IMPROVEMENTS IN MAKING MOULDS AND CORES FOR CASTING METALLIC GAS AND WATER PIPES AND TUBES, HOLLOW COLUMNS, AND OTHER HOLLOW METALLIC ARTICLES, AND IN ADDADATUS TO BE USED FOR THAT PURPOSE"
Year: 1878

page_text: LETTERS PATENT to John Roberts and Samuel Roberts, both of West Bromwich,
in the County of Stafford, Ironfounders, and Benjamin Fenton, of West
Bromwich aforesaid, Foreman Moulder, for the Invention of "IMPROVEMENTS
IN MAKING MOULDS AND CORES FOR CASTING METALLIC GAS AND WATER
PIPES AND TUBES, HOLLOW COLUMNS, AND OTHER HOLLOW METALLIC ARTICLES,
AND IN ADDADATUS TO BE USED FOR THAT PURPOSE"
PROVISIONAL SPECIFICATION left by the said John Roberts and Samuel
Roberts at the Office of the Commissioners of Patents on the 28th August
1878.
JOHN ROBERTS and SAMUEL ROBERTS, both of West Bromwich, in the County
of Stafford, Ironfounders, and BENJAMIN FENTON, of West Bromwich aforesaid,
Foreman Moulder. "IMPROVEMENTS IN MAKING MOULDS AND CORES FOR CASTING
METALLIC GAS AND WATER PIPES AND TUBES, HOLLOW COLUMNS, AND OTHER
HOLLOW METALLIC ARTICLES, AND IN APPARATUS TO BE USED FOR THAT PURPOSE."
Our Invention consists of the improvements herein-after described in making the
inoulds and cores used in casting gas and water pipes and tubes, hollow columns,
and other hollow articles, and also of the improvements herein-after described in
apparatus to be used in the production of the said moulds and cores.
Our improvements are particularly applicable to the making of moulds and cores
for casting branch and bend pipes, but are also applicable to moulds and cores for
casting straight pipes and other hollow articles.
Our Invention principally consists in making the core in green sand at the same
time that the outside mould is made, whereby the use of loam cores and core
chaplets are dispensed with, and the production of moulds and cores is much
facilitated. The castings produced in moulds made according to our Invention are
superior to those cast in moulds inade in the ordinary way.
We will describe our improvements in making the moulds and cores in con-
junction with the apparatus which we prefer to employ, and which constitutes part
of our Invention.

page_text: In making a mould and core for casting a branch pipe (the said pipe being
moulded and cast in an upright position) we take a horizontal bed plate having
upon it a seat, in which seat the base parts of the half-mould boxes are supported
and are capable of sliding. On one end of the said bed plate is a standard or
upright provided with a horizontal ledge or bracket, upon which the horizontal or
branch parts of the half-mould boxes are supported and slide. The head of the
standard is furnished with a hollow conical boss, which projects into the mould
boxes. Through this boss a conical wood plug is passed, the said plug entering the
branch parts of the half patterns in the half-mould boxes, and supporting the said
patterns firmly in their places.
The vertical parts of the half patterns rest on the seat described in which the
half-mould boxes slide. To the middle of the said seat a vertical core rod is
secured, the said core rod being fixed and adjusted by means of a set screw. This
vertical core rod forms the core rod upon which the core of the principal or straight
part of the mould is made. At right angles to the said vertical core rod is a branch
rod, upon which the core for the branch is made. This branch rod is fitted with
several "gaggers" or hooked pieces to hold the sand upon.
In making a mould and core according to our Invention we proceed as follows:-
The half patterns having been arranged about the core bar described, and fixed
in their proper positions, the half-mould boxes are moved forward upon their seat
until their opposed edges meet, thereby forming around the pattern a complete box.
Sand is now rammed outside the pattern to form the outside mould, and sand is
also rammed inside the pattern and about the core rod to form the core.
filling of the outside and inside of the pattern with sand is effected through the
open top of the mould box, and also through the hollow boss on the standard, the
wood plug having been previously removed.
The
Having filled and covered the inside and outside of the pattern with sand, the
two half-mould boxes, each box carrying its half pattern, are separated from each
other by sliding them upon their seat, and after laying them horizontally the two
half patterns are removed from them. The two half moulds in the half mould
boxes are then finished in the usual way. On separating the half-mould boxes
with their patterns the green sand core remains firmly supported upon their core
rod; a mould and core are thus produced at one and the same time. After removing
the half patterns the two half moulds in the mould boxes are again arranged upon
the seat of the bed plate, and are closed by a sliding motion upon one another and
around the core, and the mould and core are ready for casting of a pipe.
