AN IMPROVED MODE OF AND APPARATUS FOR CASTING AND HANDLING STEEL INGOTS WHICH ARE INTENDED TO BE ROLLED INTO VARIOUS FORMS."
Year: 1878

page_text: LETTERS PATENT to William Henry Osborne Taylor, of Panteg, in the County
of Monmouth, Mechanical Engineer, for the Invention of "AN IMPROVED
MODE OF AND APPARATUS FOR CASTING AND HANDLING STEEL INGOTS WHICH
ARE INTENDED TO BE ROLLED INTO VARIOUS FORMS."
PROVISIONAL SPECIFICATION left by the said William Henry Osborne
Taylor at the Office of the Commissioners of Patents on the 8th October
1878.
CE
WILLIAM HENRY OSBORNE TAYLOR, of Panteg, in the County of Monmouth,
Mechanical Engineer. AN IMPROVED MODE OF AND APPARATUS FOR CASTING AND
HANDLING STEEL. INGOTS WHICH ARE INTENDED TO BE ROLLED INTO VARIOUS
FORMS."
Steel ingots are ordinarily cast in vertical or nearly vertical moulds, open at the
lower end, and of larger sectional area at the bottom than at the top, so that the
moulds may be lifted off when the ingots have become solid. Or the moulds are
made in two or more parts, clamped or otherwise fastened together, so that they
may be readily taken apart to allow of taking the ingots out. This mode of
casting steel ingots requires much manual labor and a considerable amount of
space. It is also open to other objections, which it is the object of my Invention
to avoid. This I do by casting the ingots in a horizontal position in either closed
or open moulds, so constructed and mounted that the steel ingots when cast may
be removed therefrom with much greater facility than when cast in single vertical
moulds in the ordinary manner.
If molten steel in the state in which it usually runs into the ordinary vertical
moulds he run from the melting furnaces into my horizontal moulds it will boil
up and make unsound ingots. In order to prevent this I add to the molten steel
before it is run from the steel melting furnace into my horizontal moulds a small
per-centage of ferro-manganese and also of silicon. The effect of this treatment
Unies 1031

page_text: will be that the molten metal will be kept quiet and will not boil up in the moulds.
The quantity of silicon added for this purpose is so small as not injuriously to
affect the quality of the steel or render it brittle. For the purposes of my Invention
I add the silicon in the form of a silicous pig iron, in which it has been ascertained
by analysis that there is a certain per-centage of silicon. I find in practice that
about 0-10 per cent. of silicon will produce the result I require, and therefore I add
to the molten steel the quantity of siliceous pig iron required to give the desired
per-centage of silicon. It will be obvious that other compounds containing silicon
may be used for the purposes of my Invention, but I prefer to use the siliceous pig
iron as a matter of economy.
In adapting my Invention to the well-known Bessemer process I prefer in the
first place to eliminate the silicon from the charge by blowing slowly or at a com-
paratively moderate temperature, and then to add the required quantity of the
siliceous alloy at the end of the process. The molten steel having been properly
prepared, as above explained, I run it into the horizontal moulds, which may be
either open at top or provided with a lid or cover. These moulds (of which any
convenient number may be used in combination) may be of any suitable size and
shape, so as to form ingots; the size and shape of the ingot depending upon the
character of the manufactured article intended to be produced therefrom by the
subsequent process of rolling.
In carrying out my Invention a convenient number of moulds may be arranged
parallel to each other in a frame provided with trunnions, so that it may be turned
over in order to tip out the ingots when they are sufficiently solid or set to admit
of being handled and rolled in the usual way.
Or if preferred the moulds may be constructed in the form of a long trough made
of cast iron and lined (if desired) with a baked or burnt clay. Or the trough may
consist of a wrought-iron or other strong frame, and the moulds formed therein of
tiles or slabs made of baked or burned clay, and provided or not, as may be
preferred, with lids or covers. These long troughs may be either of a triangular
or V shape in cross section, or of a quadrangular shape, but rather wider at top than at
bottom. The lids or covers may either be loosely fitted to the moulds or they may
be firmly secured in place by clamping or other suitable devices, so that the moulds
may be turned bottom side uppermost without the lids or covers falling off. The
object of thus temporarily securing the lids in place on the moulds is that they
may be placed lid downwards on trucks or trollies. The moulds with the steel
ingots in them may then be transported to any part of the works, or by unclamping
the lid the body of the mould may be lifted off, leaving the ingot on the inverted
lid or cover.
