IMPROVEMENTS IN THE MANUFACTURE OF CASTINGS, AND Apparatus
Year: 1873

page_text: LETTERS PATENT to Jacob Geoghegan Willans, of 9, St. Stephen's
Crescent, Bayswater, in the County of Middlesex, for the Inven-
tion of "IMPROVEMENTS IN THE MANUFACTURE OF CASTINGS, AND Apparatus
"
PROVISIONAL SPECIFICATION left by the said Jacob Geoghegan Willans
at the Office of the Commissioners of Patents, with his Petition, on
the 3rd June 1873.
I, JACOB GEOGHEGAN WILLANS, of 9, Saint Stephen's Crescent, Bays-
water, in the County of Middlesex, do. hereby declare the nature of
the said Invention for "IMPROVEMENTS IN THE MANUFACTURE OF CASTINGS, AND
APPARATUS CONNECTED THEREWITH," to be as follows:-
:-
My Invention consists, firstly, in adding hydrocarbon (such as pitch,
tar, resin, oil, or solutions of them) to sand, clay, alumina, or their
compounds, or to other refractory materials, so that on the mixture being
dried, or its volatile matter expelled by heat, some of its carbon in a

page_text: divided state will be left amongst the sand or other material used as
moulds, or in the crucibles used for melting the metal for castings.
The hydrocarbon may in some cases be mixed up with the sand, etc.,
and the mould formed therefrom before the drying, or it may be added
to the sand or other material and [the mixture dried, or its volatile
matter expelled by heat before it is used to form the mould.
The hydrocarbon in some cases may be applied on the surface of the
mould in a sufficiently fluid state to penetrate it, and the mould after-
wards dried or heated if required.
One or more of the foregoing carbonaceous compounds may be mixed
with the material for pots or crucibles to be used in melting metals for
castings.
My Invention, secondly, includes the application of metallic oxides or
other substances, acting upon carbon at a red heat to the surface of
steel and iron castings before they are finally placed in the annealing
pots or ovens. I place the oxide in an adhesive manner on the entire or
on part of the casting by painting it on or otherwise.
SPECIFICATION in pursuance of the conditions of the Letters Patent,
filed by the said Jacob Geoghegan Willans in the Great Seal Patent
Office on the 3rd December 1873.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, JACOB
GEOGHEGAN WILLANS, of 9, St. Stephen's Crescent, Bayswater, in the
County of Middlesex, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her
Letters Patent, bearing date the Third day of June, in the year of our
Lord One thousand eight hundred and seventy-three, in the thirty-sixth.
year of Her reign, did, for Herself, Her heirs and successors, give and
grant unto him, the said Jacob Geoghegan Willans, Her special licence that
he, the said Jacob Geoghegan Willans, his executors, administrators, and
assigns, or such others as he, the said Jacob Geoghegan Willans, his
executors, administrators, and assigns, should at any time agree with, and
no others, from time to time and at all times thereafter during the term

page_text: therein expressed, should and lawfully might make, use, exercise, and
vend, within the United Kingdom of Great Britain and Ireland, the
Channel Islands, and Isle of Man, an Invention for "IMPROVEMENTS IN
THE MANUFACTURE OF CASTINGS, AND APPARATUS CONNECTED THEREWITH," upon
the condition (amongst others) that he, the said Jacob Geoghegan
Willans, his executors or administrators, by an instrument in writing
under his, or their, or one of their hands and seals, should particularly
describe and ascertain the nature of the said Invention, and in what
manner the same was to be performed, and cause the same to be filed
in the Great Seal Patent Office within six calendar months next and
immediately after the date of the said Letters Patent.
NOW KNOW YE, that he, the said Jacob Geoghegan Willans, do hereby
declare the nature of his said Invention, and in what manner the same
is to be performed, to be particularly described and ascertained in and
by the following statement:-
My Invention consists in mixing compounds of carbon and hydrogen,
such as pitch, tar, resin, oil, or solutions of them, which on evaporation
by heat leave a carbonaceeous residue with sand, clay, or other refractory
materials in a state of division, for the purpose of using the mixture to
form entirely or in part moulds for castings.
The mixture, with or without other substances commonly applied,
may be used to form the mould, and afterwards the mould may be
sufficiently heated to evaporate the volatile and gaseous matter there-
from, so as to leave the resulting carbonaceous residue between or coating
the particles of sand, or clay, or other material composing the mould;
or the mixture of the sand, clay, or other refractory material with
hydrocarbonaceous substance may be heated to expel the volatile
matters, and afterwards sift it to the usually required state of division
before it be used to form the mould.
By these methods the carbon will be more finely intermixed through
the sand, or clay, or other refractory material than if ground solid carbon
had been used.
In the making of other than chill moulds for steel castings it is cus-
tomary to use ground burnt clay, and ground coke, or graphite along
with some binding substance, such as raw clay or farinaceous matter,
the proportions of each being variable and well known steel founders:

