Certain other Metals.
Year: 1886

page_text: Date of Application, 6th Dec., 1886.
Complete Left, 5th Sept., 1887.
Complete Accepted, 7th Oct., 1887.
with Certain other Metals.
I JOHN CLARK of 80 Great Brook Street Birmingham in the County of
Warwick, Metallurgist do hereby declare the nature of this invention to be as
follows:-
This Invention relates to a process of producing alloys of aluminum with other
metals such as steel, steely-iron, and iron, (whether combined or not with other
metals) the process of alloying the aluminum being effected without previously
reducing the aluminum to the metallic state by a distinct operation whereby such
alloys are produced with greater economy than has heretofore been practicable.
This improved process consists essentially in mixing the hydrated chloride of
aluminum produced as hereafter described, or the chloride of aluminum produced by
any known process, with certain re-agents which will, wholly or in part, decompose
the hydrated chloride of aluminum by combining with the chlorine and forming
volatilizable chlorides, and then submitting the resulting mass in the presence of the
metal or metals to be alloyed (or in presence of or nixed with the ores from which
such metals are reduced) to a melting or roasting heat, whereby the volatile chlorides
will be driven off and the reduced aluminum will be alloyed directly with the said
metal or metals without having been obtained in the metallic state separately by itself
by some previous and distinct operation. The desired alloy is thereby produced by a
more direct and economical process than heretofore.
For the purposes of my Invention, I may produce a hydrated chloride of aluminum
Al Cl, OH, by treating alumina with nitro-hydrochloric acid, or with commercial
hydrochloric acid, or with gaseous hydrochloric acid as it is produced in soda furnaces
or otherwise. I operate on the alumina as it is found in the several kinds of clay
kaolin, bauxite, cryolite or other natural source of alumina, also on alumina when
derived from these natural sources or from alum.
I will describe this preliminary operation as applied to common brown clay,
When
remarking that the other materials may also be treated in a similar manner.
parts are stated parts by weight are understood.

page_text: I take of common brown clay, (which may be used damp as dug from the earth or
be dried and ground to powder) eight parts, and intimately mix it with sufficient
commercial nitro-hydrochloric acid (commonly called "aqua-regia") to the
consistence of a thin paste. I then let it stand in earthenware pans for about a day
to mature, during which time the acid displaces the silica, and the chlorine of the acid
unites with the alumina converting it, wholly or in part, into an hydrated chlorido of
aluminum Al C, OH,; the clay at the same time loses its plastic character, gets short,
rotten and slightly red in color. For a similar purpose commercial hydrochloric
acid may be used to effect the decomposition described, but it takes a longer time
to do so.
Although I prefer to use commercial nitro-hydrochloric and bydrochloric acids, as
described, because they are readily procured, I also use the gaseous hydrochloric acid
as it escapes from the soda furnaces in which it is usually produced, or otherwise,
when it is more convenient to do so. In using it in this way, 1 moisten with water
the clay or other materials to be acted on, or I pass in a jet of steam with the gaseous
hydrochloric acid and in this manner treat it in a separate chamber adjoining the
soda furnace, to effect the decomposition previously described.
Instead, however, of manufacturing the hydrated chloride of aluminum as above
described I may take the anhydrous chloride of aluminum produced by any known
means, and convert it into the hydrate suitable for my process, by adding water.
to it.
In whichever way the hydrated chloride of aluminum may be produced, I then
intimately mix with the mass of hydrated chloride of aluminum, a re-agent which
will, wholly or in part, take up the chlorine. This re-agent consists of four parts of
lime which I prefer to be in the caustic state as quicklime. I grind the same to
powder, and as above described mix it with the hydrated chloride of aluminum.
On adding such re-agent the mass froths up considerably and gets very hot. I
let it stand a day or two to mature, and then dry it in shallow pans or trays.