In making a mould and core for casting a bend pipe the parts of the apparatus
are arranged so as to mould and cast the straight part of the pipe in a horizontal
position, the bend part being vertical. We however make the core rod in two
separate parts, the vertical part being connected to the horizontal part by screwing
or other connection. We also make an opening in the pattern for filling the
interior of the pattern with sand. In other respects we proceed to make the mould
and core in the manner herein-before described with respect to a branch pipe.
The method of and apparatus described for making moulds and cores for casting
branch and bend pipes may be applied to the making of moulds and cores for
casting straight pipes and other hollow articles; but for making moulds and cores
for casting straight pipes and other hollow articles the core may be made separately
from the mould in the following way :-)
-We take two half-core boxes, and having
joined them together, we place in the axis of the core box a core rod and ram sand
into the core box, so as to form a core. Having separated the two parts of the
core box from the core the latter is dried, and thereby hardened.
We make the outside mould by moulding in two half-mould boxes in the manner
before described, or in the usual way. The core, supported by its core rod, being
placed and fixed in the axis of the mould, the mould and core are ready for the
casting.process.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said John Roberts and Samuel Roberts in the Great Seal Patent Office on
the 20th February 1879.
JOHN ROBERTS and SAMUEL ROBERTS, both of West Bromwich, in the County of
Stafford, Ironfounders, and BENJAMIN FENTON, of West Bromwich aforesaid Fore-
man Moulder. "IMPROVEMENTS IN MAKING MOULDS AND CORES FOR CASTING.
METALLIC GAS AND WATER PIPES AND TUBES, HOLLOW COLUMNS, AND OTHER
HOLLOW METALLIC ARTICLES, AND IN APPARATUS TO BE USED FOR THAT PURPOSE.".
Our Invention consists of the improvements herein-after described in making.
the moulds and cores used in casting gas and water pipes and tubes, hollow
columns, and other hollow articles, and also of the improvements herein-after
described in apparatus to be used in the production of the said moulds and cores.
Our improvements are particularly applicable to the making of moulds and cores
for casting branch and bend pipes, but are also applicable to moulds and cores
for casting straight pipes and other hollow articles.
Our Invention consists principally in making the core in green sand at the same,
time that the outside mould is made, whereby the use of loam cores and core
chaplets are dispensed with, and the production of moulds and cores is much.
facilitated. The castings produced in moulds made according to our Invention are
superior to those cast in moulds made in the ordinary way.
We will describe our improvements in making the moulds and cores in con-
junction with the apparatus which we prefer to employ, and which constitutes part.
of our Invention.
In making a mould and core for casting a branch pipe (the said pipe being
moulded and cast in an upright position) we take a horizontal bed plate having
upon it a seat, in which seat the base parts of the half-mould boxes are supported
and are capable of sliding. On one end of the said bed plate is a standard or.
upright provided with a horizontal ledge or bracket, upon which the horizontal or
branch parts of the half-mould boxes are supported and slide. The head of the
standard is furnished with a hollow conical boss, which projects into the mould
boxes. Through this boss a conical wood plug is passed, the said plug entering
the branch parts of the half patterns in the half-mould boxes and supporting the.
said patterns firmly in their places.
The vertical parts of the half patterns rest on the base plate of the apparatus.
To the middle of the base plate a vertical core rod is secured, the said rod being
fixed and adjusted by means of a set screw.
This vertical core rod forms the core rod
upon which the core of the principal or straight part of the mould is made. At right
angles to the said vertical core rod is a branch rod, upon which the core for the
branch is made; this branch rod is fitted with several " gaggers or hooked pieces.
to hold the sand upon.
"
In making a mould and core according to our Invention we proceed as follows:-
The half patterns having been arranged about the core bar described, and fixed in
their proper positions, the half-mould boxes are moved forward upon their seat
until their opposed edges meet, thereby forming around the pattern a complete
box; sand is now rammed outside the pattern to form the outside mould, and sand
is also rammed inside the pattern and about the core rod to form the core. The
filling of the outside and inside of the pattern with sand is effected through the.
open top of the mould box and also through the hollow boss on the standard, the
wood plug having been previously removed.
