Improvements in-Moulds Chiefly Designed for Use in the Manufacture of Armour Plates.
Year: 1886

page_text: Improvements in-Moulds Chiefly Designed for Use in the
Manufacture of Armour Plates.
3.
I'HENBY HARRIS LAKE, of the firm of Haseltine, Lake & Co., Patent Agents,
Southampton Buildings, in the County of Middlesex 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 certain improvements in molds for casting compound
ingotá, designed more especially for manufacturing armor plates, or plates having
considerable width but comparatively little thickness, the said plates being in
layers of hard and soft, steel and adapted for use in protecting the sides of
fortifications, ships, etc..
.
The object of this invention being to simplify and facilitate the process of
casting such ingots and to accomplish the same without handling or adjusting the
mold or parts thereof, during the said process, and to secure a more perfect union
of layers.
The invention consists in the combination and arrangement of the several parts
which constitute the mold and in the process or method of casting compound ingots
thereby substantially as will be hereinafter, fully and specifically described and
finally embodied in the clauses of the claim.
Referring to the accompanying drawings in which like letters indicate corre-
sponding parts in each of the several figures of the two sheets thereof. Fig. 1,
sheet 1, is a vertical, transverse, sectional view except, as to the funnels and cover,
of my improved mold. Fig. 2, is a plan view of the mold. Fig. 3, represents a
section through line y, of Fig. 4, and said Fig. 4, is a plan view, broken away at
one corner, in which is shown certain modifications in said molds. Fig. 5, is an
enlarged detail sectional view. Fig's. 6 and 7, sheet 2, represent a sectional view
and an elevation, respectively, of my improved mold arranged in an inclined
position and having a single funnel. Fig. 8, is a plan and Fig. 9, is an elevation,
showing additional features of the mold and Fig. 10, is a side elevation of what
may be termed a second cover to be used after one layer of an ingot has been cast.

page_text: In said drawings a, indicates a bottom plate designed to be arranged horizontally
on a suitable bed or support, and is provided with suitable bearings to receive or
hold ends of certain binding bars or bolts, c, c. b, b, are suitable side pieces which
are movably arranged on the bottom plate a, the said side pieces having much
greater length than vertical-width, and being disposed on said bottom plate so as
to form a hollow receptacle for molten metal. Said side pieces or one or more of
them are formed to receive a funnel or funnels d, d', which latter lead the poured
metal from the ladle or crucible to the hollow receptacle of the mold. When more
than one funnel is employed, the exits therefrom are formed at different elevations,
as indicated in Figs. 1 and 3, so that when the lower exit is filled with the lower
layer of metal the upper funnel may be employed in casting the upper layer or
layers. By using a plurality. of funnels, arranged as above described the metal
flows evenly and smoothly over the surface, thus having its quality greatly
improved, instead of falling from a greater height upon the hard bottom, whereby
it is broken into spray, resulting in the production of a less perfect cast.
Upon the movable side pieces b, b, is placed a top plate e, which is suitably
secured thereon by bolts c, or other suitable means so as to fix the sides in their
relative positions with sufficient firmness to resist the weight of the molten metal
and yet allow the same, when the pressure of the hardening and expanding metal
is brought to bear thereon, to give or move outwardly so that the mold will not be
broken. One method of fixing or binding the parts together is shown in Fig's. 3,
4, and 5, in which the side pieces b, are shown to be vertically slotted as indicated
at f, in said Fig's, or as an alternative construction the top and bottom plates may
be slotted a indicated at f1, Fig's. 1, 6, and 8, the slots extending at right angles to
the side pieces of the mold or in the direction of movement. of said side pieces.
The said slots however may be dispensed with and the binding bars or bolts be
secured on the outside of the mold away from said side pieces as shown in Fig. 2.