The mass when dry is a light-orange colored powder which I then grind. The
excess of lime acts partly as a flux, but I also mix with it borax or other suitable
flux when required.
Ι
Although I prefer to use quicklime (on account of its moderate cost) as a re-agent
as described, I also use any re-agent having a stronger affinity for chlorine than
aluminum ; and those which I have found to give a good result are metallic zinc
(which may be granulated and reduced to powder) iron borings or filings,
ammonia or the carbonate or bi-carbonate of ammonia, which may be used separately
or combined.
The aluminum powder prepared as above is now ready to add to the metal or
metals intended to be alloyed with aluminum. These consist of steel, steely-iron, and
iron in their various forms as known in commerce; also to steel and iron when
combined with manganese, nickel, and tungsten, naturally or by addition in the
course of reduction.
In using the aluminum powder prepared as above described, I may either mix it
with the ore of iron when roasted, or when melted in the blast furnace or cupola,
in the course of which operation the aluminum is taken up by the iron and alloyed
therewith; or the aluminum powder may be mixed with the other materials used
in the conversion of iron into steel in the act of cementation; or the aluminum
powder may be mixed with the pieces of steel or steely-iron and be melted with
them in the ordinary melting pots, or the iron or steel in the form of turnings
or borings or other small pieces may be mixed with the prepared aluminum
powder and be melted in pots or otherwise in a similar manner; or the prepared
aluminum powder may be introduced with the blast of air into the Bessemer or
other converter, the aluminum being in either of these cases alloyed with the steel
in a similar manner. Or, the aluminum powder may be used in any other
convenient stage of the manufacture of steel or iron where the heat is prolonged
and intense, thereby effecting the alloying of the aluminum with such metals as
above described. The quantity of prepared aluminum powder to be used will

page_text: depend partly on the kind of furnace and the richness of the alloy to be
produced, but a proportion of from one to ten per centum, I find, is sufficient for
general use.
The other metals, namely: - manganese, nickel, and tungsten, when present in
the iron or steel will be found to alloy equally well with aluminum in presence of
the prepared aluminum powder when treated at the same time in a similar
manner.
I desire it to be understood that I do not restrict myself to the precise quantities
of the metals or other materials stated, because in alloying metals it is well known
that they do not follow a definite chemical combination, but are rather mixtures of
the metals operated on the quantities of each may therefore, be varied to some
extent without departing from the main characteristics of this Invention.
I have in a previous application for a patent for an Invention for alloying
aluminum with copper and certain other metals, described part of the process of
preparing the hydrated chloride of aluminum as herein described, but the present
application of such invention to alloy aluminum so obtained, with iron, steel, and
other metals combined therewith is quite novel, and the repetition so far as given
is by way of illustration, to render the present invention complete.
Dated this 6th day of December 1886.
J. CLARK.
By A. M. & Wm. Clark,
53, Chancery Lane, London,
Patent Agents.

page_text: with Certain other Metals.
I, JOHN CLARK of 80 Great Brook Street, Birmingham, in the County of
Warwick, Metallurgist; 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 process of producing alloys of aluminum with other
metals such as steel, steely-iron, wrought and cast iron (whether combined or not
with other metals) the process of alloying the aluminum being effected without
previously reducing the aluminum to the metallic state by a distinct operation,
whereby such alloys are produced with greater economy than has heretofore been
practicable.
This improved process consists essentially in mixing the hydrated chloride of
aluminum produced as hereafter described, or the chloride of aluminum produced by
any known process with certain re-agents which will, wholly or in part, decompose
the hydrated chloride of aluminum by combining with the chlorine and forming
volatilizable chlorides, and then submitting the resulting mass in the presence of the
metal or metals to be alloyed (or in presence of, or mixed with, the ores from which
such metals are reduced) to a melting or wasting heat, whereby the volatile chlorides
will be driven off and the reduced aluminum will be alloyed directly with the said
metal or metals without having been obtained in the metallic state separately by
itself, by some previous and distinct operation. The desired alloy is thereby
produced by a more direct and economical process than heretofore.
