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` Nov. 19, 1946.. C. wEsSEL - 2,411,176
METHOD OF MAKING METAL .CASTINGS
Original Filed Dec. 16, 1940 6 Sheets-Sheet l
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`METHOD OF MAKING METAL CASTINGS
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2,411,176
METHOD 0F MAKING METAL CASTINGS
Original Filed Dec. 16, 1940 6 Sheets-Sheet 3 y
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METHOD 0F MAKING METAL CASTINGS
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METHoD oF MAKING METAL cAsTINGs
Original Filed Dec. 16, 1940
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METHOD OF MAKING METAL CASTINGS
Original Filed Dec. 16, 1940 _ 6 Sheets~5heet 6Patented Nov. 19, 1946
unico rrss a@
2,411,176
mamon or o inlener.. cas'rnvos.
Cari Wessei, Uhicago, ., assignor to Carl Wessel
` and Lew W. Gleminson, (Chicago, lll., trustees
4Eontilnuaticn ci' application Serial No'. 370,344,
Eiecemher lid, lädt). fll‘his application Septem
her 23, i942, Seriali No. 459,893 ` ‘
t cams. (ci. za-acti
il 2
1‘The present invention relates to methods oi y
making metal castings. ltherein is subjected to continuous pressure ofthe
head of metal in the ladle. .
This application is a continuation of my prior
, application, Serial No. 370,344, ñled December 16, .as the ladlehas a large body of molten metal
i940, U. S. Patent No. 2,309,608, issued January g in ity and- the mold has a relatively small amount
of metal in it and the mold is connected to the
26, i943. , . `
Vlì’hile the present‘method of making castings ladle at the discharge opening thereof, the out
may be used lfor making all kinds of castings it ermost part of the mold tends to cool ñrst and
has been illustrated in connection with a mold this is also true of the casting in the mold.
for making sludge or blanks which are to be Very soon after the mold is fì11ed,‘or immediately
drawn into metal containers. lo thereafter, cooling begins and there is a gradient
The method according to the present invention of temperature, the temperature decreasing from
may be briefly characterized as follows: ' -the iilling opening of the mold to its outermost
According to my method, any type of clean parts. The casting cools from its outermost parts
scrap or any other metal in ingot form that has down toward the iilling opening, and as it‘cools
heretofore been used for drawing may be used l5 and shrinks additional metal is supplied from the
as raw material. The raw metal is ñrst melted head of metal in the ladle until the shrinkage is
in a furnace and poured from the furnace in a all taken up and the metal casting in the mold
has congealed. ‘
heavy stream into a tilting ladle _so that it will
contact a minimum amount of air. At this time the supply of metal to the mold
Flame may be applied to the top of the liquid 20 is cut off at a relatively large sprue and the ladle
metal in the ladle for the purpose of excluding may -be tilted back, since the discharge opening
the oxygen and maintaining »the metal and mold is now closed, and the metal cannot run back
at a predetermined temperature. As a general out of the mold. 'I'he metal does, however, run
back from the closure at the discharge opening
rule, `no special iluxes are needed, provided»,the 25 of
metal was clean. x .
the mold.
The ladle constructed according to the present The4 next step comprises the cutting off of the
invention is lined with a suitable refractory and sprue or gate immediately adjacent the surface of
the casting, which produces a ilnished casting
preferably so mounted that it may -be tilted, and < Without
. the mold is preferably secured directly to the la any sprue that must be cut oiï after the
30 castings are removed from the mold.
dle at a discharge aperture which is located above
the free surface of the molten metal. ' The mold may then be opened and the castings
The mold may then alsov be preheated by the removed, and Iby means of the opening of the
application of ñame to an opening in the top closure at the discharge opening of the ladle, :any
remaining molten metal in the large sprue is per
of the closed ladle, the flame striking the sur 35 mitted to run back into the ladle. 'I'he conduits
face of the metal and being deilected upward into
the mold through the discharge opening of the ` in the mold leading to the actual cavities of the
ladle. The discharge opening of the ladle into mold are _then cleaned of their excess metal or
sprue,‘and the mold may again lbe closed after
the mold is, of course, open at this time, and removal of the castings for a recasting opera
the ladle or mold is `preferably provided with` 4,0r tion.
some means for opening‘and closing this dis Slugs made according to this method are of
charge opening. -
, Vsuch uniform homogeneous crystalline structure
*_ The next step is the mung of the iadie »umn that they do not need to be preheated before they
the free surface of the molten metal passes ‘
are drawn into tubes or boxes. Such tubes or
through the discharge opening into the mold, and 45 boxes may be drawn from slugs made according
the mold is preferably so arranged that the metal
` wells up into the mold from a filling opening 1o to this method Without preheating` and Without‘
` the diiiiculties which have .been encountered in
cated at the bottom of the mold, driving out the the drawing of tubes from blank slugs punched
small amount of air which may be in the mold, out of sheet metal. 'I'he -boxes made bythis
through the cracks between the mold parts. 50 method are practically perfect and the amount
-The amount of molten metal in the ladle and of rejections reduced to a small fraction of the
the amountl of tilt of the ladle is such that the « percentage of rejections according to the meth
mold is not only filled, but there is a head of'metal Y ods of the prior art. »
in the ladleat a higher yelevation than the metal The slugs made according to this method have
in the mold, and when the mold is full the metal 55 a smooth, bright surface, which may be im,same planes as Figs. 8 and 9, showing the same
mediately subjected to polish without any ma apparatus, with the parts in the position which
chining or grinding, and as there are practically they assume in the manipulation of the parts of
no imperfections in the slugs, there are none to the mold to cut off the sprue at the side ofl the
be drawn out into imperfections in the tubes. casting; '
It should' also be understood that the present Figs. 12 and 13 are two views similar to Figs. 8
method of casting is not confined to the making and 9, showing the Darts after one side of the
of slugs for tubes, but may be used for making mold has been withdrawn and the mold opened
castings of all kinds. for access to the castings;
Another object of the invention is the pro y. Figs. 14 and'l5 are two views similar to Figs.
