instrumentation was selected and installed in the cooling tower fill test facility and calibrated to ensure measurement accuracy. A facility control program was written to simplify the operation of the test facility via a user interface. The program calculates automatically the Merkel number and loss coefficients as measures of fill thermal and flow performance respectively. A spray frame was designed and manufactured to ensure uniform water distribution to the fill. The water distribution through different fills with varying fill heights and different water flow rates was measured. The water attached to the walls of the test facility was examined. Film, trickle and splash fills are tested in the upgraded test facility. The film and trickle fill performance determined during testing is deemed acceptable as these fills have minimal migration effects. Fills with poor distribution effects and large migration of water towards the walls of the test facility, like the splash fill tested, cannot to be tested accurately in a 1.5 x 1.5 m2 test section as the results do not represent the performance of the fill in a relatively large cooling tower. Other aspects examined were: • air flow uniformity • air fill bypass effects • location of water inlet and outlet temperature measurement points • location of pressure measurement probes. It was determined that, in the current test facility: • air uniformity is suitable for performance testing • air bypass effects can be ignored for open fills and can be minimised for dense fills by packing sponge between the fill and walls • water inlet and outlet temperatures should be measured in the pipe-work, resulting in a measurement method that is not influenced by the relative weightings of each thermocouple • pressure difference over the fill height measured by the pressure measurement tap is independent of its location on the fill outlet plane provided the pressure measurement points are perpendicular to the air stream and are not against the walls.<br>AFRIKAANSE OPSOMMING: 'n 1.5 x 1.5 m² Teenvloei pakking werkverrigting toetsfasiliteit word in detail beskryf. Instrumentasie is gekies en geïnstalleer in die koeltoring pakking toetsfasiliteit en gekalibreer om akkuraatheid te verseker. 'n Fasiliteit beheer program is geskryf om die gebruik van die toetsfasiliteit te vereenvoudig. Die program het ‘n vriendelike gebruikers intervalk. Die program bereken outomaties die Merkel-getal en verlies koëffisiënte as mate van pakking termiese- en vloeiwerksverrigting. 'n Sproeiraam is ontwerp en vervaardig om uniforme water verspreiding aan die pakking te verseker. Die water verspreiding deur verskillende pakkings met verskillende pakking hoogtes en water vloei snelhede is gemeet. Die water aangeheg aan die mure van die toetsfasiliteit is ook ondersoek. Film, druppel en spat pakkings word in die opgegradeerde toetsfasiliteit getoets. Die film- en druppelpakking werksverrigting bepaal tydens die toetse is aanvaarbaar, aangesien hierdie pakkings minimale migrasie effekte het. Pakking met swak verspreiding effekte en 'n groot migrasie van water na die wande van die toetsfasiliteit, soos gevind met die spatpakking toetse, kan nie met akkuraatheid in 'n 1.5 x 1.5 m² toets seksie getoets word nie omdat die resultate nie die werkverrigting van die pakking verteenwoordig in 'n relatief groot koeltoring. Ander aspekte wat ondersoek was: • lugvloei uniformiteit • lug omleiding effeckte • die posisie van water in- en uitlaat temperatuur meetpunte • posisie van die drukmeetapparaat. Dit is vasgestel dat, in die huidige toetsfasiliteit • lugvloei eenvormigheid geskik is vir prestasietoetsing • lug omleiding effekte kan geïgnoreer word vir oop pakkings en kan verklein word vir digte pakkings deur spons tussen die pakking en mure te pak • water inlaat- en uitlaattemperature behoort gemeet te word in die pypwerk en lei tot 'n metings metode wat nie beïnvloed word deur die relatiewe gewigte van elke thermokoppel nie • die druk verskil gemeet deur die drupmeetpunte oor die pakkinghoogte is onafhanklik van hul posisie op die pakkinguitlaatvlak op voorwaarde dat die drukmeetpunte loodreg is teen die lugstroom en nie teen die mure nie.

