Year: 1887

page_text: Date of Application, 20th Sept., 1887
Specification Accepted, 3rd Feb., 1888
I, ALFRED JULIUS BOULT of 323 High Holborn, in the County of Middlesex,
M.I.M.E. do hereby declare the nature of this invention and in what manner the same
is to be performed, to be particularly described and ascertained in and by the following
statement
This invention relates to a new and improved method and apparatus for effecting
the welding and tempering of joints between metals by the regulation of the heating
effect of an electric current and the immediate application of a tempering bath or
compound.
I am aware that a process for utilizing the heating agency of electricity has been
heretofore employed in the welding of joints or in other words such method has been
applied merely to form a joint without special attention to or the restoration of the
original temper or hardness of the metal at the point of juncture.
It will be obvious to those skilled in the art to which this invention appertains that the
juncture formed between any two like metals of the same cross section by means of
the heat developed in the ratio of the square of the flowing electric current at the
point of union or contact will be left in an annealed or softened state.
Take for instance two sections of steel railroad rails, and effect a fusion between
two adjacent extremities thereof by means of an electric current-manifestly the joint
formed will not correspond to the normal hardened condition of the other portions of said
sections and therefore it will be comparatively incapable of strength and durability;
furthermore in the fusion of joints between two steel rails as before cited if the current,
of necessarily low potential, and heavy heating effect, should be suddenly applied with
its full strength, the end of each rail will immediately assume a molten state and a
joint will be formed; but, such sudden application will destroy the tempering properties
of the steel beyond redemption or subsequent restoration by any tempering process.
Consequently although such process may be used to advantage where a mere
union is all that is required it cannot be employed successfully for welding tempered
or hardened metals, such as steel, without first gradually regulating the strength of

page_text: the current permitted to pass through the adjacent ends of the rails so that the said
ends barely attain a melting temperature and then applying an immediate and
effective tempering means.
Again, inasmuch as the apparatus necessary for fusing hardened metals by the
conversion of electrical energy into heat precludes the employment of ordinary
tempering means and as this difficulty is even more increased in the particular
adaptation of this welding and tempering process, this invention has for its object :—
1st. To provide for the regulation of the heating effect of the electric current
both before and after the formation of the joint.
2nd. To furnish a suitable tempering compound and improved means for the
immediate application of same after fusion.
3rd. To convert a primary current of high potential and small quantity into a
current of low potential and heavy heating effect by means of secondary generators
or transformers and other apparatus of special construction, and
For the attainment of these objects this invention consists in utilizing a suitable
source of electricity furnishing alternating currents in circuit with an improved
inductorium or inductional transformer, and a variable and adjustable current con-
trolling resistance switch in the primary circuit, whereby the high tension currents
of small quantity in said primary circuit are converted into low tension of great
quantity and heavy heating capacity in the secondary circuit-or, in other words,
since it is well known that the combustion of metals is dependent upon the quantity
of electricity passing in the heating circuit, it is the increase, by electric conversion
in a special form of inductional transformer, of the strength of the secondary currents
without proportionately increasing the resistance of the welding circuit.
This invention consists further in a chilling or suitable tempering compound
together with apurtenances for facilitating its ready application, and in certain com-
binations of apparatus having an organization and method of operation particularly
applicable for the utilization of the heating capacity of the converted secondary
current, in continuously and successively welding and tempering metals having a
tensive or hardened structure.
Referring to the accompanying drawings:-
Fig. 1 represents an elevation of an alternating current dynamo-a secondary
generator or convertor in circuit with said dynamo-a variable graduated current-
controlling resistance, and the respective electrical connections.
Fig. 2 is a longitudinal side elevation of the welding clamps, the auxiliary
mechanism for adjusting and sustaining same, and the tempering apparatus arranged.
upon a joint previously welded.
Fig. 3 is a theoretical diagram showing modifications of the inductorium or trans-
former the manner of organization, and the electrical connections.
Fig. 4 is a view in elevation of the inductorium with its secondary coils arranged in
parallel with adjustable means for successively bringing one or more of said" coils
into action in the secondary or welding circuit.
