Final report
Download 4.8 Kb. Pdf ko'rish
|
|
EXECUTIVE SUMMARY ........................................................................................................... i TABLE OF CONTENTS............................................................................................................... ix 1.0 INTRODUCTION, OBJECTIVES, ALLOY DESIGN AND SELECTION ......... 1 1.1 INTRODUCTION AND BACKGROUND ........................................................... 1 1.2 INCUMBENT US COINS...................................................................................... 3 1.3 DISCUSSION OF CANDIDATE ALLOY SYSTEMS ......................................... 9 1.4 COINAGE ALLOYS AND CONCEPTS FOR STUDY ..................................... 16 1.5 SUMMARY OF RECOMMENDED ALLOYS FROM ROUND ONE DOWN SELECTION TESTING ....................................................................................... 24 1.6 CANDIDATE ALLOYS FOR ROUND TWO DOWN-SELECTION TESTING ............................................................................................................................... 25 1.7 THE CARBONYL COIN MANUFACTURING CONCEPT.............................. 26 1.8 REFERENCES – CHAPTER 1 ............................................................................ 27 1.9 APPENDICES – CHAPTER 1 ............................................................................. 29 2.0 TESTING PROGRAM ......................................................................................... 36 2.1 GOALS ................................................................................................................. 36 2.2 APPROACH ......................................................................................................... 36 2.3 TEST PROTOCOLS............................................................................................. 39 2.4 RESULTS ............................................................................................................. 42 2.5 CONCLUSIONS – CHAPTER 2 ......................................................................... 88 2.6 REFERENCES – CHAPTER 2 ............................................................................ 92 2.7 APPENDICES – CHAPTER 2 ............................................................................. 93 3.0 COST TRENDS ANALYSIS............................................................................ 147 3.1 BACKGROUND ................................................................................................ 147 3.2 COIN SECURITY .............................................................................................. 148 3.3 COINAGE METALS.......................................................................................... 150 3.4 COPPER ............................................................................................................. 151 3.5 NICKEL.............................................................................................................. 152 3.6 ZINC ................................................................................................................... 153 ix 3.7 ALUMINUM ...................................................................................................... 154 3.8 IRON................................................................................................................... 155 3.9 OTHER METALS RELEVANT TO COINAGE............................................... 156 3.10 CANDIDATE COINAGE MATERIALS .......................................................... 156 3.11 ONE-CENT COIN.............................................................................................. 158 3.12 5-CENT COIN .................................................................................................... 162 3.13 DIME AND QUARTER DOLLAR COINS....................................................... 166 3.14 DOLLAR COIN.................................................................................................. 169 3.15 CONCLUSIONS – CHAPTER 3 ....................................................................... 171 3.16 REFERENCES – CHAPTER 3 .......................................................................... 174 3.17 APPENDICES – CHAPTER 3 ........................................................................... 176 4.0 OUTREACH, VALIDATION OF ALTERNATIVE MATERIAL CANDIDATE NONSENSE PIECES AND SECURITY ........................................................... 183 4.1 INTRODUCTION .............................................................................................. 183 4.2 ORGANIZATIONS PROVIDING OUTREACH FEEDBACK ........................ 185 4.3 COIN-PROCESSING EQUIPMENT................................................................. 191 4.4 RECENT EXAMPLES OF NEW COIN INTRODUCTIONS IN OTHER COUNTRIES ...................................................................................................... 192 4.5 DISCUSSIONS WITH STAKEHOLDERS ....................................................... 