Cemented carbides are used in rock tool applications by reason of their beneficial mechanical properties, i.e. a combination of high toughness, wear resistance and hardness. The cemented carbides commonly receive their hardness from tungsten carbides (WC) whereas cobalt (Co) is the dominating binder material. To obtain a beneficial balance of these desired properties, the binder phase can be strengthened by post-sintering treatment to minimize the risk of catastrophic failure. Previous work has shown that the face centered cubic (FCC) cobalt phase is stabilized by a higher degree of dissolved tungsten in the binder. The residual stresses have been related to both further stabilization of the FCC and local transformation to a hexagonal close packed (HCP) phase. By exposing the inserts to mechanical deformation, i.e. inducing stress, the Co-binder material could theoretically transform from FCC to HCP. In this master thesis, five cemented carbides with three different binder phase compositions have been investigated. Additionally, the influence of the carbon content and addition of an alloying element was evaluated. This was done by electron backscatter diffraction (EBSD) analysis of the microstructure of each sample in as-sintered state and after post-treatment to gain better understanding on how the phase stability of the binder is affected by a post-sintering process. In addition, magnetic measurements, hardness-testing and mechanical tests were performed on the materials to evaluate the effect of using different binder compositions. It was found that a low carbon content provides smaller and more rounded WC grains and binder phase dominated by FCC-Co compared to an equivalent material with a high carbon content. A low carbon content furthermore resulted in a more wear resistant material. The addition of alloy MA presented a greater increase in surface hardness after post-treatment and made the materials even more wear resistant compared to the non-alloyed. The non-alloyed material performed better in a test measuring the fracture energy. A material with an Fe-based binder showed the least increase in surface hardness and the highest increase and overall fracture energy. All materials experienced a WC grain size refinement and an increase in their surface hardness after post-treatment. Only one material gave an indication on FCC to HCP phase transformation, no conclusions could be drawn from the other samples.<br>Hårdmetaller används i bergborrstift på grund av materialets fördelaktiga mekaniska egenskaper vilket innefattar en kombination av hög seghet, hårdhet och bra nötningsmotstånd. Hårdheten uppnås vanligen av volfram karbider (WC) medan segheten ges av en bindefas som oftast är baserad på cobolt (Co). För att få ett material med en bra balans mellan seghet och hårdhet så kan bindefasen stärkas genom en ytbehandling efter sintringen för att minimera risken för att borrstiftet går sönder under användning. I tidigare studier har det framkommit att ytcentrerad kubiskt tätpackad (FCC) cobolt stabiliseras av volfram som lösts i bindefasen. Spänningar som uppkommer på grund av detta har relaterats till vidare stabilisering av FCC-fasen, men även lokal omvandling till hexagonalt tätpackad (HCP) cobolt. Genom att utsätta borrstiften för mekanisk deformation, i.e. inducera spänningar, kan bindematerialet teoretiskt sett omvandlas från FCC till HCP. I detta examensarbete har fem bergborrstift med tre olika bindefassammansättningar undersökts. Därutöver har även inverkan av kolhalten och tillägget av ett legeringsämne utvärderats. Den primära metoden för att genomföra undersöka mikrostrukturen hos de sintrade och efterbehandlade stiften var bakåtspridd elektrondiffraktion (EBSD). Syftet med undersökningen var att öka förståelsen kring bindefasens fasstabilitet då den utsatts för en efterbehandlingsprocess. Även magnetisk mätning, hårdhetstestning och mekanisk prövning utfördes på materialen för att kunna jämföra de olika bindefassammansättningarna mot varandra. Resultaten visade att en låg kolhalt gav ett material med mindre och mer rundade WC korn samt att bindefasen dominerades av FCC-Co jämfört mot ett material med samma bas och hög kolhalt. Därtill uppvisade materialen med låg kolhalt bättre nötningsmotstånd. Legeringen av bindefasmaterialet visade en ökning i ythårdhet efter efterbehandling och gjorde materialen mer nötningsbeständiga än de icke-legerade materialen. De icke-legerade materialen visade däremot på högre krosstyrka. Materialet med en järn-baserad bindefas påvisade minst ökning av ythårdheten och högst ökning samt högsta värde på krosstrykan. Samtliga material visade en förfining av WC kornen och en ökning av ythårdheten efter efterbehandlingen. Endast ett material indikerade omvandling från FCC till HCP, inga slutsatser kunde dras från de övriga proverna.

The aim of this work was to systematically study how the microstructure evolution is affected by the carbon activity in WC-Ni cemented carbides. Seven WC-9.59at%Ni alloys with different carbon activity were sintered at 1500 °C. From investigating these alloys, the carbon window has been experimentally evaluated using light optical microscopy and compared to theoretical carbon window calculated using Thermo-Calc. The overall microstructure of cross sections and raw surfaces have been investigated using scanning electron microscopy. Finally, the WC grain size and distribution have been evaluated using electron backscatter diffraction. It was found that the experimental carbon window was slightly wider than the theoretical carbon window. The WC grain size increased and the grain size distribution got wider with increasing carbon activity. In addition, the largest WC grains showed the largest grain growth by increasing carbon activity. By comparing the present results of grain size and distribution of WC-Ni to previous results of WC-Co, it was found that the WC grain growth was more pronounced and more influenced by the carbon activity.