Improvements in and relating to the Manufacture of Combined Iron and Steel Bars.
Year: 1894

page_text: Date of Application, 29th May, 1894-Accepted, 21st July, 1894
COMPLETE DIECIFICATION..
Improvements in and relating to the Manufacture of Combined
Iron and Steel Bars.
We, ALFRED HULSE MOORE, and GEORGE WHITLOCK, citizens of the
United States of America, both of 1337 Pacific Avenue, in the City of Brooklyn,
County of Kings, and State of New York, one of the United States of America,
Gentlemen, 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 has for its object the production of a billet or bar of steel encased
in iron, which will possess great tensile strength and a corresponding increase in
elastic limit.
The process consists essentially in enclosing scrap, new, or other form of steel in
a sheet-metal case, then placing the latter in an enclosure of muck-bars of iron,
forming a box-pile, then bringing the box-pile to the required temperature for
rolling, and lastly rolling the box-pile to the form required, of bar, billet, or other
form of bar.
In carrying out the invention we provide the instrumentalities shown in the
accompanying drawings, in which―
Figure 1 is a perspective view of the box-pile just prior to rolling, parts being
broken away.
Figure 2 is a detailed view of the sheet-metal case for receiving the steel.
Figure 3 is a cross-section of the box-pile.
Figure 4 is a longitudinal section of one end of the case.
The essence of the invention is in the process, consisting of the following steps:
First, enclosing the steel in a sheet-metalicase, the steel being either scrap or new
metal, and in any condition, either cold or molten; Second, surrounding the case
with bars of iron whereby a box-pile is created; Third, in heating the box-pile to
the proper temperature, and, lastly, in rolling the box-pile into the required form
to a finish from one heat.
The preferred form of sheet-metal case is constructed from a single piece of
sheet-metal, B, so shaped as to provide four thicknesses at each end to retain the
steel in place, each side having a flap 6 at its end to fold over and form a closure,
thereby providing the required thickness of metal to protect the steel. The sheet-
metal, which must be of a size equal to the length of the completed case, plus
twice the width of the same, one way, by twice the width, plus twice the height. the
other way.
.
The sheet is creased longitudinally; first at a distance from the edge equal to
one half the width, next at a distance from this crease equal to the height of the
box, next at a distance from the second crease equal to the width of the box.; next
a distance from the third crease equal to the height of the box, leaving a distance
to the other edge equal to half of the width of the box. After this is done' the
sheet is split along each crease from both ends for a distance equal to the width of
the box, which preferably made equal to its height.
Then the sheet is bent at the second and third creases until the metal outside of
these creases becomes at right angles to the part of the sheet included between
them, which piece A has its ends bent upward at right angles to the piece itself,
(which piece now becomes the bottom of the box,) the bent up portions forming a
part of the ends. The ends are completed by bending the ends of the side pieces
around at right angles to the sides as far as the slits will allow and riveting them
to the pieces already there.

page_text: •
The box is now ready to be placed down in between the muck-bars D of iron,
which have already been placed in such a manner that the box shall set on as well
as between them. After being placed between the muck-bars, the box itself is
filled with steel, either new steel is poured in, or old scrap steel is placed in the box,
then the box is closed by bending that part of the sides outside of the first and
fourth creases inward, until these parts of the sheet become parallel to the bottom;
these pieces C now become the top of the box, butting up against each other in the
centre. The small pieces of metal c which would now otherwise be extending
past the ends of the box a distance equal to the length of the slits in the first and
fourth creases, should have been bent inward before the sides were bent down, so
that they now form a part of the ends of the box, inside and parallel to them, or
else they form a part of the top of the box, being inside and parallel to the same,
as the case may be.
After this the box is covered by muck-bars, which are placed upon it in such a
manner that one bar shall lie directly over the seam where the two folds meet each
other in the middle of the top of the box; the muck-bars now completely surrounding
the box, which encases the steel equally thick upon all sides.
When in
The box-pile is heated and rolled in the usual well known ways.
heating for the rolling process, the iron cover or top of the box-pile becomes hot
enough to roll, the steel within the case will have reached a half molten state and
will be in a semi-fluid condition. In this form it throws off carbon which destroys
or consumes all of the sulphur or phosphorous contained in the iron, and cures it of
cold-short and red-short, making the billet equal to and superior to the best
charcoal iron, and with a gain of from forty to sixty per cent. in tensile strength
and elastic limit, than can be attained in either iron or steel by itself, or in any
combination attainable by any other processes.
The iron box or closure makes about one-half of the weight of the box-pile, and
it takes up just enough carbon to make it "best" iron, and not enough to make
it steel.
The steel being subjected to pressure in rolling while in a semi-fluid or molten
condition, is cured of porosity and has its tensile strength increased, which adds to
the safety of the bar or other article formed by the compound metal..
Importance is attached to the sheet metal case B, as by its use I practically
exclude the air, and the steel with which the box-pile is filled is heated to a
semi-fluid condition, as in a closed crucible, and while in this condition, is pressed
between rollers, the pressure curing the steel of all porosity and increasing the
tensile strength more than forty per cent. As soon as the sheet iron casing is
heated to a white heat, it closes up and clings about the steel and makes the case or
box-pile inside of the casing absolutely air-tight, preventing the loss of carbon
through the otherwise open ends of the box-pile. The carbon thrown off by the
-half molten steel consumes or drives off all sulphur and-phosphorous from the iron
casing or muck-bar and sheet iron, thus de-sulphurizing and de-phosphorizing and
carbonizing the iron just enough to make it what is known in the market as
"best" iron.
:
Having now particularly described and ascertained the nature of our said inven-
tion, and in what manner the same is to be performed, we declare that what we
claim is :-
1. The herein-described process of making a compound bar of iron and steel,
which consists in enclosing steel in a sheet-metal case and then surrounding the case
with bars of iron providing additional thickness at the ends, and then heating the
pile to the proper temperature for rolling, and lastly, rolling the pile into the
required form, substantially as described.
2. The herein-described box-pile, consisting of a sheet-metal case, scrap steel
-enclosed within said case, and an outer case of metal bars, substantially as shown
and described
3. The herein-described box-pile, consisting of a sheet-metal case composed of

page_text: bottom with end flaps, sides with end flaps, and a top of two parts with end flaps,.
scrap steel enclosed within said case, and an outer case of metal bars, substantially
as described.
Dated this 29th day of May 1801
JENSEN & SON,
77, Chancery Lane, London, W.C., Patent Agents.