193 4.6 SUMMARY OF IMPACT TO STAKEHOLDERS FOR EACH METALLIC COMPOSITION-DENOMINATION CONSIDERED ...................................... 218 4.7 OTHER FACTORS THAT COULD ALTER THE CONVERSION COSTS TO STAKEHOLDERS ............................................................................................. 222 4.8 VALIDATION OF NONSENSE PIECES ......................................................... 222 4.9 SECURITY ......................................................................................................... 230 4.10 ADDITIONAL REMARKS ............................................................................... 235 4.11 CONCLUSIONS – CHAPTER 4 ....................................................................... 236 4.12 RECOMMENDATIONS – CHAPTER 4........................................................... 238 4.13 REFERENCES – CHAPTER 4 .......................................................................... 239 4.14 APPENDICES – CHAPTER 4 ........................................................................... 242 4.15 REFERENCES – APPENDIX 4-C..................................................................... 284 5.0 PRODUCTION EFFICIENCY........................................................................... 292 x 5.1 INTRODUCTION .............................................................................................. 292 5.2 PRODUCTION TECHNOLOGY ...................................................................... 293 5.3 IMPROVEMENTS IN CURRENT PRODUCTION PRACTICES................... 297 5.4 CONCLUSIONS – CHAPTER 5 ....................................................................... 306 5.5 REFERENCES – CHAPTER 5 .......................................................................... 307 5.6 APPENDICES – CHAPTER 5 ........................................................................... 308 6.0 ENVIRONMENTAL ASSESSMENT ............................................................... 310 6.1 INTRODUCTION .............................................................................................. 310 6.2 PROJECT BACKGROUND .............................................................................. 312 6.3 PROJECT LOCATIONS .................................................................................... 314 6.4 PURPOSE OF AND NEED FOR THE PROPOSED ACTION ........................ 315 6.5 PROPOSED ACTION AND ALTERNATIVES ............................................... 316 6.6 PROPOSED ACTION ........................................................................................ 320 6.7 ENVIRONMENTAL ASSESSMENT ............................................................... 323 6.8 CARBONYL PROCESS .................................................................................... 353 6.9 CUMULATIVE IMPACTS................................................................................ 354 6.10 REFERENCES – CHAPTER 6 .......................................................................... 355 6.11 LIST OF PERSONS CONTACTED .................................................................. 356 6.12 APPENDIX 6-A: CORRESPONDENCE AND PUBLIC COMMENTS ......... 357 7.0 CONCLUSIONS................................................................................................. 358 7.1 POSSIBLE NEW MATERIALS ........................................................................ 359 7.2 EASE OF USE AND ABILITY TO CO-CIRCULATE..................................... 363 7.3 MINIMIZING CONVERSION COSTS............................................................. 363 7.4 MATERIAL TESTS ........................................................................................... 364 7.5 COST TRENDS FOR PRODUCTION .............................................................. 365 7.6 REDUCE THE COSTS TO PRODUCE CIRCULATING COINS ................... 366 7.7 POSSIBLE NEW TECHNOLOGIES FOR PRODUCTION OF CIRCULATING COINS................................................................................................................. 367 7.8 FRAUD PREVENTION..................................................................................... 367 7.9 POTENTIAL IMPACT ON CURRENT MATERIALS SUPPLIERS .............. 368 7.10 ADDITIONAL CONCLUSIONS....................................................................... 368 xi 8.0 RECOMMENDATIONS .................................................................................... 371 9.0 APPENDIX A: ABBREVIATIONS AND ACRONYMS ................................ 374 xii LIST OF TABLES Table 1-1. FY2011 Unit Cost of Producing and Distributing Coins by Denomination........... 2 Table 1-2. Compositions and Dimensions of US Circulating Coins........................................ 5 Table 1-3. Candidate Metallic Elements and Alloys for Coinage............................................ 8 Table 1-4. Potential Low-Cost Stainless Steels and Compositions for Coinage.................... 19 Table 1-5. Compositions of Copper-Based Alloys with Electrical Conductivity Close to That of Cu-25%Ni ......................................................................................................... 