IMPROVEMENTS IN THE TREATMENT OF STEEL AND OTHER METALS IN A MOLTEN CONDITION, AND IN MEANS AND APPARATUS ADAPTED THEREFOR, PARTS OF WHICH ARE APPLICABLE FOR OTHER PURPOSES." PROVISIONAL SPECIFIC
Year: 1880

page_text: LETTERS PATENT to George Webb, of Johnstown, in the County of Cambria
"
and State of Pensylvania, one of the United States of America, Engineer, for
an Invention of IMPROVEMENTS IN THE TREATMENT OF STEEL AND OTHER
METALS IN A MOLTEN CONDITION, AND IN MEANS AND APPARATUS ADAPTED
THEREFOR, PARTS OF WHICH ARE APPLICABLE FOR OTHER PURPOSES."
PROVISIONAL SPECIFICATION left by the said George Webb at the Office
of the Commissioners of Patents on the 13th January 1880.
GEORGE WEBB, of Johnstown, in the County of Cambria and State of Pen-
sylvania, one of the United States of America, Engineer. "IMPROVEMENTS IN THE
TREATMENT OF STEEL AND OTHER METALS IN A MOLTEN CONDITION, AND IN
MEANS AND APPARATUS ADAPTED THEREFOR, PARTS OF WHICH ARE APPLICABLE
FOR OTHER PURPOSES."
In carrying out my Invention I subject the melted steel or other metal to strong
compression, which is rapidly applied and maintained until the metal has set.
have devised a system for conveniently and effectively operating on quantities
made in the large way in modern practice. Steel in being cast into ingots does
not naturally pass from a liquid state into a dense solid. Cast iron is found to be
the most practical material for ingot moulds, but with this material for the mould
open spaces, termed pipings, will occur in the mass, especially near the surfaces,
evidently caused by the generation of a gas.
To reduce the imperfections to the smallest per centage of the mass the practice
of manufacturing larger and larger ingots has been adopted from time to time.
Nearly all the imperfections are near the surface. Theory (and it seems to be
largely supported by the practical results) indicates that the larger the ingot the
greater the proportion of clear homogeneous metal.
The practice has grown from time to time until very inconvenient and expensive
appliances are required for moulding, and for subsequently handling and hammering
or rolling large masses, even though the ultimate form of the metal may be a small
bar, rod, or wire, or at most a railroad rail weighing not more than one-eighth of
the original ingot. My Invention avoids this, and will largely reduce the percentage
of scrap in each ingot.
It has long been attempted to subject melted steel to pressure in its melted'
condition in the ingot moulds, but the operation has heretofore been conducted

page_text: under imperfect conditions, rendering it only partially successful. It has especially
involved much labor and delay, so that the work could not well be made continuous
and economical.
In the treatment of steel after it has arrived at its proper condition, time is a
very important element. In a Bessemer converter any holding of the melted mass
without blowing will allow the melted metal to flow backward and downward
into the passages through which air is admitted, and chilling there will ruin the
converter; any continued blowing beyond the proper moment will deteriorate or
destroy the steel; and if metal is retained in the converter laid on its side, the mass
soon cools so as to adhere to the lining of the vessel. A pouring of the mass
involves a necessity for its immediate treatment in moulds. My Invention is
intended to overcome the difficulties and to adapt the work to successful and
economical manufacture on a large scale, with repetitions rapidly and indefinitely
conducted.
I employ gas discharging sectional ingot moulds, which are or may be used
repeatedly without any preparation beyond a thin wash; the moulds are rapidly
filled with liquid metal. They are in long narrow sections strongly united;
provision exists for the escape of gases from all the joints. A great pressure is
applied and maintained on the limpid metal immediately after it is poured, and all
the movements may be effected easily at the right periods. Thus conditioned the
cavities in the steel will be avoided, and the resulting metallic mass will be dense
and homogeneous. Large charges may be disposed of with rapidity, and the
charges may succeed each other indefinitely.
I employ hydraulic pressure in a form of mechanism very powerfully working
and adapted for treating a single ingot at a time by one press. I can use a number
of presses together.
The provisions for conveying the molten metal from the converter, open hearth,
or other source of metal supply to the moulds may be worked out in different
forms. I cannot without experiment, which in this line of endeavour is excep-
tionally expensive, be able to determine which of the several modifications will
be most desirable for any special practice, and will therefore describe a number. I
esteem them all as forms of a general system, by which I seek to overcome the
difficulties heretofore met with in this very important branch of manufacture, by
operating on a scale of magnitude and with appliances adapted to a large
business, and yet to manufacture the steel in small ingots and of absolutely homo-
geneous steel.
According to one arrangement the hydraulic presses and accompanying mechanism
for receiving and holding the ingot moulds are arranged in straight parallel lines
with railway tracks between. Suitable cars moved by hand or otherwise on
one track carry large ladles of melted steel and supply two moulds at once; ready
means move each into place and give it pressure. Cars on another track carry the
ingot moulds with their contents away and bring fresh ones to be placed in position
and receive the melted material. Each series or row should be of sufficient length
to allow an ingot mould to be filled while another place in the series is being
supplied with a fresh mould, and another place is having the filled mould taken
away with its contents sufficiently cooled to retain its condition, and each may
hold the metal under strong pressure until it has slowly cooled to the required
consistency.
In one arrangement a mast with one or more arms, and provisions for being
raised and lowered, is favorably located for presenting a ladle at will to one or more
converters to receive the charge of melted steel, and also for transferring it to a car
or cars on suitable tracks or lines of rails.