vision. of an improved method of making blanks 8 and 9, showing the parts of the mold after the
fory drawing operations, by means of which the open mold has beenemptied of its castings and
blanks may be made of homogeneous crystal 'of the sprue or excess metal remaining in the
line structure without the imperfections that are
found in the sheet metal slugs of the prior art, conduits leading to the cavities;
Fig. 16 is a diagrammatic view in perspective,
and without the conditions of strain and tension with the parts broken away to show the structure
that are produced in the sheet metal slugs by of the mold cavities and members which form
the operations to which they have beenl sub .the conduit leading to the oavities,'and which
jected. ’ - `
Another object is the provision of' an improved are adapted -to cut oiî the sprue; '
I apparatus for casting by means of -whicn cast 20 L Fig. 1'7 is a view iti-perspective of one of the
cast metal slugs or castings made according to
ings having larger grain, softer metal. and more
homogeneous characteristics may be made. the present method; ,
v Fig. 18 is a view in'perspective of a drawn
Another object of the invention is the pro tubular box made from the slug l1 according to
vision of an improved method of' casting by
means of which the defects of> theprior art the present method; _
Fig. 19 is a fragmentary sectional view, taken
methods, such as for example~ blow holes, inclu on the plane of the line Isf-I9 of Fig. 4, looking
sions, faults, cracks, and other defects are prac
in the direction of the arrows. . ' -
tically eliminated._ ` Referring to Figs. 1'7 and 18, the slug shown
Another object of the invention is the pro-I in Fig. 17 is merely exemplary of one of the forms
vision of an improved casting apparatus, which ao of small castings that may- be made according
is adaptable to use in small plants and which is
adapted to produce characteristics of a high de to the present invention.
gree ofl uniformity of crystalline structure and It comprises a piece of metal, the shape in
plan being the same as the plan shape of the
uniform smooth outer surface adapted to be ' '
polished. 35, box or tubular member of Fig. 18. Thus it has
. Other objects and advantages of the invention four plane sides 2li, and the upper and -lower
will be apparent from the following description plane sides 2| and the corners are preferably
and the accompanying drawings, in which similar rounded at 22. À'I‘he opposite sides of the slug
characters of reference indicate similar parts _are parallel to each other and perfectly smooth
throughoutythe several views. 40 and plane. . `
Referring to the six sheets of drawings which One of the characteristics of the castings made
accompany this speciñcation, according to the present method is that the sides>
Fig. 1 is a side elevational view of a casting >oi? the castings are so smooth that they may be
apparatus constructed according to the inven polished without any intervening` machining or
' ‘ tion;
45 smoothing operations. ‘ _ « '
« Fig. 2 is a fragmentary side elevational'view v It should be understood, however, that this
of xthe side which may be seen fromjthe left of slug is merely exemplary of the many different
forms of castings that may be made, as I have
Fig. .1; . , '
Fig. 3 is .a top plan view of the casting ap made table knives, spoons, forks, and many other
paratus; 50 small articles according to the same method.
Fig. 4 is a fragmentary sectional view on a . f I desire it to be understood also that aluminum
larger scale, taken on the plane of the line 4_4 is merely lone of the metals which may beI
of Fig. 2; _ ' .
utilized according to the present method.. and
Fig. 5 is a fragmentary vertical sectional view, that the invention is not limited in its use to
taken on the plane of the line 5--5 of Fig. 4, 55 non-ferrous metals, but may be employed .for
lookingin the direction of the arrows; i practically all ferrous and non-ferrous alloys and
Fig. 6 is a fragmentary vertical sectional view metals.
taken on the .plane of the line 6--6 .of Fig. 4, Referring to Fig. 1B, this is the container which
looking in the 'direction of the arrows ; is formed from the blank of Fig. 17, and it is
Fig. 7 is ' a diagrammatic vertical> sectional` 60 provided with a bottom 23, and the four plane
view, taken on the plane of the line 1-1 of Fig. 3, sides 24, the opposite sides again being parallel
showing the complete apparatus as it appears to each other, and the corners being rounded at
after’the castings have just been completed:- 22. The box of Fig. 18 is formed according to
Figs. 8 and 9 comprise` two -fragmentary sec the usual methods of drawing such members
tional views showing the condition of the cast from metal blanks, except thatin the present>
ing in the mold after the mold has been ñlled by speciñc instance it is found that by means of
tilting and after the mold and ladle have been my cast metal slugs it is 'not necessar to anneal
held in tilted position long enough for the metal - the metal or preheat it, as it was in making the
to congeal and shrink in the mold, and to partially tubular containers from the sheet metal blanks
congeal in the conduit leading from the ladle. 70 of the priorvart. > v ' _ .