Fig. 5 is a detail view of one form of welding clamp for effecting a smooth
finished joint, with provisions as shown, to permit the expansion of the rail while
heated.
Fig. is a similar view showing another form of clamp for either smooth or
ribbed joint.
Fig. 7 is a sectional view showing a modification of the clamp wherein the jaws
are independently and simultaneously moved.
Fig. 8 is a longitudinal section on lines -x of fig. 7.
Fig. 9 is a cross section of a ribbed joint rail as formed by jaws of clamp shown
in fig. 7.
Like letters of reference mark the same parts in all the figures of the drawings.
Referring to the drawings by letters-
A represents a dynamo-electric generator of the ordinary or of any approved con-
struction, for the production in the main line of alternating currents; that is successive
electric currents of alternating negative and positive polarity.

page_text: B and C designate the terminals of dynamo A; and E and F the wires connecting
the said terminals, respectively, with the terminals ab of the primary coils of the
secondary generator or converter.
In the form shown in fig. 1 the converter or inductorium consists of an annulus
or endless ring c preferably composed of sheets or laminae of metal insulated from
each other and suitably secured together, forming substantially a closed magnetic
circuit.
The primary and secondary coils G and I are disposed around the whole surface
of the iron core in alternate segmental sections, as shown.
Primary coils G G are composed of fine wire and are electrically connected with
each other in series by wires d'd; the terminals a and b being as before stated, in
circuit with terminals B and C of generator by wires E and F.
In the spaces between the primary coils are wound the secondary coils [1 which are
formed of coarse wire wound in multiple are as shown their electrodes K and L
being connected, respectively, with the segmental conducting wires or connections M
and N of the secondary circuit P. R, leading to the welding mechanism.
By this principle of construction the inductive action is increased the loss of energy
and conversion removed, and a greater yield of current attained.
The arrangement of the primary and secondary coils in a homogeneous magnetic
fiold around the core e made up of sections insulated from each other parallel to the
lines of magnetic force will cause the inductive action to be equal upon each particle
of wire the circulation of the Foucalt currents which flow in planes perpendicular to
the lines of magnetic force will be prevented and the magnetic force in turn, can
circulate without the production of free magnetic poles, the iron core e being a con-
ductor for the lines of force and not for the electric current.
However a transformer or transformers for the purpose of converting high tension
alternating currents into low tension currents of increased quantity and heavy heating
effect may be constructed in many different ways.
The same result may be accomplished by means of the modification shown in
figure 3 in which the transformer connecting with secondary circuit A' consists of a
core having its primary coils wound at intervals thereon and connected with each
other in series and with the switch lever in the primary circuit and the secondary
coils in the spaces or segments between and corresponding in number and relative
situation to the primary; the terminals from said secondary coils being connected in
parallel with the secondary circuit A.
The convertor connected with secondary circuit B consists of a series of induction
coils having dependent cores and primary and secondary coils; the primary coils
being connected in series with each other and with the dynamo and the secondaries
also connected in series and having their terminals communicating with the secondary
circuit B.
The variable or adjustable resistance switch is indicated by the letter T and consists
of a series of graduated resistances U U.
A pivot contact arm, or other equivalent device, is arranged for varying the
amount of resistance in the primary circuit and for opening and closing the same as
shown.
As illustrated in fig. 4 of the drawings, the secondary or induction coil has distinct
and separate terminals as indicated by the letter W which extends downwardly and
forin contact bearings for the brackets X X-which are secured to a longitudinal
moving rod or bar Y which in turn has its bearings in suitable supports Z Z so that
it can be reciprocated back and forth to bring one or more of the bearing brackets
into contact with the terminals of the secondary coils, and thus increase or diminish
the induced current supplied to the welding mechanism at will.
The movable rod or bar is provided with an insulated handle A' by which it may
be manipulated and is electrically connected with the secondary or welding line of the
system.