The sections of my ingot mould are adapted, when applied together, to present a
smooth and cylindrical exterior and a smooth cavity of uniform rectangular section
on the interior, which cavity receives the melted steel and forms the ingot. The
surfaces of the ingot mould which abut together are accurately fitted together, but
instead of being left absolutely smooth are left with fine scores running across their

page_text: surfaces, such as result from filing with a coarse file. The scores may be actually
produced by that means, but I prefer that they shall be produced by machinery
having a motion analogous to planing.
This allows a junction on the surfaces sufficiently tight to prevent the passage or
even the entrance to any considerable extent of the melted steel in the joint; but
the fine scores in the surfaces allow the gases to escape which are emitted from the
melted steel or generated by the contact thereof with the cooler iron of the ingot.
mould sections.
The sections of the mould are held together by clamps, which are provided in
sufficient numbers, and with peculiar locking pieces or gibs, and embrace the ingot
mould at short distances apart along its length. The clamps are held by pivots to
swinging arms which are keyed fast on a turning mast. This latter is supported
with liberty to rise and sink, and is formed at the bottom with a foot which fits
tightly in a corresponding cylindrically bored recess in the supporting casting
adapted to receive water or oil through a passage from a pump or accumulator, in
order to lift the mast and its connections, and to lower them again when required.
On sufficiently raising the mast and the connected clamps and ingot moulds and
their contents, the whole may be swung around to allow the ingot mould to be
moved into the proper position to receive its charge of melted steel, and to be moved
back into the central position under the press to receive the compressive strain. It
will be understood that the ingot mould is lowered down until it rests firmly on the
support before the force of the hydraulic press is applied.
Before depositing the melted steel in the ingot mould a plate of common wrought
iron, previously prepared of a proper size and form, is introduced in the interior of
the ingot mould on the bottom. So soon as a proper quantity of the melted metal
has been introduced another small plate of rolled iron is placed on the top. I then
apply a piece of cold metal or "set" on the top of the upper plate, and the ingot
mould and its contents being swung around and lowered upon the bed in the
proper position the press is allowed to act.
The melted steel is ordinarily introduced into the ingot moulds at a temperature
a little above that at which cast iron melts. When the stream of melted steel,
falling from a considerable height into the ingot mould, strikes forcibly on the
bottom, there is risk of its affecting the integrity of the mould; this I prevent by
the bottom plate of wrought iron. The thin wrought plates becoming covered with
ordinary scale do not weld to the steel, but drop off in the rolling.
To remove the mould with the solidified ingot the locking pieces are removed,
the clamps thrown open, and the sectional moulds and their contents are seized by
properly shaped tongs which are attached to suitable carrying means.
A mast,
upright shaft, or swinging way may be employed for this purpose. The sectional
mould and its contents are brought to and deposited on a car on a track which is
located on the opposite side of the press from where the melted metal was poured
into the mould.
After being released from the clamps the sections of the mould are held together
by slight bands, which are afterwards to be removed.
The fresh mould may be held together in a similar manner.
The ingot, on being liberated from the sectional mould, is ready to be further
treated by rolling or hammering, either at the same or a subsequent heat, to induce
the desired form of a steel rail or other article, while the sections, etc., of the mould
may be treated with water and partially or entirely cooled, ready to be returned to
the position for use, fresh sets of sectional moulds being used in the interim. I coat
my moulds with a solution of highly magnesian limestone known as "dolomite,"
which I apply with a brush or by other suitable means.
In some cases I employ dolomite for the plates above and below my ingot. For
the purpose I evaporate the dolomite paste till it is very thick, almost dry, and then
press it into the required shapes under high pressure.
I employ a press which is compound, using in effect two bydraulic presses, one
of which receives the steam, water, or other fluid from a boiler, accumulator, or

page_text: other source, and by the motion of its plunger induces a greater pressure in another
mass of fluid, which acts in a second cylinder to apply a still greater pressure on
the plunger of the second press; this latter acts on the metal in the ingot.
The press is formed with a piston having a connected plunger, which is forced
down in the main cylinder by the admission of steam or water.
A second cylinder is employed having a stout piston working therein which
operates a connected plunger acting directly on a "set ;" the fluid above the piston
in this cylinder may constantly remain imprisoned. It may be water or other
inelastic fluid, replenished at intervals to compensate for leakages.
The pressure in the smaller cylinder is much greater than in the larger cylinder.
It is induced by the descent of the plunger of the larger cylinder.
In order to raise the piston operating on the "set" I admit water or steam
through a suitable pipe into the annular space under the said piston; a valve
controls the flow of this fluid. I can employ a corresponding pipe controlled by a
valve to admit fluid under pressure to the under side of the larger piston. In some
cases I can raise the piston operating on the "set" with such force as will induce a
pressure on the fluid above, which will, by its direct action on the lower end of the
larger cylinder, lift it and its connected piston. Any other efficient means may be
employed to raise these pistons and restore the press to its original condition, thus
releasing the ingot now under the press, and putting the parts in condition for
treating the next "set" of ingot moulds and contained metal fluid which may be
brought.
Parts of the apparatus are held together by suitable tie-rods, cross-pieces, and
supports.
The supply of liquid between the operating parts of the respective cylinders is
replenished, when required, from a suitable reservoir connected by a pipe and
passage, the opening to which is controlled by raising the piston out of its working
position by any suitable means.
The principal holes and "honey-comb" places are near the exterior of the ingots.
By applying the intense pressure before the exterior of the ingot has solidified I
prevent the development of gas, or hold it under pressure that forces it to the
surface, and it escapes through the slightly opened joints, instead of accumulating
in pipings and cavities of whatever name in the interior of the motal.