It is preferable however to pass the binding bars or bolts c, through the bottom and
top plates and the side pieces and also through the braces h, Figs. 1, 2, 3, 4, and 5, so
that the said parts are firmly bound together, the binding bars or bolts c, in Figs. 1,
2, 3, 4 and 5, being keyed by wedges i, i, by means of which the parts are brought
into intimate frictional contract so that great, or very considerable force such as is
supplied by expanding metal, is required to cause one part to move on the other.
No especial provision is needed for vertical expansion when the plates to be cast
are to be thin-say one or two feet in thickness as the expansion is not sufficient
to make such provision necessary.
To provide for vertical expansion, in casting thick plates, the mold is held
together by bolts c¹, c, Fig. 6, which extend through the bottom and side and top
plates, and the bolts c³, c³, which extend through the bottom and side plates, the
heads lying in countersunk recesses at the outer edges of the said side plates as
indicated in Fig's. 6, 7, 8, 9 and 10, so as not to interfere with a proper engage-
ment of the cover with the side plates and edges, while the lower extremities of
Baid bolts c², c³, project below the bottom and there receive springs g³, g³, and
nuts, . The side plates of the second cover hereinafter referred to, are bolted in
like manner to the top plate e as illustrated in Figs. 6, 7, and 10. The bolts o¹
move in the slots f, Fig. 6 to give or allow the lateral motion and their heads are
arranged with springs and nuts as above referred to. The said springs having
power to hold the parts together while the casting is in a liquid form, but allowing
a slight separation as the casting expands in solidifying.
The advantage of placing the mold in a tilted or inclined position as shown in
Figs. 6 and 7, is that by being in this position the impurities in the molten metal,
when the mold is filled or partly filled with said molten metal, are caused to rise
to one place in the molten metal and not be diffused over the whole upper surface.
In casting the ingot in the improved mold as shown in Fig's. 1, 2, 3 and 4, the
parts of the mold being disposed and fixed in the relations shown, the bottom
is first covered with molten metal, after having calked the joints with fire clay
or other material, the metal being poured through funnel d¹ and allowed to rise,
J

page_text: .
partially filling the chamber as shown at m, in Fig. 3, said metal being of softer
quality than the second layer which is introduced as follows; As soon as a crust is
formed on the upper surface of the first layer and before it has cooled below
welding heat a second layer of harder metal is poured through the funnel d,
flowing over the first and perfectly adhering thereto, so that the two become
integral though varying in quality.
In Fig. 7, the metal is poured through the funnel d, and forms in the chamber of
the mold the first lower layer of the compound ingot, the said lower layer being
preferably of softer metal and the thicker of the two layers of the complete ingot
and forming the backing of the finished armor plate; After the layer thus cast has
partly cooled as described above, the cover e³, is removed and a second cover e³, b³;
illustrated in Fig's. 6 and 10, is substituted for it forming in the mold a chamber
above the first casting, which is filled with an upper layer of harder metal than
that of the first casting before the said first casting has cooled below a welding
heat; The second cover is also provided in the side wall or other suitable position
therein with a perforation or opening for the funnel as at k³, said funnel being.
either the one first used in casting the bottom layer, which funnel is broken, from
said casting as soon as the metal becomes hard enough to prevent its flowing
through the perforation ³, or another independent funnel.
When the first is used. I form the side walls or plates through which the per-
foration passes as indicated in Fig's. 8 and 9, in which said side wall or plate is .
shown to be in two parts one of which 6, Fig. 9, is removable to allow the said
funnel to be broken away from the casting and then part 64, be replaced before the
second cover is arranged in position, as will be understood.
The removable part referred to marked b, in Fig. 9, slides in suitable ways
formed in or on the body of the side plate, as indicated in Fig. 8 in dotted outline.
Under some circumstances the funnel d, may be connected with either the top or
bottom plates, for example, the first layer of the ingot being cast, the metal for the
second layer or ingot may be poured through a funnel attached to the top plate or
cover as will be understood, without disturbing the first funnel until after the
ingot is completed and in casting the first layer the same may be done by ordinary
bottom casting, the funnel entering the mold from the bottom.