21 Table 1-6. Electrical Conductivity of Experimental PMX and Commercial Alloys along with Selected Coins and Coinage Alloys ...................................................................... 22 Table 1-7. Down-Selected Recommendations for Round One Testing* ............................... 25 Table 1-8. Down-Selected Recommendations for Round Two Testing ................................ 26 Table 2-1. Test Program Summary ........................................................................................ 37 Table 2-2. Rockwell 15T Hardness for One-Cent Coin Alternative Material Candidates..... 43 Table 2-3. Rockwell 15T Hardness for 5-Cent Coin Alternative Material Candidates ......... 43 Table 2-4. Rockwell 15T Hardness for Quarter Dollar Coin Alternative Material Candidates ............................................................................................................................... 44 Table 2-5. Tensile Properties of One-Cent Coin Alternative Material Candidates................ 45 Table 2-6. Tensile Properties of 5-Cent Coin Alternative Material Candidates .................... 45 Table 2-7. Tensile Properties of Quarter Dollar Coin Alternative Material Candidates........ 46 Table 2-8. Steam Corrosion Color Change of One-Cent Coin Alternative Material Candidates............................................................................................................. 47 Table 2-9. Steam Corrosion Color Change of 5-Cent Coin Alternative Material Candidates48 Table 2-10. Steam Corrosion Color Change of Quarter Dollar Coin Alternative Material Candidates............................................................................................................. 48 Table 2-11. Steam Corrosion Color Change of Dollar Coin Alternative Material Candidates 49 Table 2-12. Electrical Conductivity for One-Cent Coin Alternative Material Candidates ...... 50 Table 2-13. Electrical Conductivity for 5-Cent Coin Alternative Material Candidates........... 51 Table 2-14. Electrical Conductivity for Quarter Dollar Coin Alternative Material Candidates ............................................................................................................................... 51 Table 2-15. Color Measurement of One-Cent Coin Alternative Material Candidates............. 52 Table 2-16. Color Measurement of 5-Cent Coin Alternative Material Candidates ................. 53 Table 2-17. Color Measurement of Quarter Dollar Coin Alternative Material Candidates..... 53 Table 2-18. Color Measurement of Dollar Coin Alternative Material Candidates .................. 54 Table 2-19. Grain Size of One-Cent Coin Alternative Material Candidates............................ 55 Page xiii Table 2-20. Grain Size of 5-Cent Coin Alternative Material Candidates ................................ 56 Table 2-21. Grain Size of Quarter Dollar Coin Alternative Material Candidates.................... 58 Table 2-22. Progressive Strike Results for One-Cent Coin Alternative Material Candidates – Round One ............................................................................................................ 59 Table 2-23. Progressive Strike Results for 5-Cent Coin Alternative Material Candidates – Round One ............................................................................................................ 59 Table 2-24. Progressive Strike Results for Quarter Dollar Coin Alternative Material Candidates – Round One ...................................................................................... 60 Table 2-25. Post Striking Steam Corrosion and Wear Test Results for One-Cent Coin Alternative Material Candidates – Round One..................................................... 67 Table 2-26. Post Striking Steam Corrosion and Wear Test Results for 5-Cent Coin Alternative Material Candidates – Round One........................................................................ 68 Table 2-27. Post Striking Steam Corrosion and Wear Test Results for Quarter Dollar Coin Alternative Material Candidates – Round One..................................................... 68 Table 2-28. Progressive Strike Results for One-Cent Coin Alternative Material Candidates – Round Two............................................................................................................ 71 Table 2-29. Progressive Strike Results for 5-Cent Coin Alternative Material Candidates – Round Two............................................................................................................ 72 Table 2-30. Progressive Strike Results for Quarter Dollar Coin Alternative Material Candidates – Round Two...................................................................................... 72 Table 2-31. Measured Thickness of Dura-White Plating Layers by Metallographic Sectioning ............................................................................................................................... 