The cooling commences on the exterior, adjacent to the surfaces of the mould
sections and of the "set." It is found that a large ingot will set over its whole
exterior, so that it may be handled as a solid while the interior is still fluid, and,
if allowed, will "bleed" through any aperture which is burst or otherwise produced
in the tender skin. Inasmuch as the pipings and other cavities and imperfections
are mainly near the surface, it may not be necessary to hold the ingot under
compression until it is solid throughout, but it is essential to the success of the
operation that it be held awhile; the metal shrinks in cooling. It is better that
the pressure follow it up as it shrinks, until a considerable thickness of the surface
metal is set or solidified. Experiment will determine the period during which the
pressure should be kept up. I propose always to keep the full force of the steam
or water on my press, and consequently to maintain the full pressure on the ram
for a considerable period, during which the latter will descend slowly.
When the pressure has been maintained for a sufficient time the steam or other
fluid under pressure is shut off from the larger cylinder, and the fluid above its
piston is allowed to escape. Then both the larger and smaller pistons and their
connections are raised and the ingot is relieved from pressure.
A car moves on each of the tracks carrying a ladle, which is at each return filled
from one of the converters, and as each car is rapidly moved, step by step, along its
track, it is stopped at the proper points and tapped at two or more places to supply
the proper quantity to each ingot mould, which latter is, by the lifting and turning
of the proper carrying device, presented in the proper position to receive it, and
on being filled is promptly returned to its position under the press, and its contents
subjected to the required pressure and held so.

page_text: A car moves forward and back on suitable tracks adapted for bringing fresh
ingot moulds and placing them in position, returning loaded with the filled moulds
previously cooled under pressure to a point below that at which pipings form, to be
taken care of at a distant point.
.
Several masts may be arranged so that four or other number of ingot moulds
may be presented at once, and receive their supply of melted steel simultaneously.
In one arrangement the presses are arranged in a series along a single line of
railway, which railway extends close to the converter or other source of metal, and
is practically continuous, so that a car with a full ladle may go from the supply
with a full ladle in one direction, and return with empty ladle in the other
direction, or in the same direction, as convenience may require. The melted metal
is supplied to the several ingot moulds in the same general manner as above
explained.
According to another arrangement the presses are arranged in a circular or
nearly circular form. Each form of the devices may have a lift to accommodate
the ladle to the varying heights of the mouth of a converter, or other means may
be employed.
According to another arrangement I propose to use a circular track with a stout
broad ring carrying the ingot moulds thereon, with only one or two presses to exert
the required compressive force on the melted metal immediately after it is received
from the converter. Strong means are provided for holding the "set" down firmly
upon the melted metal after the force of the press is removed, and this pressure is
maintained as the ingot moulds and their carrying means are successively moved
around the circle until the ingots have had time to become certainly solid. Then
the confining means are released and the moulds are opened and the ingots removed.
The same or another set of sections is retained or placed on the carrying ring, and
the series are successively filled, held, compressed, opened, emptied, and restored to
a condition for refilling in proper succession.
In this arrangement the ingot holding means are, by preference, equally spaced,
so that in any part of the ring when one is presented to be pressed, another is
presented to one of the ladles to receive a supply of metal.
The converters pour into ladles held in cars on lifts. When a ladle is filled and
brought to the level of the bridge, it is moved horizontally on the latter to a point
over the ring which may be turned by any suitable power, and may run on
wheels to reduce friction.
The "sets" for use in this modification are made with a tapering top projecting
above the moulds. Stout levers, hinged together by joints, are formed with
tapering ends, which are held together by a link or other suitable holding means. The
conical top of the "set" is received in a corresponding recess in the levers. The
taper form allows it to be held strongly at different levels, simply by bringing the
levers more or less closely together by driving the link on to a greater or less
distance. The levers embrace fixed posts, one or both of which has a stout nut
threaded thereon.
Immediately under each press the ring rests on a very massive fixed support,
which constitutes the base of the press. The ring slides on these supports with
gentle force when moving.
I can employ open hearths, crucibles, or any suitable mode of producing the
molten metal. I can treat steel or other metals.
For locomotive wheels, car wheels, locomotive and car axles, crank pins, cross
heads, and many other useful forms; the proper condition can be obtained at once.
The required pressure should be from 10,000 to 45,000 pounds per square inch,
according to the nature of the metal, and its intended use. For such articles the
metal moulds should be washed with dolomite wash, and the points where the
tream of metal impinges on entering should be lined with substantial slabs of
lolomite.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said George Webb in the Great Seal Patent Office on the 1st July
1880.
GEORGE WEBB, of Johnstown, in the County of Cambria and State of Penn-
sylvania, one of the United States of America, Engineer. "IMPROVEMENTS IN THE
TREATMENT OF STEEL AND OTHER METALS IN A MOLTEN CONDITION, AND IN
MEANS AND APPARATUS ADAPTED THEREFOR, PARTS OF WHICH ARE APPLICABLE
FOR OTHER PURPOSES."
I subject melted metal to strong compression, which is rapidly applied and
maintained until the metal has set. I have devised a system for conveniently and
effectively operating on quantities made in the large way in modern practice.
Steel in being cast into ingots does not naturally pass from a liquid state into a
dense solid. Cast-iron is found to be the most practical material for ingot moulds,
but with this material for the mould, open spaces, termed pipings, will occur in the
mass, especially near the surfaces, evidently caused by the generation of a gas.
To reduce the imperfections to the smallest percentage of the mass the practice
of manufacturing larger and larger ingot moulds has been adopted from time to
time. Nearly all the imperfections are near the surface. Theory (and it seems to
be largely supported by the practical results) indicates that the larger the ingot the
greater the proportion of clear homogeneous metal.