In the improvement herein described, the covering part or parts lie horizontally,
or approximately horizontally, over the ingot layer first cast so as to prevent an
overflow when the mold is tilted, or if it be in a tilted or inclined position, to
prevent such overflow at the lower edge. The second cover e³, is placed in position
above the first casting after the latter bas sufficiently hardened, but before it has
cooled below a welding heat, it lies a little way above the horizontal or approxi-
mately horizontal. upper surface of the ingot, parallel or approximately parallel
there with, forming a vertically contracted but horizontally extended chamber
therewith into which the metal is caused to enter to form a thin second layer, the
two layers welding very perfectly together, because the first casting is not yet
cooled below the requisite temperature. The horizontal position of the cast metal
layer secures a larger bearing surface beneath the liquid mass and but little lateral
pressure so that the movable sides are not forced until said mass begins to set or
harden at which time there is but little danger of the metal escaping through the
opening joints as there is but little weight to cause the metal to burst the "skin
or crust which forms at the outside surfaces of the ingot, a disaster which
would be almost sure to happen were the ingot turned up edgewise, all as will be
understood.
"
Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is to be performed, as communicated to
me by my foreign correspondent, I declare that what I claim is :-
1. The improved ingot mold herein described, combining the bottom and top
5 plates, movable side-plates, bolts, wedges or keys, and a funnel or apperture
through which the metal may be poured, substantially as set forth.

page_text: 2. The combination in a mold, with the bottom and top-plates and movable
side-plates, of funnels having their exits to the mold chamber at different
elevations, substantially as shown and described.
4
3. The combination of bottom and top-plates, movable side plates, a funnel or
funnels and braces h, said parts being arranged and combined, substantially as set
forth.
4. In combination with the bottom and top plates, intermediate movable side
plates, funnels, bolts which extend from the said bottom to the said top plates and
suitable keys which bear on said top plate and positively prevent vertical play or
movement thereof, substantially as set forth.
5. A mold substantially such as herein described for casting plates for covering
the exposed sides of ships, fortifications, etc., having yielding sides, a top plate or
cover and a bottom bolted together, and a funnel, combined substantially as set
forth
'
6. In combination, in an ingot mold, a top-plate or cover, movable, sides, and a
bottom, and bolts which extend from the bottom through the cover and hold the
sides in place, said bolts being arranged in slots which extend in the direction of
expansion of the solidifying metal or approximately at right angles to the sides of
the mold, substantially as set forth.
7. In combination with the bottom and top plates and movable sides, funnels d d¹
having their exits at varying heights in said movable sides, substantially as set
forth.
"
8. In an ingot mold, in combination, the bottom plate a, movable sides b, and
top plates e, e, the latter adapted to form a chamber with the ingot-layer first
cast in the mold,' substantially as and for the purposes set forth.
9. In an ingot old in combination, a bottom a, sides b, and top plate or
cover e, having sides b¹, adapted to raise said plate above the ingot to form a
horizontal chamber thereover, substantially as and for the purposes set forth.
10. In an ingot mold in combination with a bottom and movable sides and a
. top cover, bolts c' and springs or compressible pieces, said parts being arranged
and adapted to operate substantially as set forth.
11. In an ingot mold in combination with a bottom a arranged on an incline,
movable sides b, and suitable bolts for holding said parts together, of a cover e¹
and a second cover having movable sides b¹, substantially as and for the
purposes set forth.
12. A mold for casting armor plate, combining therein a bottom plate a,
sides b, one of which is provided with a movable piece b, and perforation k³, a
cover plate e, and a cover plate e³, having movable sides 61, one of which is per-
forated, and a funnel; substantially as and for the purposes set forth.
13. In combination in a ingot mold, a bottom, cover and movable sides and bolts
which extend from the bottom through the cover and hold the sides in place, said
bolts being arranged in' slots which extend in the direction of the expansion of the
solidifying metal or approximately at right angles to the sides of the mold, as set
forth.