As a modification of the above the open moulds may be placed in an inverted
position on a table mounted on wheels for the convenience of transport. This
table would thus form the bottom of the moulds, which would thus be closed
moulds. The moulds may be provided with hooks, rings, or other equivalent
devices, whereby they may be lifted off the ingots by means of suitable tackle,
leaving the red hot ingots on the travelling tablo. If preferred the moulds may be
made without either top or bottom, and therefore when placed on the travelling
table would be simple open moulds, which may be handled in the same manner as
the inverted close moulds. In the cases of long trough moulds the moulds will be
arranged in a long line, end to end; and the separate moulds are made by placing
cross tiles or blocks across the trough, so as to form the ends of the ingots and
divide up the space into separate compartments. As these cross tiles or blocks are
moveable they may be placed at any part of the trough, so as to produce ingots of
any desired length or weight. A passage or opening is made through the lower or
some other convenient part of these transverse tiles or blocks for the purpose of
allowing the molten steel to run from the melting furnace or Bessemer converter
into and through all the moulds, so that they may be filled simultaneously or from
one running. Instead of brick or tile partitions extending across the trough, as
above described, the division of the ingots may be effected by simply coating or

page_text: lining a limited length of the mould with loam or other bad conductor of heat, so
that that portion of the molten metal which is in contact with the loam will be
kept hotter than the other part. A rupture of the metal will take place at these
parts, and will thus divide the casting into separate ingots. These long troughs or
frames are provided at each end with a trunnion, so that they can be turned over
and the ingots tipped out as in the former instance. Instead of having one long
trough sub-divided by means of transverse partitions, as above mentioned, two or
more ingots may be simultaneously cast by placing the required number of open-
ended moulds, end to end, the outer ends of the extreme moulds being of course
closed. The ingot will then divide at the point where the ends of the moulds come
together. When using this arrangement of moulds sometimes I find it convenient
to place at certain points inside the moulds a little loam or other substance, which
will keep that part of the ingot hotter than the rest, and will thus cause the ingot
to divide at these points.
Instead of making the horizontal moulds moveable, so that they may be trans-
ported from place to place or turned over on centres for the purpose of tipping out
the ingots, the moulds may be stationary and the ingots may be removed there-
from by being lifted out by means of any suitable mechanical device. In order to
lift the ingots out of the moulds, rings, hooks, or other analogous devices may be
embedded or cast into the ingot in such a manner as to admit of them being laid
hold of and lifted by means of chairs or otherwise.
Instead of casting hooks or rings into the ingots I can lift them by means of dogs,
which will clip hold of any convenient part of the ingot, and may then be drawn up by
means of chains. In order to enable the dogs to get a firm grip of the ingot I cut
notches, slots, or openings in the sides or ends of the moulds, and temporarily close
the saine by means of iron, clay, or other suitable material, which may be removed
when the metal has become solid in the mould.
Another mode of providing for lifting the ingots consists in forming short pro-
jecting pieces at the ends or side of the ingot, under which projections hooks or
rings may be laid before the metal is cast.
When a number of moulds are arranged in close proximity for the purpose of
being charged this operation may be effected by means of a travelling ladle or a
travelling trough. When a ladle is employed it is first filled from the steel melting
furnace or from a Bessemer converter, and is then brought either opposite or over
the moulds, which are filled (as the ladle travels slowly along) by means of the
ordinary nozzle or by means of a spout adapted to the lower part of the ladle. Or
the moulds may be filled in the way usually adopted in the Bessemer process. The
travelling trough is a long inclined channel, which is mounted on wheels, and is
provided at its lower end with a spout, which extends at right angles therefrom, or
nearly so, so as to run the metal direct from the steel melting furnace into the
moulds as the trough travels slowly along either above or parallel to the moulds.
When the ingots have become sufficiently set and solid to admit of handling they
are removed from the moulds either by the means above described or otherwise,
and are placed in order upon an ingot bench, which is mounted on wheels. This
bench is constructed of two parallel arms, which are connected together either at
the middle or at one end; and the ends are supported on wheels so arranged that
the charging trolly or bogie can be pushed in between the parallel arms for the
purpose of allowing the ingots to be taken away on the charging bogie without the
use of a crane.

page_text: '
SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said William Henry Osborne Taylor in the Great Seal Patent Office
on the 8th April 1879.