81 Table 2-32. Round Two Post Striking Trial Test Results – One-Cent Nonsense Pieces ......... 84 Table 2-33. Round Two Post Striking Trial Test Results – 5-Cent Nonsense Pieces.............. 85 Table 2-34. Round Two Post Striking Trial Test Results – Quarter Dollar Nonsense Pieces . 85 Table 2-35. Round Two Post Striking Trial Wear Test Comparison....................................... 86 Table 2-36. Performance Test Results of One-Cent Coin Alternative Material Candidates ... 89 Table 2-37. Performance Test Results of 5-Cent Coin Alternative Material Candidates ........ 90 Table 2-38. Performance Test Results of Quarter Dollar Coin Alternative Material Candidates ............................................................................................................................... 91 Table 2-39. Performance Test Results of Dollar Coin Alternative Material Candidates......... 92 Table 2-A-1. Baseline Coin Blank Specifications...................................................................... 93 Table 2-A-2. Baseline Planchet Specifications .......................................................................... 94 Table 2-G-1. Color Measurements and Total Color Vector Change Readings for Corrosion Inhibitor Treated Surfaces................................................................................... 137 Table 3-1. Incumbent Composition (weight percent) of US Circulating Coinage............... 147 Table 3-2. Cost (dollars per kilogram) for Candidate Coin Metals (as of March 2012)...... 147 xiv Table 3-3. One-Cent Coin Alternative Material Candidates Unit Costs.............................. 159 Table 3-4. 5-Cent Coin Alternative Material Candidates Unit Costs................................... 163 Table 3-5. Dime Coin Alternative Material Candidates Unit Costs..................................... 167 Table 3-6. Quarter Dollar Coin Alternative Material Candidates Unit Costs ...................... 168 Table 3-7. Dollar Coin Alternative Material Candidates Unit Costs ................................... 170 Table 3-A-1. Metallic Composition of Selected Coins Throughout the World ....................... 176 Table 3-B-3. Cost Breakdown of Alternative Material Candidates for One-Cent Coin .......... 177 Table 3-B-4. Cost Breakdown of Alternative Material Candidates for 5-Cent Coin............... 178 Table 3-B-5. Cost Breakdown of Alternative Material Candidates for Dime Coin................. 179 Table 3-B-6. Cost Breakdown of Alternative Material Candidates for Quarter Dollar Coin .. 180 Table 3-B-7. Cost Breakdown of Alternative Material Candidates for Dollar Coin ............... 181 Table 3-B-8. Annotation Key for Cost Breakdown Tables...................................................... 182 Table 3-B-9. Commodity Metals Costs.................................................................................... 182 Table 4-1. Stakeholder Groups Directly Contributing to Outreach ..................................... 187 Table 4-2. Conversion Costs ($M) for Large Vending Machine Owners and Operators .... 197 Table 4-3. Conversion Costs ($M) for Small Vending Machine Owners and Operators .... 198 Table 4-4. Conversion Costs ($M) for Laundromat Owners and Operators........................ 202 Table 4-5. Conversion Costs ($M) for Pay Phone Owners and Operators .......................... 203 Table 4-6. Conversion Costs ($M) for Municipal Parking Authorities ............................... 204 Table 4-7. Conversion Costs ($M) for Amusement Machine Owners and Operators ......... 204 Table 4-8. Conversion Costs ($M) for Car Wash Owners and Operators ........................... 208 Table 4-9. Conversion Costs ($M) for Merchants ............................................................... 210 Table 4-10. Impact to Stakeholders: Maintain Incumbent Coin Dimensions and Change Material Composition of US Coins..................................................................... 220 Table 4-11. Impact to Stakeholders: Change Both Coin Dimensions and Material Composition of US Coins ................................................................................... 221 Table 4-D-1. Circulating Coin Production from the United States Mint ................................. 285 Table 4-D-2. Estimated Number of US Coins in Circulation – Based Upon Method # 1 ....... 286 Table 5-1. Comparison of Critical Values for Various Net-Shape Production Processes ... 296 Table 5-A-1. Total Condemned Scrap Rates per Denomination.............................................. 308 Table 6-1. Summary of Environmental Impacts .................................................................. 311 Table 6-2. Eliminated Candidate Metallic Elements and Alloys for Coinage ..................... 319 Table 6-3. OSHA PELs for Alloys in Incumbent Circulating Coins ................................... 337 Table 6-4. OSHA PELs for Recommended Alloys and Other Alternative Material Candidates to Circulating Coins ......................................................................... 