The practice has grown from time to time until very inconvenient and expensive
appliances are required for moulding, and for subsequently handling and hammering
or rolling large masses, even though the ultimate form of the metal may be a small
bar, rod, or wire, or at most a railroad rail weighing not more than one-eighth of
the original ingot. My Invention avoids this, and will largely reduce the per-
centage of scrap in each ingot.
It has long been attempted to subject melted steel to pressure in its melted
condition in the ingot moulds, but the operation has heretofore been conducted
under imperfect conditions, rendering it only partially successful. It has especially
involved much labor and delay, so that the work could not well be made continuous
and economical.
In the treatment of steel after it has arrived at its proper condition, time is a
very important element. In a Bessemer converter any holding of the melted mass
without blowing will allow the melted metal to flow backward and downward into
the passages through which air is admitted, and chilling there will ruin the
converter; any continued blowing beyond the proper movement will deteriorate or
destroy the steel, and if metal is retained in the converter laid on its side the mass
soon cools so as to adhere to the lining of the vessel. A pouring of the mass involves
a necessity for its immediate treatment in moulds. My Invention is intended to
overcome the difficulties and to adapt the work to successful and economical manu-
facture on a large scale, with repititions rapidly and indefinitely conducted.
I employ gas-discharging sectional ingot moulds, which are or may be used
repeatedly without any preparation beyond a thin wash; the moulds are rapidly
filled with liquid metal, they are in long narrow sections, strongly united; provision
exists for the escape of gases from all the joints; a great pressure is applied and
maintained on the limpid metal immediately after it is poured, and all the move-
ments may be effected easily at the right periods. Thus conditioned the cavities
in the steel will be avoided, and the resulting metallic mass will be dense and
homogeneous. Large charges may be disposed of with rapidity, and the charges
may succeed each other indefinitely.
I employ hydraulic pressure in a form of mechanism very powerfully worked and
adapted for treating a single ingot at a time by one press. I can use a number of
presses together.

page_text: The accompanying Drawings form a part of this Specification, and represent
what I consider the best means of carrying out the Invention in several ways.
Fig. 1 is a plan view representing the general arrangement of the parts.
Fig. 2 is a cross section through the same.
Fig. 3 is a vertical section through one of the ingot moulds and the associated
parts on a larger scale.
Fig. 4 is a plan of the same.
Fig. 5 is a vertical section through the press with an ingot mould in position.
Fig. 6 is a horizontal section.
Fig. 7 is an end elevation of the lines of presses with the several straight rail-
ways, and the crane which carries the ladles thereto. The crane with its load is
raised and lowered as required by the ordinary hydraulic power.
Fig. 8 is a plan view of a modification. It represents the general arrrangement
of the parts on a small scale.
Fig. 9 is a vertical section through the centre of this modified arrangement.
Fig. 10 is a section of part of Fig. 9 on a larger scale.
Fig. 11 is a detached view of one of the ladles and of a lift partly in section.
Figs. 12, 13, and 14 are outline plans showing variations from the circular forms
of the track, and how I propose to dispose the parts when such shall be necessary
or expedient.
Fig. 15 is a general plan view showing a circular arrangement with a double
crane or double derrick instead of a circular railway to support the ladles.
Fig. 16 is a vertical section through the same, showing the double derrick
delivering on both sides.
Fig. 17 is a plan view of a modification adapted specially for holding the molten
steel, mainly by what I term dead pressure.
Fig. 18 is a central cross section thereof.
Fig. 19 is a vertical section through one of the ingot moulds and its immediate
connections in position on an annular platform, which is traversed around carrying
the ingot moulds and their connections upon it, and thus presenting many succes-
sively to the same press. The presses in this modification are mounted, as before,
upon a stationary foundation, with the ring carrying the ingot moulds traversing
through them.
Fig. 20 is a plan view of certain levers employed.
Fig. 21 is a section of the press taken vertically through the centre. It is shown
in the act of inducing pressure on the contents of an ingot mould which has been
previously clamped in proper supports carried on the ring, and has by the step-by-
step revolution of the ring been presented in the press.
Fig. 22 is a horizontal section showing some of the same parts.
Fig. 23 is a vertical section through the ingot mould and through the ring or
annular platform. The ingot mould is shown only in dotted lines. This section is
in the plane of one of the bridges carrying the ladle for filling the several ingot
moulds. This Figure shows also the lift for raising and lowering the ladle.
Fig. 24 is a plan view of these parts.
Fig. 25 is a plan view of a modification in which a semi-circular railway with
two lifts takes the place of the cranes indicated in Figures 1, 7, and 16.
Similar letters of reference indicate corresponding parts in all the Figures.
The provisions for conveying the molten metal from the converter, open hearth,
or other source of metal supply to the moulds may be worked out in different
forms. I cannot without experiment, which in this line of endeavour is exceptionally
expensive, be able to determine which of the several modifications will be most
desirable for any special practice, and will therefore describe a number. I esteem
them all as forms of a general system, by which I seek to overcome the difficulties
heretofore met with in this very important branch of manufacture by operating on
a scale of magnitude and with appliances adapted to a large business, and yet to
manufacture the steel in small ingots and of absolutely homogeneous steel.
In the arrangement shown in Figures 1 and 2 the hydraulic presses and

page_text: accompanying mechanism for receiving and holding the ingot moulds are arranged
in straight parallel lines with railway tracks between. Suitable cars moved by
hand or otherwise on one track carry large ladles of melted steel, and supply two
moulds at once; ready means move each into place and give it pressure.