For the purposes of my invention, I may produce a hydrated chloride of aluminum
Al Cl, OH, by treating alumina with nitro-hydrochloric acid, or with commercial
bydrochloric acid, or with gaseous hydrochloric acid as it is produced in soda
furnaces or otherwise. I operate on the alumina, or the fluoride of aluminum, as
it is found in the several kinds of clay, kaolin, bauxite, cryolite, or other natural
source of alumina, also on alumina when derived from these natural sources or from
alum. I will describe this preliminary operation as applied to common brown clay
and the oxide of aluminum, remarking that the other materials may also be treated in
a similar manner. When parts are stated, parts by weight are understood.
I take of common brown clay (which may be used damp as dug from the earth, or
be dried and ground to powder) eight parts and intimately mix it with four parts
(more or less) of the oxide or hydrated oxide of aluminum, and intimately mix
therewith sufficient commercial nitro-hydrochloric acid, (commonly called " aqua
regia") to the consistence of a thin paste. I then let it stand in earthenware pans to
mature, during which the acid displaces the silica, and the chlorine of the acid unites
with the alumina converting it wholly or in part, into an hydrated chloride of
aluminum Al Cl, OH,; the clay at the same time loses its plastic character, gets
short, rotten, and slightly red in color. For similar purpose, commercial

page_text: hydrochloric acid may be used to effect the decomposition described, but it takes a
longer time to do so. In either case, the acid may be used cold, or be moderately heated.
Although I prefer to use commercial nitro-hydrochloric and hydrochloric acids as
described, because they are readily procured, I also use the gaseous hydrochloric acid
as it escapes from the soda furnaces in which it is usually produced or otherwise,
when it is more convenient to do so. In using it in this way, I moisten with water
the clay or other materials to be acted on, or 1 pass in a jet of steam with the gaseous
hydrochloric acid, and in this manner treat it in a separate chamber adjoining the
soda furnace to effect the decomposition previously described. Instead, however, of
manufacturing the hydrated chloride of aluminum as above described, I may take the
anhydrous chloride of aluminum produced by any known means, and convert it into
the hydrate suitable for my process, by adding water to it.
In whichever way the hydrated chloride of aluminum may be produced, I then
intimately mix with the mass of hydrated chloride of aluminum a re-agent which will
wholly or in part, take up the chlorine. This re-agent consists of four parts of lime
which I prefer to be in the caustic state as quicklime. I grind the same to powder
and, as above described, mix it with the hydrated chloride of aluminum. On adding
such re-agent, the mass froths up considerably and gets very hot. I let it stand a few
days to mature, and then dry it in shallow pans or trays. The mass when dry is a
light orange colored powder which I then grind. The excess of lime acts partly as a
flux, but I also mix with it borax or other suitable flux when required. I also mix
with the mass about one fourth of its weight of ground coke or other carbonaceous
matter which makes it light and spongy and promotes the reduction of the aluminum
or its combination with the iron referred to.
Although I prefer to use quicklime (on account of its moderate cost) as a re-agent
as described, I also use any re-agent having a stronger affinity for chlorine than
aluminum has; and those which I have found to give a good result are metallic zinc
(which may be granulated and reduced to powder) iron borings or filings, ammonia
or the carbonate or bicarbonate of ammonia, the carbonate or bicarbonate of soda or
potash which may be used separately or combined.
The aluminum powder prepared as above, is now ready to add to the metal or
metals intended to be alloyed with aluminum (or to the ores from which such metals
are produced). These consist of steel, steely-iron, wrought and cast iron in their
various forms as known in commerce; also to steel and iron when combined with
spiegellisen, chromium manganese, nickel, and tungsten, naturally or by addition in
the course of reduction.