Fig. 8 is a horizontal section taken on the same I desire it to be understood also that the tuj
plane as Fig. 4; ' bular container'of Fig. 18 is merely exemplary~
Fig. 9 is a vertical section taken -on the same _ of one form of receptacle or container ‘or’ drawnv i
plane as F18. 6; . metal member that may be made accordingto `
Figs. 10 and 11 are two views taken on the 75 the present method..A The presentl methods may be ,j ' '. 5 l
anniv@
utilized fol-‘making all kinds oi’ containers, such
as kitchen utensils orother articles which may is of substantial thickness, being substantially
be made -by drawing processes. equivalent in insulation to the iirebrick layer 46.
Referring to Figs. 1 to 3 and 7, all indicates the It is carried by any additional metal cover member
casting apparatus in its entirety. This apparatus 6 53 of substantially disc'shape, which in turn is
may have its parts further designated ascom supported by a rectangular metal frame mem
ber 54, which may have a. vertical ilange 55 and
prising the ladle 3i and the mold apparatus 32. ' horizontal
The ladle 3i is preferably supported for pivotal ilange 56.
movement upon a pair of bearing brackets 3,3, The rectangular frame 54 may project beyond
which may be identical in shape. ' the cylindrical shell 53 at the four corners of the
Each oi' these bearing brackets has the foot rectangular frame member 54 and may be pro
nanges 3c and the upwardly extending columns vided with apertures in the horizontal flange 56
35 suitably reinforced by reinforcing flanges 36, foi-.receiving the elongated bolts 51, which ex
and at its upper end the bearing bracket hasl a tend to the` lower end of the metal shell 44 and
horizontally extending socket 3l for receiving the 15 there pass through the radially projecting ears _58.
be i i im: mâmbel‘ 33. The bolts 51 clamp the upper frame 54 to the
The 4bearing member 38 may be provided with shell 44 and secure the cover members 52 and 53
vertically extending trunnions 39 at the top and in place. The cover member 52 is preferably pro
bottoni.l and located in bearing apertures 40 so vided with a. pair of tapered apertures or con
that the bearing 38 is mounted for pivotal move duits 58 and 68. The aperture ‘59 is merely for
ment on a vertical airis, and is self-aligning with application of heat by means of the name 6I from
respect to the same bearing on the other‘ a gas burner 62, having an adjusting member 63
bracket lili. > for determining the amount of air which is 'fed
into the noz‘zle e2 with the gas. _ _ _
The ladle 3l is preferably pivotally supported
on the brackets 3b by means of a centrally located 25 The gas burner t2 maybe secured by means of
metal bearing band di, which has a laterally pro- a bolt b4 to one of the vertical iianges 55 oi the
jecting trunnion ¿l2 at each end, as shown in Figs. rectangular frame 5i. Conduit 59 tapers up
l and 2. The trunnions d2 are rotatably mounted wardly andv is arranged at one side of the con
in the bearings 3b, which are aligned with suitable tainer dd so thatthe flame bl may be directed in
bearing metal at d3. ` wardly toward the surface b5 of the molten metal
The band di embraces the sheet metal housing iid-and be deñected upwardly into the conduit
dit of the ladle, to which it may be secured by bil, which is the discharge conduit leading to the
mold apparatus 82. '
rivets, welding, or any convenient method. The
trunnions ¿i2 are preferably located substantially Conduit 3b is preferably also provided with a
refractory lining b1, similar to' the refractory lin-`
midway between, the ends of the ladle, or slightly 35
upward of the middle oi' the container so that ing ¿i8 previously described. This conduit also
when the ladle is empty and the mold apparatus tapers upwardly to the discharge opening leading
32 is attached, it is still held in upright position. into the mold apparatus 32.
When it is iilled with metal, the ladle tends to The cover 52 is secured to the metallic cover
maintain its upright position by virtue of its own 40 plate 53 by means. of suitable bolts which are
weight and the weight of the metal in the ladle. embedded in the ñrebrick cover 52 at some' _ dis- ‘
but it may be easily tilted because the apparatus tance from the lower surface of the cover 52. The
is in a condition approximating 'a balance. ñrebrick insulation of which cover 52 is made ex
The ladle 3i consists of a member which has an tends upwardly into an aperture 10 in the metal
outer sheet metal shell, such as the jacket 44, cover plate 53, and the refractory lining »61 ex
carried by trunnions d2. Inside the metal jacket tends upward into an aperture 'H in a guide plate
44 there may be a layer of suitable insulation, 12 so that the conduit 60 is adequately insulated
against the transmission of heat. '
such as rock wool d5 or other temperature re
sistant heat insulating material. The metal cover plate 53 preferably supports
The ladle 3i has its next inner layer 46 made 50 the metallic guide plate 12, which is provided with
of iirebrick or other suitable heat retaining and the aperture 1I, registering with the discharge
temperature resistant heat insulating material, aperture 60.0f the ladle. The guide plate 12 (Fig.
and the ñrebrick may be suitably spaced from the 6) comprises a flat metal member, which may
metal shell 44 by spacer blocks 41 at the bottom ' , be of substantially rectangular shape, as shown in
and sides ofthe shell. Figs. 8 to 15, and provided with an upwardly pro-`
55 jecting border 13 surrounding three sides of the ,
The spacer blocks 41 would also be made of the ,hat surface or bed 14 of this guide plate. The
same material as the iirebrick and would trans
mit a minimum amount of heat through the rock inner‘walls _15, 16 of this border (Fig. 14) act as
wool 45 to the shell 44. ' . - guides for certain other parts, further to be de
'I'he ladle has its innermost lining 48 made of 60 scribed, and the border 12 may be provided with
suitable refractory material which is adapted to apertures for receiving the screw bolts 11, which
withstand the high temperatures to which this pass through this guide plate and are threaded
into the metallic cover plate 53.