Cars on
another track carry the ingot moulds with their contents away, and bring fresh
ones to be placed in position and receive the melted material. Each series or row
should be of sufficient length to allow an ingot mould to be filled while another
place in the series is being supplied with a fresh mould, and another place is
having the filled mould taken away with its contents sufficiently cooled to retain
its condition, and each may hold the metal under strong pressure until it has
slowly cooled to the required consistency.
A mast N, with one or more arms N¹, and provisions for being raised and
lowered, is favorably located for presenting the ladle at will to either of the
converters M, M, to receive the charge of melted steel, and also for transferring it
to either of the cars J¹ on the two tracks J.
Referring to Figures 3 and 4,-
A', A², etc., are the sections of an ingot mould adapted when applied together
to present a smooth and cylindrical exterior and a smooth cavity of uniform
rectangular section on the interior, which cavity receives the melted steel and
forms the ingot. The surfaces of the ingot mould A1, A2, which abut together
are marked a. They are accurately fitted together, but instead of being left
absolutely smooth are left with fine scores running across their eurfaces, such as
result from filing with a coarse file. The scores may be actually produced by that
means, but I prefer that they shall be produced by machinery having a motion
analogous to planing.
This allows a junction on the surfaces sufficiently tight to prevent the passage
or even the entrance to any considerable extent of the melted steel in the joint,
but the fine scores in the surfaces a allow the gases to escape which are emitted
from the melted steel or generated by the contact thereof with the cooler iron of
the ingot mould sections A¹, A³
The sections A1, A2, etc., are held together by clamps B¹, B', which are provided
in sufficient numbers and with peculiar locking pieces or gibs D1, D2, and embrace
the ingot mould at short distances apart along its length. The clamps are held by
pivots 6, b, to swinging arms B, which are keyed fast on a turning mast C. This
latter is supported with liberty to rise and sink, and is formed at the bottom with
a foot C', which fits tightly in a corresponding cylindrically bored recess in the
supporting casting adapted to receive water or oil through a passage c from a pump
or accumulator, not represented, in order to lift the mast C and its connections and
to lower them again when required. On sufficiently raising the mast C and the
connected clamps and ingot moulds and their contents the whole may be swung
around to allow the ingot mould to be moved into the proper position to receive its
charge of melted steel and to be moved back into the central position under the
press to receive the compressive strain. It will be understood that the ingot mould
is lowered down until it rests firmly on the support before the force of the hydraulic
press is applied.
Before depositing the melted steel in the ingot mould a plate of common wrought
iron, previously prepared of a proper size and form, is introduced in the interior
of the ingot mould on the bottom. So soon as a quantity of the melted metal has
been introduced, another small plate of rolled iron is placed on the top; these
plates are marked a¹, a². Then, as rapidly as may be, a previously prepared piece
of cold metal E, which I term a set, is applied on the top of the upper plate a³,
and the ingot mould and its contents being swung around and lowered upon the
bed A in the proper position, the press is allowed to act.
The melted steel is ordinarily introduced into the ingot moulds at a temperature
a little above that at which cast iron melts. When the stream of melted steel
falling from a considerable height into the ingot mould strikes forcibly on the
bottom, there is a risk of its affecting the integrity of the mould. This I prevent

page_text: by my lower plate a¹ of wrought iron. The upper plate performs two functions; its
edges by fitting closely to the interior of the ingot mould reduces the tendency of
the melted metal to gush up under the heavy pressure through the joint between
the set and the surrounding pieces, and it also interposes an important barrier to
the transmission of any injurious degree of temperature to the set. The thin
wrought iron pieces a¹, a², being covered with the ordinary scale do not weld to
the steel, but drop off in rolling.
"
To remove the mould with the solidified ingot the locking pieces D, D', are
removed, the clamps B1, B2, thrown open, and the sectional mould A¹, A³, and its
contents will be seized by properly-shaped tongs, which tongs are attached to a
swivel hanging from a "traveller," which is located and moves on a straight, or
curved, or a swinging overhead way. Z represents a mast or upright shaft for a
swinging way for this purpose. The sectional mould A', etc., and its. contents
are thus brought to and deposited on a car R¹ on a track R, which track is
located on the opposite side of the press from where the melted metal was poured
into the mould.
After release from the clamps B1, B2, the sections of the mould are held
together by slight bands, not represented, which bands are afterwards to be
removed when the car and its load have been hauled away a convenient distance.
The fresh mould is to be held together by similar small bands, and brought in by
the same route and appliances, and thus delivered to the clamps B¹, B².
The ingot on being liberated from the sectional mould is ready to be further
treated by rolling or hammering, either at the same or a subsequent heat, to induce
the desired form of a steel rail or other article, while the sections A', etc., of the
mould may be treated with water, and partially or entirely cooled ready to be
returned to the position for use, fresh sets of sectional moulds being used in the
interim.
I have discovered that the effect may be improved by a peculiar surfacing of the
interior of the iron moulds. I employ a highly magnesian limestone, known as
dolomite," mixed with water in the form of a thin paste, and coat therewith the
whole interior surface of the several sections of the moulds A'; I can effect this
with a brush, or I can dip the several sections therein.
A good effect is also produced by using dolomite as a material for the top and
bottom plates a¹, a². For the purpose I evaporate the dolomite paste till it is very
thick, almost dry, and then press it into the required shapes under a pressure of,
say, ten thousand pounds per square inch. The slabs thus made should be further
dried if there is much moisture remaining, and then be placed at the bottom and
top of the ingot, the same as the iron plates a, a, above described. They serve the
same as the iron, but with less liability to induce air bubbles or pipings.
The construction of my press affords a peculiarly powerful and persistent com-
pressing force.