338 xv LIST OF FIGURES Figure 1-1. Predicted and measured coining pressure (Kim). ................................................. 10 Figure 1-2. Two-day atmospheric exposure of bare A190 planchets to rainwater.................. 11 Figure 1-3. A190 planchets after 30-day atmospheric exposure during a rainy period. ......... 11 Figure 2-1. Aluminized steel one-cent nonsense pieces struck at 50 tonnes........................... 60 Figure 2-2. 5052-H32 one-cent nonsense piece struck at 35 tonnes. ...................................... 61 Figure 2-3. JZP copper-plated steel one-cent nonsense piece struck at 40 tonnes. ................. 61 Figure 2-4. Dura-White-plated zinc 5-cent nonsense piece struck at 54 tonnes. .................... 62 Figure 2-5. Multi-Ply-plated steel 5-cent nonsense pieces struck at 54 tonnes....................... 62 Figure 2-6. Copper-based alloys G6 mod, 669z and nickel-plated 31157 5-cent nonsense pieces struck at 50–54 tonnes. .............................................................................. 63 Figure 2-7. 302HQ stainless steel 5-cent nonsense pieces struck at 70 tonnes. ...................... 64 Figure 2-8. 430 stainless steel 5-cent nonsense piece struck at 70 tonnes. ............................. 64 Figure 2-9. 669z-clad C110 quarter dollar nonsense piece struck at 62 tonnes. ..................... 65 Figure 2-10. Multi-Ply-plated steel quarter dollar nonsense piece struck at 62 tonnes............. 66 Figure 2-11. 302HQ stainless steel one-cent nonsense piece struck at 60 tonnes..................... 73 Figure 2-12. 5052-H32 one-cent nonsense piece struck at 25 tonnes. ...................................... 74 Figure 2-13. Copper-plated steel one-cent nonsense piece struck at 50 tonnes from planchets supplied by the RM. .............................................................................................. 75 Figure 2-14. Copper-plated steel one-cent nonsense piece struck at 40 tonnes from planchets supplied by JZP..................................................................................................... 75 Figure 2-15. 302HQ stainless steel 5-cent nonsense piece struck at 70 tonnes......................... 76 Figure 2-16. G6 mod 5-cent nonsense piece struck at 54 tonnes. ............................................. 76 Figure 2-17. 669z 5-cent nonsense piece struck at 54 tonnes.................................................... 77 Figure 2-18. Unplated 31157 5-cent nonsense piece struck at 54 tonnes.................................. 77 Figure 2-19. Dura-White-plated zinc 5-cent nonsense piece struck at 54 tonnes. .................... 78 Figure 2-20. Multi-Ply-plated steel 5-cent nonsense piece struck at 60 tonnes. ....................... 78 Figure 2-21. Nickel-plated steel 5-cent nonsense piece struck at 54 tonnes. ............................ 79 Figure 2-22. 302HQ stainless steel quarter dollar nonsense piece struck at 73 tonnes. ............ 80 Figure 2-23. Multi-Ply-plated steel quarter dollar nonsense piece struck at 65 tonnes............. 80 Figure 2-24. Dura-White-plated zinc quarter dollar nonsense pieces struck at 54 tonnes. ....... 81 Figure 2-25. 669z-clad C110 quarter dollar nonsense piece struck at 62 tonnes. ..................... 82 Figure 2-26. aRMour quarter dollar nonsense piece struck at 62 tonnes. ................................. 83 Page xvi Figure 2-A-1. Stainless steel heat treatment bag prior to sealing. ............................................... 94 Figure 2-D-1. Steam corrosion tested copper-plated zinc planchets (incumbent US one-cent coin material). ............................................................................................................... 99 Figure 2-D-2. Steam corrosion tested copper-plated steel one-cent planchets from JZP. ......... 100 Figure 2-D-3. Steam corrosion tested copper-plated steel one-cent planchets from the RM. ... 100 Figure 2-D-4. Steam corrosion tested 5052-H32 blanks. .......................................................... 101 Figure 2-D-5. Steam corrosion tested aluminized steel blanks from Atlas. .............................. 101 Figure 2-D-6. Steam corrosion tested cupronickel 5-cent planchets (incumbent US 5-cent coin material). ............................................................................................................. 102 Figure 2-D-7. Steam corrosion tested Dura-White-plated zinc 5-cent planchets. ..................... 102 Figure 2-D-8. Steam corrosion tested Multi-Ply-plated steel 5-cent and quarter dollar planchets. ............................................................................................................................. 103 Figure 2-D-9. Steam corrosion tested nickel-plated steel 5-cent planchets............................... 103 Figure 2-D-10.Steam corrosion tested G6 mod 5-cent blanks.................................................... 104 Figure 2-D-11.Steam corrosion tested 669z 5-cent blanks......................................................... 104 Figure 2-D-12.Steam corrosion tested 430 stainless steel 5-cent blanks.................................... 