lining is subjected by the molten metal and by the
application of heat with llame. asillustrated in The' mold apparatus 32 preferably includes an
Fig. '1. ' ' upwardly extending frame, indicated in its en
65 tirety by the numeral 80. 'I'he frame 80 consists
The shape of the container chamber 49 is pref
erably round when viewed in plan and tapering of a pair of upwardly extending angles 8|, 82 at
from'the bottom toward the top, and the lower the side of the machine in Fig. 1, and another
comers at 50 are preferably rounded so as to pair of similar bars 83, 84 at the opposite side.
facilitate cleaning ofthe chamber 49. ` ` 70 These bars are bolted to the rectangular frame
At its upper end the nrebrick lining 46 is pro 54 at their lower ends, and they are joined to
vided with a. cylindrical recess 5I for receiving gether by auxiliary frame members 85, 86 at each
a removable cover 52, which may also be made of side of the machine and by elongated frame mem
iìrebrick material. _ bers 81, 88 extending across the top of the frame
(Fig. 3).
. The cover 52 lits in the cover aperture 5| and 75
This provides a top frame which comprises the2,411,176
» 7 the form of an insulating covering ||4, which isy
members 85, 88, 81, 88, supported by the columns protected by a metal shell ||6 extending up the
8| to 84. The top frame may support a guide side of these mold members under the top and
plate 90 (Fig. 2) similar in constructionto the over the bottom thereof to a predetermined point.
guide plate 12 previously described, but oppositely The bolts which secure -the brackets ||0 to
located. Í ||3 to the mold members pass through the shell
'I'hls guide'plate also has a depending wall or and insulation and may be threaded into the
border _9| which serves to guide the adjacent mold members. These brackets ||0 to ||3 are
parts for sliding movement, but is open on one preferably formed with an offset. as at ||8, for the
side, that is, the right side (Fig. 6). The mold 10 purpose of the size of the mold apparatus to the
may be indicated in its entirety bythe numeral size of the guide plates and giving the mold ad
96. . ditional support. ‘
Referring to Fig. 16, the main parts of the mold The mold members 99, |00 may also be sub
comprise the oppositely disposed mold members stantially similar in construction, with a few ~
98 and 91, each of which is provide‘d with a plu-k slight differences. Mold member 99 may com- ’
rality of cavities 98 and the two oppositely dis prise a bar of iron or steel or other suitable metal,
posed >members 99 and |00, which form the con
cut oif the which is provided with the rectangular horizon
duit to these cavities, and serve to tally extending ribs |01 at regularly spaced points
sprue. - Ñ on each of its opposite sides and- projecting from-
In addition to this, the mold has a pair of the plane parallel surfaces |20, « | 2 | . .
doors, best illustrated at |0|, |02 (Fig. 8) and 20 The sides of the mold members 98, 91 also have
other associated parts for controlling these mem plane surfaces at |22 and |23 for' engaging the
bers. surfaces |20 and |2|, respectively. At its inner
The mold members 98, 91 may be similar'in side the member 99 is provided with a longitu
structure except that they are right hand and dinally extending substantially hemicylindrical
left hand members, as disposed in the drawings. 25
groove |25. ' y
As a matter of fact, if the member 91 is This groove has such a diameter that it leaves
«turned end for end, it will be seen to be sub a, plane surface or rib formation |28, |21 at each
stantially similar to member 96. Each of these ‘ side of the groove on the inner face. Rib forma--l
. members and all of the main parts of the mold tions |26, |21 are formed with the Plane Surfaces
’may be constructed of suitable metal of sum 30 |29 at their inner ends, registering with what may
ciently high melting point in relation to the metal 'be called a. filling slot |29 leading t'o the filling
to be used for the castings, so that it will with aperture |08 of the mold cavities 98. ' '
stand the heat without damage. For example, The mold member |00 is similar in shape to
the present molds may be made of iron or steel, the member 99, previously described, but is op
35
when used for aluminum slugs, and the interior. - positely disposed, and it is also adapted to fit
finish of the mold is, therefore, very smooth, for against the adjacent sides of the molds, as it has
the purpose of producing a casting of finished ribs |01 for sliding in the grooves |08. It also'
characteristics. , . has the mold filling grooves> |29, a part of which
`Each of the members 96, 91 comprises a vbar of 40 may be seen at Fig. 16. The mold members 99
metal, having a plane face` |03, >which is formed and. |00 may meet at a, point between the front
with a multiplicity of the cavities 98 comple and back of the mold cavities.
mentary in shape to the slug, which is shown in The guide plates 12 and 90 are adapted to slid
Fig. 1'1. One of the larger planel faces of this , ably support an additional pair of mold plates
slug is arranged in the plane of the surface |03 |30, I3I, one located at the top and one. at the
of the mold so that it will be formed by means of bottom of the mold assembly. The mold plates
the plane surface |04 on the door |0| or |02. » |30, |3| may be substantially similar in structure,
The mold member 98 is provided with a ñlling except the mold plate' |3| has a tapered filling
aperture |05 at one side of the cavity 98, and the aperture |32, which registers with the refractory
filling aperture preferably communicates with a 50 lined conduit 80 at the top of the ladle, while the
transverse slot |08, which is rectangular in cross mold plate |30 is imperforate, being located at
section and just as wide as the filling aperture the top of the mold. Each of these plates is of
|05 from top to bottom. . Y sufßcient width to nt in between the side walls
- The slots or grooves |08 are adapted to receive |35, |38, |31, |38 on the upwardly and down
the regularly vspaced transverse ribs |01, which 55 wardly projecting borders of the guide plates 12
are locatedv on the mold members 99» and |00.