In compressing ingots in the melted state the motion need be but little, but the
force required is great, and it is better to be a live force which shall follow up and
maintain the pressure as the ingot shrinks in cooling.
I employ a press which is compound, using in effect two hydraulic presses, one of
which receives the steam, water, or other fluid from a boiler, accumulator, or other
source, and by the motion of its plunger induces a greater pressure in another mass
of fluid which acts in a second cylinder to apply a still greater pressure on the
plunger of the second press. This latter acts on the steel in the ingot.
Referring to Figures 5 and 6, F is a pipe bringing steam or water at an available
pressure from any suitable source, and f is a valve which controls it.
The piston g and its connected plunger g¹ is forced down in the main cylinder G
by the admission of the steam or water, and the resulting motion of the plunger g¹
in the tight-fitting space provided for it below, may be in all respects similar to
that of well known hydraulic presses.
H is a second cylinder, and h a stout piston working therein. It operates a

page_text: connected plunger h¹, which acts directly on the set E. The fluid above the piston
in this cylinder H may constantly remain imprisoned. It may be water or other
inelastic fluid, replenished at intervals to compensate for leakages.
The pressure in this cylinder H is much greater, say ten-fold greater than in the
cylinder G. It is induced by the descent of the plunger g¹. Its pressure on a
given area of the piston h is obviously the same as that on the corresponding area
on the lower end of the plunger g¹. The mechanical effect of this second cylinder
depends upon the difference of area between the piston h and the cross-section of
the plunger g¹.
In order to raise the piston h, I allow water or steam to flow through a pipe I
into the annular space under said piston. The valve i controls the flow of this
fluid. I can employ a corresponding pipe controlled by a corresponding valve, to
admit fluid under pressure to the under side of the piston g, and thus to raise it in
a similar manner. But in case of derangement of the latter apparatus, or in the
absence thereof, I can raise the piston h with such force as will induce a pressure
on the fluid above h, which will by its direct action on the lower end of the
plunger g¹ lift it and its connected piston 9. Any other efficient means may be
employed to raise these pistons, and restore the press to its original condition, thus
releasing the ingot now under the press, and putting the parts in condition for
treating the next set of ingot moulds and contained fluid steel which may be
brought.
The tie rods are marked O, and the stout nuts thereon O¹. A tube or thimble
surrounds each rod O to support the weight of the upper work when the press is
not in action. The cross-pieces or cross-heads of the press above the bottom are
marked P, P, P¹.
Qis a supply cup, and q, q¹, a connected pipe and passage by which I introduce
oil or water to be added to the fluid below the plunger, to compensate for losses by
leakage or otherwise. To accomplish this the piston g and its connected parts are
raised by some appliance, not shown, taking hold of the upper end of the piston
rod, and when sufficiently raised the fluid from Q, q, q', finds a passage into the
space under g, through a slight recess formed in the lower end thereof, as shown in
Fig. 5.
The press may be used for other purposes than compressing metals. It is
available for any purpose when great force is required with only a small range of
notion.
I shall for brevity denote my entire press when necessary by the single letter G.
I shall also designate an entire ingot mould when necessary by the simple
marks A¹.
It is essential that the heavy pressure induced by my hydraulic press G shall be
applied to the melted metal before it begins to harden even on the outside. The
principal holes and " "honey-comb" places are near the exterior of the ingots
within an inch or so from the surface. By applying the intense pressure before the
exterior of the ingot has solidified, I prevent the development of gas, or hold it
under pressure that forces it to the surface, and it escapes through the slightly
opened joints a instead of accumulating in pipings and cavities, of whatever name,
in the interior of the metal.
The cooling commences on the exterior adjacent to the surfaces of the mould
sections A', A2, and of the set E. It is found that a large ingot will set over its
whole exterior, so that it may be handled as a solid while the interior is still fluid,
and if allowed will "bleed" through any aperture which is burst or otherwise
produced in the tender skin. Inasmuch as the pipings and other cavities and
imperfections are mainly near the surface, it may not be necessary to hold the
ingot under compression until it is solid throughout. But it is essential to the
success of the operation that it be held a while. The metal shrinks in cooling. It
is better that the pressure follow it up as it shrinks, until a considerable thickness
of the surface metal is set or solidified. Experiment will determine the period
during which the pressure should be kept up. I propose usually to keep the full

page_text: force of the steam or water on my piston g, and consequently to maintain the full
pressure on the ram h¹ for a considerable period, during which the latter will
descend slowly.
When the pressure has been maintained for a sufficient time the steam or
other fluid under pressure is shut off from the cylinder G, and the fluid above the
piston g is allowed to escape. Then both the pistons g, h, and their connections
are raised and the ingot is relieved from pressure.
Referring again to Figures 1 and 2, a car J¹ moves on each of the tracks J,
carrying a ladle which is at each return filled from one of the converters M, and as
each car is rapidly moved step-by-step along its track, it is stopped at the proper
points, and tapped at two places, to supply the proper quantity to each ingot
mould, which latter is by the lifting and turning of the proper mast C, C¹, presented
in the proper position to receive it, and on being filled is promptly returned to its
position under the press and its contents subjected to the required pressure and
held so.
A car R¹ moves forward and back on each of the tracks R, bringing fresh ingot
moulds and placing them in position, returning loaded with the filled mould,
previously cooled under pressure to a point below that at which pipings form, to be
taken care of at a distant point not represented.