page_text: My improvement is to apply the hydrocarbonaceous mixture in place
of wholly, or in part, both the burnt clay and the ground carbon hitherto
used, and in a like state of division. I prefer to use an equal bulk to both
of these after it has been subjected to such heat as will have expelled
its volatile matter, and left the particles of sand or clay or other
refractory material coated or finely intermixed with the carbonaceous
residue.
I prefer to prepare the material by mixing up and tempering well
with ground raw Stourbridge clay one-sixth its weight of coal tar, and
with ground burnt Stourbridge clay I mix and temper one-fifth its weight
of coal tar.
I charge the mixture of either of these into a retort, and keep it at a
low red heat until the mass be charred, and its volatile matter expelled.
I then withdraw the charge with little access of air into close vessels, or
cool it with water. The charred mixture is afterwards sifted to the 1
required state of division for use in place of ground burnt clay or
ground carbon hitherto applied. Moulds of this mixture may also be
used for cast iron and other metals.
I sometimes use the finest portion of this charred mixture for forming
the interior surface of the moulds for castings. When the mould is of 2
baked sand or loam I apply the fine sifting wetted with water to form
the surface that the fluid metal will be in contact with, but if green
sand be used I apply the finest siftings as charcoal dust is now applied
to form the surface of the mould.
What I claim in respect to this part of my Invention is the casting of 2
steel or other metals in moulds formed entirely or in part of clay, sand,
or other refractory material containing a carbonaceous residue resulting
from the evaporation of a hydrocarbonaceous substance previously
intermixed and heated therewith, substantially as described.
My Invention further includes the manufacture of pots or crucibles 3
used in melting steel and other metals for casting into chills or other
moulds. In the making of crucibles for this purpose as now commonly
practised, ground burnt clay, and ground coke, also sometimes other
refractory materials, such as plumbago or sand, are added in variable
proportions well known to crucible makers to the unburnt plastic clay 3
used in making the crucible, in place of such ground burnt clay and
such ground coke or other refractory material.

page_text: I substitute wholly or in part for each clay or other refractory material
with which a hydrocarbonaceous substance, such as pitch, tar, resin, oil,
that will leave a carbonaceous deposit on being strongly heated in a
retort had been mixed.
I prefer to intermix and temper with raw Stourbridge clay, or with
burnt Stourbridge clay, both sifted to the usual size, the same pro-
portions of coal tar as before specified for the moulding material, namely,
one-sixth or one-fifth its weight. I char the mixture in the same
manner, and after it be cooled in the same way I sift it for use.
I substitute preferably an equal bulk of this charred material for the
ground burnt clay, and also an equal bulk for the ground coke or other
refractory material hitherto used.
The following mixture will make a good crucible :-Five measures of
ground raw Stourbridge clay, one and one-eighth (%ths) measures
sifted charred burnt clay and tar mixture, and one measure sifted charred
raw clay and tar mixture.
Pitch or resin reduced to a fine powder may in some cases be mixed
with the moist plastic clay from which the crucible be made, or the
pitch or tar may be mixed up with the burnt clay, and then used in the
construction of pots or crucibles; but I prefer to use the mixture in the
charred state.
I claim in respect to this part of my Invention the use in the manu-
facture of pots or crucibles (for melting metals for casting into chills or
other moulds) of clay or other refractory material with which is inter-
mixed a carbonaceous residue resulting from the evaporation of a hydro-
carbonaceous substance heated therewith, substantially as described.
I also claim, in the manufacture of pots and crucibles for said purpose,
the addition of a hydrocarbonaceous substance such as described in a
divided or divisible state to the clay used in their construction.
My Invention lastly includes the application of metallic oxides, such
as oxide of iron or other substances acting upon carbon at a red heat,
such as salts of iron to the surface of steel or iron castings before they
are annealed without being embedded in oxidizing substances.
I prefer to use red hematite ore ground to a thick paint with water,
and I lay it with a brush on the entire or on part of the casting, pre-

page_text: fering to give a thicker coating to the more solid parts of the casting.
I afterwards anneal the castings as steel castings are generally annealed,
without their being embedded in oxyde. The oxydizing substance in
contact with the casting will more or less increase the softening effect
of the annealing process.
I claim in respect to this part of my Invention the annealing steel
and iron castings with an adhering, oxydizing substance without the
casting being embedded therein.
In witness whereof, the said Jacob Geoghegan Willans, has
hereunto set his hand and seal, this Second day of December,
in the year of our Lord One thousand eight hundred and seventy-
three.
J. G. WILLANS. (L.s.)