. . .
WILLIAM HENRY OSBORNE TAYLOR, of Panteg, in the County of Monmouth,
Mechanical Engineer. "AN IMPROVED MODE OF AND APPARATUS FOR CASTING
AND HANDLING STEEL INGOTS WHICH ARE INTENDED TO BE ROLLED INTO VARIOUS
FORMS."
Steel ingots are ordinarily cast in vertical or nearly vertical moulds, open at the
lower end, and of larger sectional area at the bottom than at the top to allow of the
moulds being lifted off when the ingots have become solid. Or the moulds are
made in two or more parts clamped or otherwise fastened together, so that they
may be readily taken apart to release the ingots. This mode of casting steel ingots
requires much manuel labour and a considerable amount of shop space. It is also
open to other objections which is the object of my Invention to avoid. This I do,
firstly, by casting the ingots in either closed or open moulds (placed preferably in a
horizontal position) the moulds having a larger area at the top than at the bottom,
so that the steel ingots when cast may be removed therefrom with much greater
facility than when cast in vertical moulds in the ordinary manner.
If molten steel in the state in which it usually runs into the ordinary vertical
moulds be run from the melting furnaces into my improved moulds it will boil up
and make unsound ingots. In order to prevent this, I add to the molten steel
before it is run from the steel melting furnace a small per-centage of ferro-manganese,
in most cases from two-tenths to three-tenths per cent. will be found sufficient, and
also a small per-centage of silicon. The effect of this admixture will be that the
molten metal will be kept quiet and will not boil up in the moulds. The quantity of s
silicon added for this purpose is so small, as not injuriously to affect the quality of
the steel or render it brittle. For the purposes of my Invention I add the silicon in
the form of siliceous pig iron, in which analysis has shewn that there is a certain
per-centage of silicon. I find in practice that about 0.10 per cent. of silicon in the
steel will produce the result I require, and therefore I add to the molten steel the
quantity of siliceous pig iron required to give the desired per-centage of silicon. It
will be obvious that other compounds containing silicon may be used for the
purposes of my Invention, but I prefer to use the siliceous pig iron as a matter of
economy.
In adapting my Invention to the well-known 'Bessemer process, I prefer in the
first place to eliminate the silicon from the charge by blowing slowly or at a
comparatively moderate temperature and then to add the required quantity of
siliceous alloy at the end of the process. The molten steel having been properly
prepared, as above explained, I run it into the improved moulds which may either
be open at top, or provided with a lid or cover. These moulds (of which any
convenient number may be used in combination) may be of any suitable size and
shape so as to form ingots, the size and shape of the ingot depending upon the
character of the article intended to be produced therefrom by the subsequent
process of rolling. I would here remark that the metal combined with the siliceous
alloy as above explained may be used with advantage when casting ingots in 4
ordinary vertical moulds, as a more perfect ingot is thereby insured.
In some cases instead of using moulds of the length required for the ingots,
I propose I make long trough moulds as shewn at Fig. 1, in Sheet I. of the
accompanying Drawings, and to divide up this mould into any lengths suitable for
casting ingots of any desired size. To this end I insert tiles or blocks of fire-clay i
transversely of the trough, and as these clay divisions may be set at any points in
the length of the trough, ingots of any desired size may be obtained. It will be under-
stood that a passage or opening must be made through the lower or some other
convenient part of these transverse tiles or blocks for the purpose of allowing the
molten steel to run from the melting furnace or Bessemer converter into and through

page_text: all the moulds, so that they may be filled simultaneously or from one run of meta.l.
Instead of brick or tile partitions extending across the trough as above described,
the division of the ingots may be effected by simply lining a limited length of the
mould with loam or other bad conductor of heat, so that that portion of the molten
metal which is in contact with the loam will he kept hotter than the other part.
A rupture of the metal will take place at these parts, and will thus divide the
casting into separate ingots. To permit of this I recess the mould both at its
bottom and sides at the part where the division is required to take place for a
depth sufficient to hold a lining of loam. These long troughs are provided at each
end with a trunnion, so that they can be turned over and the ingots tipped out.
Instead of having one long trough subdivided by means of transverse partitions
as above-mentioned two or more ingots may be simultaneously cast by placing the
required number of open-ended moulds end to end and luting the joints with clay,
the outer ends of the extreme moulds being of course closed. The cast ingot in
cooling will then divide at the joints of the moulds. When using this arrangement
of moulds, I may sometimes find it convenient to place at certain points inside the
moulds a little loam or other substance which will keep that part of the ingot hotter
than the rest, and will thus as above explained facilitate the division of the casting
at these points.