It is theoretically possible to move the ladle and its supporting car J¹ to a
greater distance at each interval between the pourings, and to so arrange and turn
the several masts C, C, that four ingot moulds instead of two shall be presented
at once, and receive their supply of melted steel simultaneously. In such case two
moulds will be swung outward from the tier of presses and their accompanying
mechanisms on the right side of the car J, and two will be swung out on the left
side of the same car; but I esteem it preferable on the whole to attempt to fill
but two ingot moulds at a time, swinging one from the right and one from the
left, and then rapidly shifting the position of the ladle to the next pair of presses,
and so on.
In the arrangement shown in Figures 8 to 14 inclusive, the presses are arranged
in a series along a single line of railway, which railway extends close to the
converter or other source of metal, and is practically continuous, so that a car with
a full ladle may go from the supply with a full ladle in one direction, and return
with empty ladle in the other direction, or in the same direction, as convenience
may require. The melted metal is supplied to the several ingot moulds A¹ in the
same general manner as above explained, two ingot moulds being filled at once from
the same ladle by swinging the moulds from two adjacent presses into close
proximity to each other, as indicated in dotted lines on the right in Figure 8.
The arrangement shown in Figures 15 and 16 will only serve with a circular
arrangement of the presses. The effect is in general similar to the last, but the
crane arms J' may be moved with still less resistance than the cars J. Each form
of the devices may have a lift to accommodate the ladle to the varying heights of
the mouth of a converter, but the form shown in Figures 15 and 16 may have
provisions for raising and lowering the entire mass J and its attachments instead
by means of a hydraulic cylinder and friction with proper connections arranged
under the step of the mast.
With any of these modifications I can make a smaller number of presses serve
by providing any efficient and quickly operated means for strongly locking the sets
down in the ingot moulds and then relaxing the force of the press and releasing
the mould. We may remove each mould and substitute another in the press
without necessarily waiting for the surface of each ingot to harden. I have devised
a further modification with especial reference to this mode of working.
I propose to use a circular track with a stout broad ring carrying the ingot
moulds thereon with only one or two presses to exert the required compressive
force on the melted metal immediately after it is received from the converter.
Strong means not represented are provided for holding the set down firmly upon
the melted metal after the force of the press is removed, and this pressure is main-

page_text: tained as the ingot moulds and their carrying means are successively moved around
the circle until the ingots have had time to become certainly solid. Then the
confining means are released, and the moulds are opened, and the ingots removed.
The same or another set of sections is retained or placed on the carrying ring, and
the series are successively filled, held, compressed, opened, emptied, and restored to
à condition for refilling in proper succession.
Figures 17 to 22 inclusive represent this form of the apparatus. The parts are
lettered the same as in the other Figures for corresponding parts, further letters
being added for parts which have no counterpart in the others.
V is my stout ring or revolving platform carrying the series of appliances B, C,
etc., for holding the moulds, and the appliance Z for removing them filled, or for
removing ingots when, as I prefer, the ingot mould is opened in its place on the
ring without removal.
The ingot holding means are equally spaced, so that in any part of the ring when
one is presented to be pressed another is presented to one of the ladles J to receive
a supply of metal.
The converters M pour into ladles J' held in cars on the lifts U. When a ladle
is filled and brought to the level of the bridge Y it is moved horizontally on the
latter to a point over the ring V. In Figure 17 the ladle J' on the right is on its
lift U to be supplied with metal, while the ladle J¹ on the left is on its bridge Y
to fill the several ingot moulds, which shall be in turn presented under it by the
partial turning of the ring V.
The ring V may be turned by hand or by any suitable power; it runs on wheels
v to reduce the friction.
The sets E for use in this form of my apparatus are made with a tapering top E
projecting above the moulds A'. I provide two stout levers W¹, W³, hinged
together at the point w, and formed with tapering ends w¹, w², adapted to receive
the link W³ The conical top E¹ of the set is received in a corresponding recess in
the levers W¹, W. The taper form allows it to be held strongly at different levels
simply by bringing the levers W', W2, more or less closely together by driving the
link W³ on to a greater or less distance. If the quantity of molten steel is in
excess the set will stand high, and the link will not be driven on so far. The link
is always driven on as far as it will go. The levers W', W, embrace fixed posts,
one or both of which has a stout nut W threaded thereon.
So soon as the levers are fully secured by driving on the link W³ the nut W4
may be turned rapidly down either by manual power or by a suitable connection
to a steam engine not shown. This being done while the force of the press G is
still on takes up all the slack and spring of the parts, and when the plunger of
the press has lifted, and the ring V has partially revolved so as to move the mould
away, the stress which the press has enforced remains. There will be always some
elasticity in the levers W₁, W2, which is available, thus conditioned, to follow up
any yielding or shrinkage of the ingot after its removal from the press; but this
is so slight that I term the action in this form of my apparatus "dead pressure
to distinguish it from the live pressure, which obtains when the press is kept in
action on the ingot until the latter has set.
"
The ring V and its load runs on the wheels v mounted, as shown, to lessen
friction, but I wish to apply much greater forces by my presses G than such wheels
would withstand. Immediately under each press G the ring V rests on the base A
of the press. The ring V slides on such base with gentle force when moving. As
soon as the ring comes to rest, and the great force of the press G is applied, the
ring V springs downward a little at those points and is then firmly supported.
It will be understood that further modifications may be made in the form and
proportions of the details. I can use more than two sources of metal supply in
some of the modifications. As already indicated I can use open hearths, crucibles,
or any suitable mode of producing the melted steel. The dotted circles M³ in
Figure 17 represent the position of open hearths when such are used. I can treat
other metal than steel.

page_text: I prefer for steel rails to make the ingots about seven inches square, and of a
length from four to six feet, sufficient to serve for one railway rail with a minimum
wastage at the ends.