Having filled and covered the inside and outside of the pattern with sand the two
half-mould boxes, each half box carrying its half pattern, are separated from each
other by sliding them upon their seat, and after laying them borizontally the two half
patterns are removed from them. The two half moulds in the half-mould boxes
are then finished in the usual way. On separating the half-mould boxes with their

page_text: patterns the green sand core remains firmly supported upon the core rod. A mould
and core are thus produced at one and the same time. After removing the half,
patterns the two half moulds in the mould boxes are again arranged upon the seat
of the bed plate, and are closed by a sliding motion upon one another and around
the core, and the mould and core are ready for the casting of a pipe.
In making a mould and core for casting a bend pipe the parts of the apparatus
are arranged so as to mould and cast the straight part of the pipe in a horizontal
position, the bend part being vertical. We, however, make the core rod in two
separable parts, the vertical part being connected to the horizontal part by screwing.
or other connection. We also make an opening in the pattern for filling the interior_
of the pattern with sand. In other respects we proceed to make the mould and
core in the manner herein-before described with respect to a branch pipe:
"
The method of and apparatus for making moulds and cores for casting branch.
and bend pipes may be applied to the making of moulds and cores for casting
straight pipes and other hollow articles, but for making straight pipes and other.
hollow articles the core may be made separately from the mould in the following
way We take two half-core boxes, and having joined them together we place in
the axis of the core box a core rod, and ram sand into the core box, so as to form a
core.
'
-
Having separated the two parts of the core box from the core the latter is dried,
and thereby hardened.
..We make the outside mould by moulding in two half-mould box in the manner
herein before. described or in the usual way. The core supported by its core rod
being placed and fixed in the axis of the mould, the mould and core are ready
for the casting process.
We will now proceed to describe, with reference to the accompanying Drawings,.
the manner in which our Invention may be performed.
Figure 1 represents in elevation, and Figure 2 in vertical section, our improve-
ments in making a mould and core for casting a branch pipe; Figure 3 represents
a horizontal section of the same; and Figure 4 is a plan of the upper side of the
same. The vertical section, Figure 2, is taken on the line c, d, Figure 3, and the
horizontal section, Figure 3, is taken on the line a, b, Figure 2.
The same letters of reference indicate the same parts in Figures 1, 2, 3, and 4.
e is the horizontal base-plate.of the moulding apparatus provided with step seats
at ², e². The position of the seats e², e², on the base plate e is best seen in the
horizontal section, Figure 3; f, g, are the two half-mould boxes provided with the
usual eyes or snugs for fixing the two half boxes together by means of cotters and
wedges. The mould boxes are perforated for permitting of the ready escape of the
gaseous products evolved during the casting operation. The base parts of the two
mould boxes e, f, are supported, and are capable of sliding upon the step seats e³, e²,
on the base plate e, the base of the said mould boxes being shaped to fit upon the
said step seats (see Figure 2); h is a standard or upright bolted to one end of the
base plate c. To this upright a horizontal ledge or bracket i is fixed by the
screw pins and nuts and slots at 2. By means of the said screw pins and slots the
height of the said horizontal ledge or bracket i is made capable of adjustment to
suit the different sizes of pipes to be made. The said horizontal ledge or bracket i
is for the purpose of supporting the horizontal or branch parts of the mould boxes
k, 1, (see Figure 2). On the head of the upright or standard h is a tubular boss 2³,
which projects into the half-mould boxes f, g. Through this boss 3 a slightly
conical wood plug m is passed, the said plug entering the branch parts of the half
patterns k, l, in the half-mould boxes f, g, and supporting the said half patterns at
those parts firmly in their places. The vertical parts of the half patterns k, l, are
supported at bottom on the cross bar n² (see Figure 3), carried by the base plate e,
and the lateral position of the said half patterns in their respective half-inould
boxes is adjusted by the set screws p, p, passing through and working in the said
half-mould boxes (see Figure 1); q is the vertical core rod upon which the core in
green sand of the principal or straight part of the mould is made, and is the..

page_text: branch core rod upon which the core for the branch is made, the said branch core
rod being made capable of ready removal from the principal coro rod q. The said.
branch core rod is fitted with a series of " gaggers or hook pieces s for holding
the sand upon as represented in Figure 2. The base of the vertical core rod q
takes into the socket n on the cross bar n³ of the base plate e, and its axial position
in the half patterns. k, l, is adjusted and fixed by the set screw n². The branch.core
rod is situated at one end in the principal or vertical core rod q, and its outer end
is supported by..the wood plug m in a hole in which the outer end of the said
branch core rod takes when the plug is introduced into the half patterns k, l, 89.
seen in Figure 2.