The rails to be welded are laid as shown in figure 2, with their ends adjacent and
the current from the secondary coils is gradually passed through such adjacent ends

page_text: in any convenient manner so as to heat them to a welding temperature; it being
remembered that even though the resistance is extremely small at their point of
contact heat will be developed sufficiently to melt the juxtaposed ends.
After being thus heated and welded it is evident that the metal will as before
explained, be annealed or softened at the point of juncture, and will not possess the
same hardened characteristics as the other portions of the rails; and it is one of the
objects of this invention to restore the metal of the rails at the united points to their
original condition by tempering the same immediately after welding.
It will be obvious that in order to prevent the rails from being superheated beyond
the spaces occupied by the clamps, which might result from the heat conductivity of
said rails a suitable cooling or freezing compound may be conveniently applied near
the said clamps in any suitable manner; however, this would be a mere expedient and
consequently will not be further dwelt upon.
The process of tempering the rails may be briefly described as follows:-The
adjacent ends of the metal after fusion, and while still heated, are surrounded with a
tempering or chilling material of suitable nature and subjected to the action thereof
for a required period of time; various substances may be used for this purpose, and
hence I do not desire to limit the invention to any particular tempering compound;
but for general purposes pulverized or powdered carbon of any character has been
found to be effective.
It will he obvious that if, after union, the rails should become cool, they could be
reheated up to the desired temperature for applying the tempering bath; or as
preferred the joint may he first formed, and the tempering process completed after a
short interim of time.
In order to hold the ends of the rails to be welded in contact with each other and
under slight pressure, while the current is being applied numerous forms of clamping
devices may be employed.
Referring to fig. 6 the letter B indicates the lower half of a clamp, and ("the
upper half of same; the two being pivotted together at D¹.
The said parts are provided with recesses E E in which the end of one of the rails
is held during the heating and welding process.
The forward edge of the lower part of a clamp is provided with a lug F and the
corresponding edge of the upper part with a similar lug having a hand lever which
engages the lug on the lower part, and holds the portions together when required.
In this form of plant the recess is of such size and construction as to permit the
clamps to be run along the rails from joint to joint as the sections are successively
welded.
In the modification shown in fig. 5 the clamp is provided with vertically arranged
jaws having mutual recesses to receive the ends of the rail; the jaws have lips or lugs
at their upper ends through which passes loosely a headed bolt G which is provided
with a cam lever H' at one end, and a spring at the other between its bearing
against the lip and head, so as to hold the respective parts of the clamp securely
against the rails, but at the same time permits them to expand and relieve the said
rails while heated.
As shown in figure 7 of the drawings, the clamp is composed of two laterally
approaching and receding jaws having also mutual recesses for the rail.
The said jaws are operated by a right and left screw to open and close them from
and around the adjoining ends of the rails, so as to admit or release the same as
required.
In this form of clamp the reciprocating jaws are respectively tongue and grooved
so that when separated a support will be provided on either side for the end of a rail
as shown in fig. 8: one jaw being provided with a screw-headed bolt which enters a
corresponding recess in the opposite jaw when they are closed and this screw bolt
can be so adjusted as to keep said jaws slightly separated when normally closed;
both the recesses of these jaws are so shaped as to form the ribbed joint, shown in
fig. 10.
If, in practice, it should be found necessary to weld two metals of different density,

page_text: such for instance, as rolled and cast steel it will be readily understood that one of said
metals will offer a greater resistance to the current than the other and therefore, the
clamp adjusted upon the end of the better conductor must be sufficiently removed from
its extremity to proportionate the amount of resistance of that particular metal to the
resistance of the poorer conductor to which it is to be joined.
The means for applying and holding the tempering compound or bath consists
preferably of a suitable enclosing box or casing Jas shown in figure 2, having
adjustable means for clamping the same upon the rails and over the joint, and
provided with an interior receptacle for the chilling material.
It will be understood that any equivalent form of the tempering apparatus to that
shown and described may be employed.