For locomotive wheels, car wheels, locomotive and car axles, crank-pins, cross-
heads, and many other useful forms, the proper condition can be obtained at once.
The required pressure should be from 10,000 to 45,000 pounds per square inch,
according to the nature of the métal and its intended use. For such articles the.
metal moulds should be washed with dolomite wash, and the points where the
stream of metal impinges on entering should be lined with substantial slabs, similar
to the plates a¹, a³, above described.
I claim as my Invention,―
First. The combination of a molten metal supply with a press, a ladle, and a
ladle-carrier, arranged to move the ladle between the supply and the press, a mould,
and an independent or separate jib adapted to hold the mould in two different
positions for pouring and pressing, and to transfer it from one position to the other,
substantially as shown and described.
Second. A series or line of presses, each provided with means for holding and
transferring removable moulds from a filling point to a compressing point, as shown,
in combination with a laddle-carrier and a molten metal supply, and suitable means
for moving the ladle in succession to the several moulds, so as to supply a number
from the same ladleful, as herein specified.
Third. The arrangement of the presses and their carrying and holding devices
B, C, relatively to each other and to the ladle-carrier, so that two or more moulds
may be filled at once from a properly constructed ladle, and each mould moved
rapidly and independently to its proper place for subjection to compression, as
herein specified.
Fourth. In combination with a series of presses and mechanisms for holding and
moving the moulds filled with melted metal, the jib Z turning on a centre within
or near each press or other suitable transferring means adapted for introducing the
empty and removing the filled moulds, as herein specified.
Fifth. The combination and arrangement of three lines of railway J, R, R, two
lines of presses G, and a source of molten metal M, as and for the purpose herein
specified.
Sixth. The combination of four or more lines of presses and their appurtenances
and ladle-carrying means, with a molten metal supply and a jib N, N¹, arranged as
shown, substantially as herein specified.
Seventh. The within described mode of operation, consisting in supplying the
melted material into moulds, at once relieving the moulds of gases, and submitting
the melted metal to pressure therein, holding it compressed until it is set,
mechanically conveying away the filled mould and returning the empty one to the
filling place, as herein specified.
Eighth. In combination with one or more sources of melted metal the lift or
lifts U, railway track J, cars J', and a series of means G for compressing the metal
in moulds, as herein specified.
Ninth. The series of presses G in combination with the sources of metal M, the
track J, and cars J traversing thereon, all combined and arranged to operate
together as herein specified.
Tenth. The series of presses G and moulds A in combination with the railway J
and car J', and the intermediate lift U, all combined and arranged for joint operation
as herein specified.
Eleventh. The ring platform V, rollers v, and abutments A, in combination with
the series of moulds A¹ and one or more presses G mounted on posts or ties O
spanning the ring V, all as herein specified.
Twelfth. The levers W¹ and W2, link or clip W³, and nut W4, in combination
with the set E having a taper head E', and with the moulds A1, A2, adapted to
serve in connection with a press G, in the treatment of melted steel in changing
from a fluid to solid, as herein specified.

page_text: Thirteenth. The bridge or bridges Y and lift U, in combination with each other
and with the ladle J¹ adapted to traverse each, and with the ring platform V,
carrying moulds A¹, and with one or more sources of metal supply M, and one or
more presses G, all arranged for joint operation as herein specified.
Fourteenth. The general arrangement and grouping together of the several
implements and apparatus employed in compressing metals in molten condition, as
shown in the Drawings hereto annexed.
Fifteenth. In combination with an ingot mould formed of sections A¹, A³, etc.,
the clamps B1, B2, mounted on a mast C, C', adapted for vertical lifting and
horizontal swinging, as herein specified.
Sixteenth. The locking pieces D, D', adapted to sit in corresponding recesses in
the clamps B', B2, in combination with clamps and their supporting means' c, and
with sectional ingot moulds A¹, A, etc., as herein specified.
Seventeenth. The thin plates of wrought metal a', as, at the top and bottom
respectively of the ingot mould in combination with sections A1, A2, each constituting
a portion of the side, and of the bottom of the mould formed in one, and with the
separate set or top-piece E, all substantially as and adapted to serve the purposes
herein specified.
Eighteenth. A metallic mould faced on its inner surface with dolomite so as to
serve as herein specified.
Nineteenth. A mould coated on its interior with a mixture of dolomite and water
of the consistency set forth..
Twentieth. The compound hydraulic press described composed of two or more
cylinders and pistons G, g, H, h, mounted in line and connected by the rods O and
cross beads P1, P2, P3, combined and arranged for joint operation, substantially as
and for the purposes herein specified.
Twenty first. In combination with a compound hydraulic press having the
pistons g, h, and their connections as shown, a pipe or passage leading from any
source of fluid under pressure to the bottom of either cylinder G or H, or both, and
controlled by a suitable valve adapted to cause the elevation of the pistons, as herein
specified.
Twenty-second. In combination with a compound hydraulic press having a
quantity of inelastic fluid imprisoned between the plunger g and the piston h, the
supply vessel Q, and connected passage q arranged to supply additional fluid when
the plunger g¹ is in the extreme raised position and to cut off the escape by the
descent of the plunger, as herein specified.
Twenty-third. The series of presses G and moulds A' in combination with a
railway track J and car J, and with the intermediate lift U, all combined and
arranged for joint operation as herein specified.
In witness whereof, I, the said George Webb, have hereunto set my hand
and seal, this Thirty first day of May, in the year of our Lord 1880.
Witnesses,
THOMAS DREW STETSON,
Patent Solicitor,
New York,
WILLIAM COLBORNE BROOKES.
GEORGE WEBB. (L.S.)