?"
We will now proceed to describe the making of a mould and core according to
our Invention. The compound core rod q, r, having been placed and fixed in the
socket n the two half patterns k, l, are arranged about the said core bar and sup-
ported by the cross bar n³ and plug m, the latter also supporting the branch core
rod r.
The half-mould boxes f, g, are next moved forward upon their seats e², e³, 2, by
means of their handles f, g, until their opposed edges meet, thus forming around
the half patterns k, l, a complete mould, the lateral adjustment and fixing of the
half patterns in the half-mould boxes being effected by the set screws at p. P..
Sand is now rammed outside the patterns A, l, to form the outside mould, and sand
is also rammed inside the said patterns and about the compound core rod to form
the core, the ramming of the sand being effected in the ordinary way of making
sand moulds. The filling of the outside and inside of the patterns k, l, with sand
is effected through the open top of the mould box f, g, and also through the hollow
boss 3, the plug m having been removed. The several parts of the mould now
occupy the respective positions represented in Figures 1, 2, and 4, the inside and
outside the pattern being filled and covered with sand in the manner described,
the two half-mould boxes f, g, being unfastened and separated from each other by
sliding them upon their seats es, es, and i, each half-mould box carrying its half
pattern. The half-mould boxes f, g, are next laid horizontally and their half
patterns k, l, removed from them. Two half moulds are thus produced, which are
finished in the usual way. By the separation of the two half-inould boxes with
their patterns as described a green sand core remains firmly supported upon the
compound core rod q, . The mould boxes f, g, containing the half moulds are
again arranged upon the seats e², e², i, of the bed plate e and bracket h, and by the
sliding of the said boxes upon the said seats they are closed upon one another and
around the core supported on the bed plate, and the mould and core are ready for
the casting of a pipe in the ordinary way.
Figure 5 represents in longitudinal section, Figure 6 in plan of upper side, and
Figure 7. in end elevation, a mould and core for casting a bend pipe.made accord-
ing to our Invention. The parts of the apparatus are arranged so as to mould
and cast the straight part of the pipe horizontally, the bend and socket parts being
vertical as represented. The core rod is made in two pieces, marked respectively
9, 7, which are connected together at by screwing or other connection which will
permit of their ready separation. By making the core rod in two parts, capable of
separation, the said core rod may be readily removed from the cast pipe, and the
same core rod may be used for the moulding of a great number of cores. The core*
rod for the branch pipe, Figures 1, 2, 3, and 4, may be similarly constructed.
An opening is made at u in the top of the pattern k, l, for filling the interior of
the said pattern with sand. The base parts of the half patterns k, l, rest upon the
supports t, t, (see the section; Figure 5).
In making the mould and core of a bend pipe according to our Invention, and by
the use of the apparatus represented in Figures 5, 6, and 7, we proceed in the
manner herein-before described and illustrated in Figures 1, 2, 3, and 4, with
respect to the making of a mould and core for a branch pipe, and corresponding
parts of the apparatus are marked with the same letters of reference.
The improvements in making moulds and cores for branch pipes and bend pipes,
ر

page_text: and the apparatus used, herein described and illustrated in Figures 1 to 7, may be
used for making moulds and cores for straight pipes, hollow columns, and other
hollow metallic articles, such changes in the process and the details of the apparatus
being made as are necessary to adapt them to the particular article being moulded.
Figure 8 represents in elevation, Figure 9 in vertical section partly in elevation,
and Figure 10 in plan of upper side, our improvements in and apparatus for
making green sand cores separately from the moulds.
Figure 11 represents detached the ramming "kellet" used in making the core.
Figure 12 represents in vertical section a green sand core made according to our
Invention in combination with the outside mould, the parts of the mould being
ready for the casting of a pipe vertically.
:
The same letters of reference indicate the same parts in Figures 8, 9, 10, 11,
and 12.
In making a green sand core separately from the outside mould, we take a hollow
conical core rod or bar a, represented in Figure 9, the said core rod or bar being.
perforated for the escape of the gaseous products evolved during the casting process.