105 Figure 2-D-13.Steam corrosion tested 302HQ stainless steel 5-cent blanks. ............................. 105 Figure 2-D-14.Steam corrosion tested 31157 5-cent planchets. ................................................. 106 Figure 2-D-15.Steam corrosion tested cupronickel-clad C110 quarter dollar planchets (incumbent quarter dollar coin material)................................................................................ 106 Figure 2-D-16.Steam corrosion tested nickel-plated steel quarter dollar planchets. .................. 107 Figure 2-D-17.Steam corrosion tested 669z-clad C110 material................................................ 107 Figure 2-D-18.Steam corrosion tested incumbent dollar coin planchets.................................... 108 Figure 2-D-19.Steam corrosion tested Y42 copper alloy dollar blanks...................................... 108 Figure 2-D-20.Steam corrosion tested K474 copper alloy dollar blanks.................................... 109 Figure 2-D-21.Steam corrosion tested C69250 copper alloy dollar blanks................................ 109 Figure 2-D-22.Steam corrosion tested yellow bronze- (88Cu-12Sn-) plated zinc dollar blanks.110 Figure 2-E-1. Steam corrosion tested one-cent nonsense pieces (incumbent material). ........... 111 Figure 2-E-2. Steam corrosion tested copper-plated steel (JZP) one-cent nonsense pieces. .... 112 Figure 2-E-3. Steam corrosion tested copper-plated steel (RM) one-cent nonsense pieces. .... 112 Figure 2-E-4. Steam corrosion tested 5052-H32 one-cent nonsense pieces. ............................ 113 Figure 2-E-5. Steam corrosion tested aluminized steel (Atlas) one-cent nonsense pieces. ...... 113 Figure 2-E-6. Steam corrosion tested aluminized steel (Ryerson) one-cent nonsense pieces... 114 Figure 2-E-7. Steam corrosion tested 302HQ stainless steel one-cent nonsense pieces. .......... 114 Figure 2-E-8. Steam corrosion tested 5-cent nonsense pieces (incumbent material)................ 115 xvii Figure 2-E-9. Steam corrosion tested Dura-White-plated zinc 5-cent nonsense pieces............ 115 Figure 2-E-10. Steam corrosion tested Multi-Ply-plated steel 5-cent nonsense pieces. ............. 116 Figure 2-E-11. Steam corrosion tested nickel-plated steel 5-cent nonsense pieces. ................... 116 Figure 2-E-12. Steam corrosion tested G6 mod 5-cent nonsense pieces. ................................... 117 Figure 2-E-13. Steam corrosion tested 669z 5-cent nonsense pieces.......................................... 117 Figure 2-E-14. Steam corrosion tested 430 stainless steel 5-cent nonsense pieces..................... 118 Figure 2-E-15. Steam corrosion tested 302HQ stainless steel 5-cent nonsense pieces............... 118 Figure 2-E-16. Steam corrosion tested nickel-plated 31157 5-cent nonsense pieces.................. 119 Figure 2-E-17. Steam corrosion tested unplated 31157 5-cent nonsense pieces......................... 119 Figure 2-E-18. Steam corrosion tested quarter dollar nonsense pieces (incumbent material). ... 120 Figure 2-E-19. Steam corrosion tested Multi-Ply-plated steel quarter dollar nonsense pieces... 120 Figure 2-E-20. Steam corrosion tested nickel-plated steel quarter dollar nonsense pieces......... 121 Figure 2-E-21. Steam corrosion tested 669z-clad C110 quarter dollar nonsense pieces. ........... 121 Figure 2-E-22. Steam corrosion tested 302HQ stainless steel quarter dollar nonsense pieces. .. 122 Figure 2-E-23. Steam corrosion tested Dura-White-plated zinc quarter dollar nonsense pieces.122 Figure 2-F-1. Wear tested one-cent nonsense pieces (incumbent material). ............................ 123 Figure 2-F-2. Wear tested copper-plated steel (JZP) one-cent nonsense pieces. ...................... 124 Figure 2-F-3. Wear tested copper-plated steel (RM) one-cent nonsense pieces. ...................... 124 Figure 2-F-4. Wear tested 5052-H32 one-cent nonsense pieces. .............................................. 125 Figure 2-F-5. Wear tested aluminized steel (Atlas) one-cent nonsense pieces. ........................ 125 Figure 2-F-6. Wear tested aluminized steel (Ryerson) one-cent nonsense pieces. ................... 126 Figure 2-F-7. Wear tested 302HQ stainless steel one-cent nonsense pieces. ........................... 126 Figure 2-F-8. Wear tested 5-cent nonsense pieces (incumbent material). ................................ 127 Figure 2-F-9. Wear tested Dura-White-plated zinc 5-cent nonsense pieces. ............................ 127 Figure 2-F-10. Wear tested Multi-Ply-plated steel 5-cent nonsense pieces. ............................... 128 Figure 2-F-11. Wear tested nickel-plated steel 5-cent nonsense pieces...................................... 128 Figure 2-F-12. Wear tested G6 mod 5-cent nonsense pieces. ..................................................... 129 Figure 2-F-13. Wear tested 669z 5-cent nonsense pieces. .......................................................... 129 Figure 2-F-14. Wear tested 430 stainless steel 5-cent nonsense pieces. ..................................... 