By again referring to fig. 2 it will be seen that the welding clamps therein repre-
sented are mounted upon a movable adjustable base or support E, which, in turn,
rests upon the inclined welding platform. This platform is provided with means, as
shown, for varying the inclination of the table F so as to increase or decrease the
gravity pressure of the higher clamp B2: A2, and A³, represent two rails of similar cross
section held in contact by the clamps B2 B2 under slight gravity pressure owing to the
inclined horizontal surface of the table and the weight of the rail A³
The operator manipulates the device shown in fig. 4 thereby gradually passing and
applying the induced alternating currents of the secondary circuit, through the
clamps B B Fig. 2, to the ends of the rail until both extremities are barely fused;
the cables D2 D2 consisting of stranded insulated wire being electrically connected,
respectively with one terminal of the secondary coil and with the rod Y, as shown
in fig. 4; and the bottom of each clamp being insulated from the support E², Fig. 2.
After the joint has been thus formed between the rails A² and A³ the box J' con-
taining the tempering compound is unfastened from its position and advanced in
convenient proximity to this joint so that it may be applied immediately after the
removal of the clamps and the diminution of the heat to the desired degree necessary
for the application of a tempering means, at which time the box J' is secured over
the joint and allowed to there remain until the next junction is formed.
Thus the operation may proceed indefinitely.
In constructing and laying railway tracks by the use of this improved welding and
tempering system, the employment of nut locks, fish-plates and such analogous devices
is entirely dispensed with and the surface of the road is rendered even and smooth;
thereby saving the wear and tear of the rolling stock and insuring the comfort of the
passengers but it will be apparent that at certain distances along the track, provision
must be made for the expansion and contraction of the rails due to the extremes of
heat and cold.
Having now particularly described and ascertained the nature of the said invention,
as communicated to me by my foreign correspondent and in what manner the same is
to be performed, I declare that what I claim is —
1. The method such as described of effecting a hardened or tempered joint between
two metals which consists first in placing the adjacent extremities of the respective
metals in contact and passing an electric current of heavy heating effect through said
abutting ends, and gradually increasing the current's strength until they are fused
and united; and secondly, in tempering the joint thus formed by the application of a
suitable chilling or tempering compound, as specified.
2. The herein described method of welding together two metals of hardened or
tempered structure without destroying their respective re-tempering properties at the
point of union, which consists in passing an electric current of heavy heating effect
through the ends in contact, and gradually increasing the current's strength until they
reach a fusing temperature, as described.
3. The method of electric welding which consists in the application of heavy currents
to the ends of the metals in contact and under slight pressure and gradually increasing
the current's strength until the same are united whereby the re-tempering properties
of said metals are not destroyed beyond restoration.

page_text: 4. The herein described method of effecting a hardened or tempered juncture
between two metals of similar density and like cross sections, which consists first, in
welding the ends in contact by the passage of an electric current or currents there-
through; and secondly, in re-heating the said joint and supplying a suitable tempering
compound when the joint has reached the desired degree for tempering.
5. In an apparatus for electric welding and tempering the adjustable receptacle or
box holding the tempering compound having means for securing it over the joint and
a longitudinal opening of the desired size to allow the entrance of the metals welded
as set forth.
6. In an apparatus for electric welding and tempering railroad rails a clamp having
jaws provided with corresponding recesses conforming to the shape of the rails and
further provided with means for locking and unlocking said jaws in combination with
an inclined and adjustable table having a supplemental removable top insulated from
the clamp as shown and descrihed.
7. The combination of a suitable source of electricity furnishing alternating currents
of heavy heating effect the adjustable movable clamps respectively, in circuit with said
source of electricity and the adjustable tempering box containing a suitable tempering
compound and the rails held by said clamps, as specified.
S. In combination a suitable source of electricity furnishing alternating currents of
heavy heating effect the means such as described for regulating and controlling the
strength of the current the adjustable removable rail clamps the adjustable supporting
table the rails held by the clamps and the electrical connections as shown.
9. In combination a suitable source of electricity furnishing alternating currents of
heavy heating effect, the means such as described for controlling the flow of the
electric currents the adjustable removable rail clamps the tempering hox provided with
means for securing the same over a welded joint the rails held by said clamps and the
electrical connections as set forth.
Dated this 20th day of Santambar 1987