The said core bar a has a conical end or base b, the wide end of the cone b having
the diameter of the core to be made. The said core bar a, b, is supported firmly
during the making of the core by means of the ramming "kellet". or base plate c,
the said "kellet "being provided with a. conical seat or socket d of a shape and
size proper for receiving the conical base or end b of the core rod a. We also take
core box
e, e, made in halves, preferably hinged together. The interior of the core
box e, e, is bored truly, and has the diameter of the core to be made. In making
the core, the core bar a, b, is supported in the seat or socket d of the ramming
kellet .C, and the half-core boxes e, e, are placed around the said core bar, and closed
upon one another in the position represented in Figures 8 and 9, that is, the base
of the closed core box e, e, is supported on the ramming kellet c, the inside of the
said base of the core box bearing against the cylindrical outer sides of the seat or
socket d.
b.
Having thus arranged and fixed the core box e, e, green sand is rammed into the
annular space between the said core box and the core bar a in the ordinary way of
making a sand mould, and a green sand core thereby formed as represented in.
Figure 9, and marked.f. The core box e, e, being opened upon its hinges, the core
fis liberated therefrom; and is left supported upon and attached to the core bar a,
The core is now removed to the drying stove, where it is subjected to heat sufficient
to "skin dry" it. The core is now ready to be inserted in the outside mould of the
pipe to be cast, as represented in Figure 12, where the said core is shown in con-
junction with the outside mould g, g, made in the half-mould boxes h, h, the said
outside mould g, g, being made in the ordinary way.
For supporting the core and mould for casting, we use a "kellet" or supporting
plate of the kind represented in Figure 12, and marked i, the said plate or kellet
being furnished with a taper seat or socket k, of a size proper for the taper end or
base b of the core bar a to fit in as represented in the said Figure 12.
33
Having arranged the outside mould g, g, around the green sand core f, and.
formed the
" runner or "get" in the ordinary way, the mould is ready for the
casting of the pipe, the space between the core and outside mould in which the.
metal is cast being marked l.
By making cores according to the last described method, and by the use of the:
apparatus represented, no hay-bands are required on the core bar, and the core bar
in consequence of its taper figure can be readily drawn out of the cast pipe.
By means of the conical base on the core bar, and the construction described and
represented of the ramming, and supporting kellets, the core bar is supported
centrally during the making of the green sand core and the casting of the pipe, and
the crushing of the core is prevented.
By the green sand herein-before referred to, we mean fresh sand, or sand which
has undergone no preparatory treatment, which unprepared sand is commonly.
called by ironfounders, green sand,

page_text: Having now described the nature of our Invention, and the manner in which the
same is to be performed, we wish it to be understood that we do not limit ourselves
to the precise details herein described and illustrated, as the same may be varied
without departing from the nature of our Invention, but we claim as our Inven-
tion,―
First. The improvements in making moulds and cores for casting metallic gas
and water pipes and tubes, hollow columns, and other hollow metallic articles
herein-before described and illustrated with respect to Figures 1, 2, 3, 4, 5, 6, and 7
of the accompanying Drawings, that is to say, making the core in green sand at the
same time as the outside mould, substantially as described and illustrated, whereby
the use of the ordinary loam cores and core chaplets are dispensed with.
Secondly. The construction and combination of the parts of apparatus to be used
in the production of moulds and cores for casting metallic gas and water pipes and
tubes, hollow columns, and other hollow metallic articles herein-before described
and illustrated in Figures 1, 2, 3, 4, 5, 6, and 7 of the accompanying Drawings.
Thirdly. The improvements in and apparatus for making green sand cores used
in casting metallic gas and water pipes and tubes, hollow columns, and other hollow
metallic articles herein-before described and illustrated in Figures 8, 9, 10, 11, and
12 of the accompanying Drawings, that is to say, making the said green sand cores
upon a core rod or bar arranged within a core box, the said core rod or bar and
core box, and the appliances connected therewith, being constructed and used sub-
stantially as described and illustrated.
In witness whereof, we, the said John Roberts, and Samuel Roberts, and
Benjamin Fenton, have hereunto set our hands and seals, this Thirteenth
day of February, in the year of our Lord One thousand eight hundred
and seventy-nine.
0 Witness,
JOHN HAMPTON,
West Bromwich.
JOHN ROBERTS.
SAMUEL ROBERTS.
(L.S.)
(L.S.)
BENJAMIN FENTON. (L.S.)