130 Figure 2-F-15. Wear tested 302HQ stainless steel 5-cent nonsense pieces. ............................... 130 Figure 2-F-16. Wear tested nickel-plated 31157 5-cent nonsense pieces. .................................. 131 Figure 2-F-17. Wear tested unplated 31157 5-cent nonsense pieces. ......................................... 131 Figure 2-F-18. Wear tested quarter dollar nonsense pieces (incumbent material)...................... 132 Figure 2-F-19. Wear tested Multi-Ply-plated steel quarter dollar nonsense pieces. ................... 132 xviii Figure 2-F-20. Wear tested nickel-plated steel quarter dollar nonsense pieces. ......................... 133 Figure 2-F-21. Wear tested 669z-clad C110 quarter dollar nonsense pieces.............................. 133 Figure 2-F-22. Wear tested 302HQ stainless steel quarter dollar nonsense pieces..................... 134 Figure 2-F-23. Wear tested Dura-White-plated zinc quarter dollar nonsense pieces. ................ 134 Figure 2-G-1. A26-coated A190 one-cent nonsense piece struck at 40 tonnes. ........................ 136 Figure 2-G-2. B21-coated A190 5-cent nonsense piece struck at 54 tonnes. ............................ 136 Figure 2-G-3. Coated A190 planchets as-coated and after steam corrosion testing. ................. 138 Figure 2-G-4. A26-coated A190 one-cent nonsense pieces before and after steam corrosion testing. ................................................................................................................. 138 Figure 2-G-5. B21-coated A190 5-cent nonsense pieces before and after steam corrosion testing. ............................................................................................................................. 139 Figure 2-G-6. Type II A26-coated A190 one-cent planchets before and after steam corrosion testing. ................................................................................................................. 139 Figure 2-G-7. Type II A26-coated copper-plated zinc one-cent planchets before and after steam corrosion testing.................................................................................................. 140 Figure 2-G-8. Type II A26-coated steel planchets before and after steam corrosion testing. ... 140 Figure 2-G-9. Carbonyl nickel-coated zinc surface after hammer indent testing with a steel punch................................................................................................................... 142 Figure 2-G-10.Carbonyl nickel-coated zinc surface after hammer indent testing...................... 142 Figure 2-G-11.Carbonyl nickel-coated steel specimen after single-bend testing. ...................... 143 Figure 2-G-12.Carbonyl nickel-coated steel specimen bent back and forth several times......... 143 Figure 2-G-13.Single bend test of carbonyl nickel deposited on C110...................................... 144 Figure 2-G-14.Carbonyl nickel deposited on C110 strip bent back and forth several times...... 144 Figure 2-G-15.Bent carbonyl Ni-coated and annealed Zn alloy A190 strip............................... 145 Figure 2-G-16.CVMR prototype carbonyl reactor. .................................................................... 146 Figure 3-1. Current and inflation-adjusted US dollars per tonne of selected metals............. 151 Figure 3-2. Nickel price behavior since 1989........................................................................ 153 Figure 3-3. Nickel, copper and zinc 10-year commodity pricing.......................................... 154 Figure 3-4. Aluminum and steel (3-month futures) commodity pricing. .............................. 155 Figure 3-5. Components of standard coin production costs. ................................................. 157 Figure 3-6. Cost components of the one-cent coin (FY2011). .............................................. 159 Figure 3-7. Cost components of the 5-cent coin (FY2011). .................................................. 163 Figure 3-8. Cost components of the dime and quarter dollar coins (FY2011). ..................... 167 Figure 3-9. Cost components of the dollar coin (FY2011).................................................... 170 Figure 4-D-1. Estimated number of US one-cent coins in circulation. ..................................... 288 Figure 4-D-2. Estimated number of US 5-cent coins in circulation. ......................................... 288 xix Figure 4-D-3. Estimated number of US dime coins in circulation. ........................................... 289 Figure 4-D-4. Estimated number of US quarter dollar coins in circulation............................... 289 Figure 5-1. Die life with improved lubricant for 5-cent coins............................................... 299 Figure 5-2. Tooling progression for making a coin............................................................... 301 Figure 5-3. Monthly production targets compared with annual demand............................... 304 xx 1.0 INTRODUCTION, OBJ ECTIVES, ALLOY DESIGN AND SELECTION Download 4.8 Kb. Do'stlaringiz bilan baham: 
|