These ribs |01 are also rectangular in cross sec and 90.
The platesl |30, |3| »may also be formed
tion and have an accurate smooth i‘lt in the with the depending border |40.,and the upwardly-
grooves |08. They are of such length,on the projecting border |4| for the purpose of provid
member 99, for example, that they leave a `small ing a guide for other mold parts. These border
aperture at |08, which is actually the ñlling aper members |40, |4| also extend around three sides
ture of the moldcavity. _ of the plates like those of plates 12'and 90, but
In other words, the ribs |01 partially close'the the plates are oppositely disposed, having what
aperture |05, previously mentioned. The molds would be called _their open side extending in the
96 and 99 are viixedly secured to the framework
in vertical position, parallel to each other, and 88 opposite direction from the open sidevof the plates -
spaced from each other sufiiciently so that the 90 and 12.v
The thickness of the plates |30, |3|, seen in
members 99, |00 can slide between the molds 98, Fig. 5, is such that there is a clearance between
` 91, with the ribs |01 in the grooves |06.
these plates and the mold members 98, 91 at |42
Thusv the mold members 98, '91 are secured at „70‘» (Fig. 5). The space between the side walls |43
the bottom by means of brackets ||0, ||| to the y and |44 (Fig. 5) of the plates |30 and |3| is such
guide plate 12. At the top these mold members that the rectangular ends‘of the members 99, |00
are similarly secured to the guide plate 90 by , may be iixedly secured or slidably mounted bc
means _of brackets || 2, | |3. ‘ tween these side walls |43, |44. Thus the mold
These metal mold members are preferably
provided with heat insulation, which may take '75 member |00 (Fig. 6) may be iixedly secured to2,411,176
the plate |3| and plate |30 at the bottom and top 10 "
of the mold assembly by means of the screw bolts is tilted the free surface 65 of the metal 66 in the
ladle would well up into the mold.
|45 which pass through the plate and are thread- _
ed into the mold member. when the casting operation is to be begun", the '
parts are in the position of Figs. 7 and 8.‘ 'I'he
Thus the mold 'member moves with the plates ladle cavity 49 is ñlled with a charge of clean
|30 and |3| at all times,` and for the purpose of metal, which has been kept from‘exposure to the
‘ actuating these members the member |00 is pro
air as much asV possible. The tilting of the ladle
vided with a thrust plate |46, which is secured
to it by screw bolts |41, and which has a socket 3| caused the metal 66 to well'up into theA conduit
|48. An actuating screw |49 has its end in the 10 bers 60 and into theconduit |25 formed by the mem
socket |48 and is provided with a groove |50 of 99, |00 between'the molds 96 and 91. From
circular cross section, which registers with a
the conduit . |25, it passes laterally through the
similar groove |5|. ' -
apertures |29, |08 into each of the cavities`98,
the cavities filling by the gradual rising of the _
A circular wire |52 (Fig. 4) bent to annular
shape, and located in the'grooves |50, |5|, may 15 out free surface of the metal in these 'lcavities'with
hold these parts together, but permitrotary mo any splashing or exposure to air other than
that which is in the cavities. _
tion Ibetween the screw |49 and thrust plate |46. The moldV cover plates or doors |0|, |02 fit
- Wire |52 may be forced in through a tangential
aperture. Screw |49 (Fig. 4) extends through quite closely against the molds 96 and 91, but the
an internally threaded member |53 constructed 20 there air may still escape through the cracks, although
is substantially no nn formed on the cast
like a follower, but fixedly secured to the ver- .
tically extending bars 63 and 84 by screw-bolts ings, due tothe close iit of the parts of the mold.
| 54. Handle |55 permits the screw shaft to be 'I'he ladle is'then tilted .back to the vertical po
rotated and causes the mold member |00 to move
sition shown in Fig. 7, and due to the cooling of
back and forthas desired, in Fig. 6. In this mo 25 looks the metal the‘metal in the mold and conduits
as it is shown in Fig. 7. ’ `
tion it carries with it the plates |30, |3|, which The manipulation of the mold is then as fol
are guided by the plates 90 and 12. i l
lows: Referring to‘Figs. 8 and 9, it will be ob
'I'he mold member 99 is slidably mounted be served that the parts are shown here in the posi
tween the walls |43, |44 of the plates- |30, |3|, tion of Fig. 7. The cavities are all nlled and par
its movement being limited by the mold member 30 tially congealed, 'and a small amount of metal is ,
|00 and by the abutment at |60. l
congealed in the conduitl |25, but the molten
This mold member may be provided with a pair metal at the center runs back into the ladle.
of rearwardly projecting lugs' | 6| for engaging The next step is the turning of the stop `cam
the cams |62 carried by cam shafts |63, which ' shaft |63 by means of lever |66 from the position`
are rotatably mounted in the bearings |64, |65, 35 of Fig. 8 to that of Fig. 10, establishing a1 diner
and adapted to be actuated by lever | 66 (Fig. 10).