In using the aluminum powder prepared as above described, I may either mix it
with the ore of iron when roasted, or when melted in the blast furnace or cupola, in
the course of which operation the aluminum is taken up by the iron and carbon and
alloyed therewith; or the aluminum powder may be mixed with the other materials
used in the conversion of iron into steel in the act of cementation, or the aluminum
powder may be mixed with the pieces of steel or steely-iron and be melted with them in
the ordinary melting pots; or the wrought and cast iron in the form of turnings or borings
or other small pieces may be mixed together in any proportion as may be required, and be
also mixed with the prepared aluminum powder and then melted in pots or otherwise,
in a similar manner; or the prepared aluminum powder may be introduced with the
blast of air into the Bessemer or other converter, the aluminum being in either of
these cases alloyed with the steel in a similar manner. Or, the aluminum powder
may be used in any other convenient stage of the manufacture of steel or iron where
the heat is prolonged and intense, thereby effecting the alloying of the aluminum
with such metals as above described. The quantity of prepared aluminum powder
to be used will depend partly on the kind of furnace and the richness of the alloy to
be produced but a proportion of from one to ten per centum, I find is sufficient for
general use. The other metals-namely-spiegeleisen, chromium, manganese, nickel,
and tungsten, when present in the iron or steel will be found to alloy equally well
with aluminum in presence of the prepared aluminum powder when treated at the same
time in a similar manner.

page_text: I desire it to be understood that I do not restrict myself to the precise quantities of
the metals or other materials stated, because in alloying metals it is well known that
they do not follow a definite chemical combination, but are rather mixtures of the
metals operated on; the quantities of each may therefore be varied to some extent,
without departing from the main characteristics of this invention.
I have in a previous application for a patent for an invention for alloying aluminum
with copper and certain other metals, described part of the process of preparing the
hydrated chloride of aluminum, as herein described, but the present application of
such invention to alloy aluminum so obtained with wrought iron cast-iron, steel, and
other metals combined therewith quite novel and the repetition, so far as given, is
by way of illustration to render the present invention complete.
Having now particularly described and ascertained the nature of the said
invention and in what manner the same is to be performed I declare that what
I claim is;
1st. The application of the process of treating alumina and the fluoride of aluminum
derived from any source, with nitro hydrochloric acid or with hydrochloric acid in
the liquid or gaseous state, so as to obtain a hydrated chloride of aluminum, as the
preparatory or first stage of the herein described process of alloying aluminum with
wrought iron, cast iron, and steel (and other metals when combined-therewith)-as-
herein specified, but I do not claim the use of hydro-chloric acid in the liquid state
irrespective of aud apart from the process as herein specified.
2nd. The process of alloying aluminum with wrought iron, cast iron, and steel (and
other metals when combined therewith) which consists in treating hydrated chloride
of aluminum with re-agents which will combine with the chlorine and form
volatilizable chlorides, and then bringing the prepared aluminum powder into intimate
contact with the metal or mixture of metals to be alloyed, or the ores of such metals,
and submitting the whole to a roasting or melting heat whereby-the volatile chlorides
will be driven off and the reduced aluminum will be alloyed at one direct operation
with the wrought iron, cast iron, and steel (and other metals combined therewith) as
berein specified.
3rd. In the herein described process of alloying aluminum with wrought iron, cast
iron, steel, and certain metals combined therewith, I claim the employment -as
reducing agents for the hydrated chloride of aluminum used, of lime (which I prefer
to use as caustic or quicklime) zinc, iron, and ammonia, or the carbonato or
bicarbonate of ammonia, or the carbonate or bicarbonate of soda or potash, separately
or mixed together, as herein specified.
4th. The obtaining alloys of aluminum with wrought iron, cast iron, steel, and
certain specified metals combined therewith, without reducing aluminum to the
metallic state by a separate and previous operation, thereby effecting greater economy
in the production of such alloys of aluminum with iron, cast iron, steel, and the
metals specified, than heretofore obtained.
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