The cams |62 are adapted to provide a variable - f ent stop position for the member 99'. The screw
shaft handle |55 may then be rotated in a clock
abutment for limiting the movement of the mold wise direction to cause the member :|00 (Fig. 10)
member 99 toward the right in Fig. 6. i '
to move toward' the right ,from the position of
The-mold doors |0|, |02_ are best illustrated in Fig. 8. Member |00 is secured to theI guide plates
' Figs. 8 to 15 and Fig. 4. The main bodies of each
of these doors comprise -a bar of the same metal ‘
|30 and |3|, which move with it, andthe member
99 also moves toward the right by the pressure
1 as the rest of the mold and of substantially rec of the member |00 against it. The turning of the l
tangular cross section. These bars of metal ñt) . screw‘is continued until members 99 and |00 are
against the plane surfaces |03 of the molds 96, 91 45
stopped by the engagement of the lugs |6| with
and close the cavities 96- on that side. The doors v-the cams |62, as shown in Fig. 10. This motion
|0|, |02 are provided with upwardly and down has caused the member |00 to shear olif the sprue
wardly extending trunnlons |10, the trunnlons at a point immediately adjacent the side of the
being rotatably mounted in bearings carried by casting, by means of the cutting edge of the ribs
e
the guide plates 90 and 12.
50 |01 in the grooves |06. In this action the con
'I'he oppositely facing edges of these doors ‘~|0|, duit |25 in the mold members 99 and |00 has
|02 are also provided with the slots |1| (Fig."12) also been placed slightly off registry with the
of rectangular cross section for permitting the conduit 60 in the ladle, as seen in Fig. 11.,
sliding of the ribs |01 on the mold members 99, The next step is the withdrawal of the mem
|00 (Fig. 16). '
55 ber |00 by means of the screw shaft | 49 and han
The metal bodies of the doors |00, |0| are dle |55, bringing the parts in thel position of Figs.
preferably provided with a layer of insulation at 10 and 11 to that of Figs. 12, and 13. 'I‘his move
|12, covered by a metal shell |13 secured to the ment of the mold member .|00 ‘draws with itthe
doors |0|, |02 by screw bolts, and the shell |13 is lower plate | 3| and cuts `off the vertically ex
curved around the trunnlons |10 so as to permit 60 tending sprue at the aperture |32 (Fig. 13).
suitable clearance between the doors and the
mold members 96, 91, so the doors may open'to In addition, the member |00 is wholly with
the position shown in Fig. 12 from that of Fig. 8 drawn from between the doors |0‘|, |02, so there
for removal of the castings. ` „ willbe no longer any .binding‘between the adia
The operation of the mold is illustrated in Figs. 65 cent sides> of thegdoors, and the _- member |00,
'l to 15. The mold is secured in Fig. '1 in ver and the doors may then be pivotally opened from
tical position on the top‘of the ladle 3|. 'I‘his the position of Fig. 10 to that `of Fig. 12.
is satisfactory in the present case because the The castings may then be removed from the
filling conduits are so large that the metal ad- ^ cavities, and the hollow sprue |15 (Fig. 12) may
vances in a solid stream without any splashing. be removed ,from the groove I|25 in the member
70 99, where it stands, and the parts are ‘then in the
In other embodiments of the invention, where Y
large castings are made, the mold would be tilted position as shown in Figs. 14 and 15,~when the
toward the left, for example, in Fig. `'1, at an angle ' cam |62 may be turned back to the position oi'
to the top of the ladle, such as, for example, Fig. 8 and lthe mold closed again to the position
thirty or forty-live degrees, so that as the .ladle 76 of Fig. 8, to beused again. l -\ -
My method lof making castings is-as-follows:2,411,176
, . , ' l‘12' ' > ,
y ` The ladle 3l and the mold are preheated byv removed from the mold. This is done while the
- , parts are in the position of Figs. 12 and _13.
means of the' gas burner 62 »until they have Thereafter the castings are taken out imme
y, reached approximately the temperature at which _ diately, the Iparts being again placed inthe posi#
the molten'metal is to be kept. The ladle is then . tion of Figs. 14 and 15 within a very short time
filled with a charge of metal, which is made by after the ladle and mold have been tilted back
melting down clean scrap or other metal'in'ingot
to vertical‘position‘. '
form. This may be any metal which has so far At this time the castings are still very hot. and -
been used for drawing and extruding. and the> such shrlnkage'as takes place during the congela
melting may bev done ina furnace where the tion of any part of the casting is taken -up by the
vmetal may be cleaned and skinned offv so that it ‘ supply of additional metal from the head of metal
will be clean in the ladle. 1 which is impressed upon the mold cavities. By
It is poured in the ladle in such manner as to removing the castings from the mold immediately
reduce the contact between the air and metal to after they> have congealed, any additional shrink
a minimum, such as the pouring in a large
age may take place without inducing any undesir
stream.' ,
Thereafter, the preheating of the mold may be able strains because the casting is not held by
completed by the application of the gas flame ,I any mold, nor, is there any contract-ion or strain
through the aperture 59 into engagement with~ brought upon the casting by shrinkage of the
the metal which deñects it up into the mold. _ sprue.
Castings made according to the present inven
With the `parts of the _mold in the positions 20.tion have a smooth surface, which may be imme
which they assume in Figs. 7 and 8,-the mold is diatelyv subjected to a polish, and therefore many
tilted toward the right on its trunnions 42, and
the free surface 65 of the metal gradually pro articles which 'may be made by casting can be
gresses up the conduit 60 and conduit [25 in a manufactured with 'a minimum amount ofy labor.
solid stream in such manner that the molds are 2.5 a remarkably smooth finish without necessity for
Knives. forks, spoons, 'and other tableware' show
filled without _any splashing or any contact with any machining or other smoothing operations ex
air other than that which happens to be in'the cept polishing. ` ' - - '
ladle or in the mold cavities.- , .' ï ' The slugs which are ~made according to the pres
The amount of` oxygen in this air is reduced to4
a minimum on account of the application ofthe 30 ent method have smooth surfaces without defects. y
-There are practically no inclusions or faults or
flame, which carries products of combustion~ up cracks, and consequently'the slugs are perfectly
into thevconduit |25 and tends to drive out _the adapted to the drawing of the tubular boxes which
all'. ‘ - ‘
When the mold has been filled, the ladle may are shown in Fig. 8. "
be immediately tiltedv back, and it is found, as a 35 The grainof the metal is large and the metal a'
matter of practice, that this tilting operation is easily worked, and it is> not-'necessary to pre
-may be accomplished quite quickly with hardly heat the metal for drawing Purposes; but it may
any hesitation, as the mold fills immediately, and be drawn cold into containers or members of all
the metal begins to congeal in the mold, begin ' different sizes and shapes. ~
ning at a point farthest from the filling openings, v 40 As distinguished from the tubular members
and maintaining a gradient of heat', the temper which were made out of blanks that -came from
sheet metal, the drawing may be accomplished
ature increasing from the remotest part of the with my blanks without laboring of the machin
mold to the flllin'g opening. . l
This is also true down to the metal in the ladle, ery, as the metal is much more )easily worked.
which has the highest temperature of any metal 45 Furthermore, the large percentage of defective
boxes, which result from the methods of the prior
in the assembly because the metal in the ladle is art, is not present according to my method, as
the source of the heat for the metal in themold; practically all of the tubular members are per- f
and the mold, being more remote from the ñame, fect. There is a large saving in the cost be
is necessarily cooler than the metal in the ladle,
- particularly after the mold has been filled. 50 cause clean scrap or ingot metal is much cheaper
While the mold is being filled and the metal is than the sheet metal of which the blanks were
congealing, the metal shrinks in the mold cavi made according to the prior art.
In the castings made according to the pres
ties, but the shrinkage is taken up by the pres ent invention approximately fifty per cent vof
sure of metal caused by the head of metal in the the sprue runs back ‘into the ladle so that this .
ladle,r which is above all of the cavities, when the 55 effects a large saving'in the remelting of metal
mold is fully tilted. - ‘
` Thus the free surface 6_5 of the metal may com
j due to the fact that the sprue is hollow and thin.
l -pletely cover the discharge opening 60 inside the One of the most important features of the
ladle chamber 49 when full tilting is ` reached. inventiony is the location of the mold at a pre
When the ladle is tilted back to vertical position, determined angle so that the metal wells up in the
' as shown in Fig. '1, congelatlon has taken place mold without splashing or spurting. The action
, ls merely a uniform raising of the level from the
in the mold' cavities, shrinkage has been taken
up, and congelation has partially taken place in lower part of the mold.
the conduit |25, so that something likea >tube is Another` important feature of the invention is
formed, the metal running back out of the hol the provision of a filling opening for the mold,
which is commensurate with the size of the mold
‘low tube into the ladle 3l.- cavity.
.The next step is the cutting off Aof the sprue of Insome embodiments of the invention, such as
each slug or casting immediately adjacent the the casting of metal plates, the opening of the
side surfaces of the casting. This is accomplished
Q by means ofthe mechanism of the molds by mov o, mold may extend across the full cross-sectional
ing the parts from the position ofk Figs. area of one end of the mold. This is to be care
, fully distinguished from methods in which there
to that of'FigsJlO and 1l. isa small opening in which the metal would spurt
„ î,flx‘heznext step is the Vcompletecutting off of the4 - ` up into the mold instead of welling up gradually
'larger'tubular sprue and the opening of the molds 76 according to the present method.
so that the castings and Àdetached sprue may "ne2,411,176 i
' 13
l 14 „ .
In other embodiments of the invention the ñll the mold cavity, and promptly removing the cast
ing opening of the mold does not necessarily ing from‘its mold after congelation to permit
cover the whole cross-sectional area, but it is a furtherl shrinkage of the casting `without restraint
relatively large opening for filling the mold and of the mold or sprue. '
always located at the lowermost corner or p0r 3. The method of casting, comprising main-_
tion of the mold. - ~
taining a supply of molten metal in a closed ladle
According to my method, no part of the melted having a mold with its filling opening applied
metal is separated from the compact stream of directly to said ladle, maintaining a neutral at
melted metal Welling up into the mold. ‘ Any liquid mosphere in‘said container by projecting a flame
metal which has separated from this compact 10 into said container to engage the ñlling opening
stream surrounds itself immediately with oxygen .« of said mold, filling said mold with molten metal
and will not fuse again in the mold to make a from said container by causing the molten metal
homogeneous structure. The arrangement to ñow upward from the ñlling opening located
should be such as to provide an uninterrupted
at the bottom of the mold and maintaining a
stream of metal of large cross-sectional area 15 gradient of‘heat in said mold and casting dimin-`
passing uniformly into the mold. ishing from the filling opening of said mold to
While I have illustrated a preferred embodi
ward the remote parts of said mold whereby the
ment of my invention, many modifications may be casting congeals from the remote parts of said
made without departing from the spirit of the mold toward said filling opening while- metal is
invention, and I do not wish to he limited to the 20 being supplied under pressure to take up the
precise details of construction set forthybut de shrinkage of metal in the mold, and separating the
sire to avail myself of al1 changes within the scope mold and the casting promptly after congela
of the appended claims.
Having thus described my invention, what I tion in order to permit the free contraction of
claim as new and desire to secure by Letters Pat
the casting in the subsequent cooling thereof.
25 4. The method of making castings which com
ent of the United States is: prises maintaining a supply of molten metal in a,
1. The method of casting which comprises
maintaining a supply of clean molten metal in substantially closed and heat-insulated container
a substantially closed container having a mold having a mold attached directly to said. container,
maintaining a neutral atmosphere in. said con
I' provided with `a ñlling opening applied directly 30 tainer by projecting a ñame in said container to
to a discharge opening of said containen'main engage the free surface of the metal and to be
taining a neutral atmosphere in said container deñected backward into the mold, and tilting
by projecting a flame in said container in suchv
manner _as to heat sai-d iilling opening, causing said container and mold until the metal wells up
said molten metal to ñow upward from the illling ward into the mold from a filling opening located
at the bottom of the mold to form a casting.
opening .located at the bottom of the mold in a
substantially solid stream into a mold cavity With 5. The method of making castings which com
out splashing, maintaining a heat gradient from prises maintaining a, supply of molten metal at
predetermined temperature in a substantially
the extreme portion of said mold cavity to the
supply of metal whereby the casting congeals at 40 closed and heat insulated container having a mold
its remotest part ñrst and at its ñlling opening attached directly to said container and communi
eating with said container through a filling open
last, and supplying additional metal to the mold ing, projecting a flame into said container to en
cavity while shrinkage and congelation takes place gage the free surface of the metal and to be de
by means of a head of metal impressed upon the ilected backward into the illling openingßof the
mold cavity, the -mold being made of another 45 mold to maintain a neutral atmosphere and effect
metal of higher melting point, whereby the cast a heating of the filling opening of the mold, tilt
ings may be polished without intermediate ing said container and mold until the metal wells
smoothing operations, and cutting off the sprue upward in a solid stream without splashing or
of the casting immediately adjacent the side of
the casting promptly after congelation of the 50 separation from the ñlling opening located at the
metal in the mold cavity. bottom of the mold into the mold to fill` the mold,
2. The method of 1casting which comprises and thereafter impressing a gravity head of metal
in the ladle on the metal in the mold while the
maintaining a supply ofclean-molten metal in a metal in the mold cools and solidiñes from all
substantially closed container having a mold pro sides inward toward the center of the casting
vided with a ñlling opening applied directly to a 55 and toward the -ñlling opening to provide addi
discharge opening of said container, maintaining tional metal to take up shrinkage during the con
a neutral atmosphere in said container by pro gelation of the casting.
jecting a flame in sai-d container in such manner 6. The method of making castings which com
as to heat said filling opening, causing said molten i prises maintaining a supply .of molten. metal at
metal to flow upward from the filling opening 60 predetermined temperature in a substantially
located at the bottom of the mold in a substan closed and heat insulated container having a mold
tially solid stream into a mold cavity without attached directly to said container and com
splashing, maintaining a heat gradient from the municating with said container through a illling
extreme portion of said mold cavity to the supply opening, projecting a ñame into said container to
of metal whereby the casting congeals at its re 65
motestpart ilrst and at its ñlling opening last, engage the free surface of the metal and to be
deñected backward into the filling opening of the
and supplying additional metal to the mold cav mold to maintain a neutral atmosphere and ef
~ity while shrinkage and congelation takes place fect a heating of the ñlling opening of vthe mold,
by means of a head of metal impressed upon the , tilting> said container and mold until the metal „
mold cavity, the mold being made of> another wells upward in a solid stream without splashing
metal of higher melting point, whereby the cast or separation from the filling opening located at
ings may be polished without intermediate .the bottom of the mold into the mold to ñll the
smoothing operations, cutting otî the sprue of the mold, and thereafter impressing a gravity head
casting immediately adjacent the side of the cast of metal in the ladle o_n the metal in the mold
ing promptly after congelation of the metal in while the metal in the mold cools and solidi?es2,411,176 ’
15 l . , 16 `
tilting said container and mold until the metal
from all sides inward toward the center of the wells upward in a solid stream without splashing
casting and toward the filling opening to `pro or separation from the filling opening located at the
vide additional metal to take up shrinkage during
the congelation of the castinß, and cutting oil the bottom of the mold intothe mold to illl the mold,
sprue of the casting immediately adjacent the and thereafter impressing'a gravity head of metal
face of the casting while the casting is in the in the iadle on the metal in the mold while the
mold, after the casting has congealed to the point - «metal in the mold cools and solitliiïles4 from all
o! cutting. .
sides inward toward the center of the casting and
7. The method oi’ making castings which com toward the filling opening to provide additional
prises maintaining a supply of molten metal at 10 metal to take up shrinkage during the congela
predetermined temperature in a ` substantially tion of the casting, and cutting of! the sprue of
closed and heat insulated container having a mold the casting immediately adjacent the face of the
attached directly to said container and communi casting while the casting is in the mold, after the
cating with said container through a filling open-v ,
.casting has congealed to the point of cutting, and
ing. projecting a' dame into said container,- to en 15 promptly removing the casting from the mold to
gage -the free surface `oi the ~ metal and to be permit the casting to cool Aand shrink without
detected backward into» the illling opening of the consti-aint of the mold after removal oi’ the sprue.
mold to maintain ‘a neutral atmosphere and ef CARL weisser..
-tect a heating of the filling opening of the mold,You can also read