I propose in some cases to lift the ingots out of the moulds by means of any
suitable mechanical device. To this end I provide the ingots with rings, hooks, or
other analogous devices, which being embedded in or cast with the ingot will
provide a hold for grappling irons pendent from lifting chains. This part of my
Invention is illustrated in Sheet II., where Fig. 2 shews in longitudinal section an
ingot cast with lugs of wrought iron, and Fig. 3 an end elevation of a group of
ingot moulds with the tackle for lifting out the ingots attached thereto. In these
Figures A. are the moulds; B, the ingots cast therein; and C, lugs of wrought iron
suspended on rods D, hung transversely across the ends of the moulds from lifting
chains E.
The pendent extension of the lugs C dip into the moulds, and as the molten
metal is poured therein they will be united with the ingot, and thus afford the
means for lifting the same when set out of their respective moulds, another
means for lifting the ingots out of the moulds is shewn at Figures 4 and 5. In
this case the moulds A are made with loose end pieces A', which are recessed at
their centre as at a to ensure the attachment of the ingot to these loose pieces;
C are staples or rings attached to the loose end pieces at the time of their being
cast, when therefore lifting chains are attached to these staples as shewn at Fig. 4,
and the hoisting chains are drawn up, the ingot B will be lifted together with the
loose end pieces A¹ of the mould.
A further modification is shewn at Figures 6 and 7, where the ends of the moulds
are cast with recesses to receive lifting rings C, which are fitted in place with a
loam lining, and through which the molten metal runs, thereby forming a lug or
end extension of the ingot, which rests in the lifting ring when the same is raised
by the hauling chains.
This modification, like that last described, provides for the disengagement of the
lifting ring from the ingot when the same has been deposited on the truck or other
receptacle. Figures 8 and 9 shew substantially the same arrangement of the ring
applied to the middle of the ingot mould. In this case the ingot when lifted out of
the mould will hang balanced in its ring or loop C, and may be readily disengaged
therefrom.
In some cases I propose so to form the mould that it will admit of the ingot
being gripped by the grippers while in the mould; this is illustrated in Sheet I.
Figures 10 and 11 shew an ingot mould A formed with removeable ends A', which
fit into rebates in the sides of the mould. Lugs a are cast on the ends of the side
walls of the inould to receive cross bars a¹, which serve with the help of wedges a²
to hold the loose end plates firmly in position. In order to remove the ingot it is
only necessary to knock out the wedges, remove the cross bars and end plates, and

page_text: the end of the ingot will then be free to receive the grippers, as illustrated at
Figure 11ª, Sheet II.
Figures 12 and 13 shew in end and plan view a mould with fixed ends, which
are slotted vertically for a greater.part of their length to permit of the ingot being
cast with a rib on its opposite ends for the grippers to take hold of while the ingot
is in the mould. In these Figures as are the vertical slots, which are covered by
thin end plates a. These plates are held in place by the same means as that
described for retaining in place the loose ends of the moulds. When these plates
are removed the lifting grippers may be applied directly to the exposed ends of the
ingot. Instead of making these slots in the ends of the mould side slots may be
made, as shewn, in plan, elevation, and cross section at Figures 14, 15, and 16, for
exposing a portion of the ingot to the action of the grippers. These slots may be
closed before the casting takes place by the insertion therein of pieces of metal or
fire-bricks, and on removing these pieces of metal or fire-bricks when the ingot is
set the grippers may be applied to the ingot as shewn at Fig. 16. To ensure an
easy disengagement of the ingot from the mould it will be requisite to taper it
both at the sides and ends, as is clearly shewn in the Figures in Sheets I., II.,
and III.
This part of my Invention, namely, the means described for removing ingots from
their moulds, is applicable not only to ingots cast in horizontal moulds, but also to
all ingots cast in moulds where the top is larger than the bottom. In Sheet III.
Figures 17 and 18 illustrate this with reference to a vertical rectangular mould.
The mould A is slotted at a on two of its sides a short distance, commencing from
the upper end thereof, and these slots are closed by the insertion of a wedge-shaped
block of metal, fire-clay, or other suitable material, which is held in place in the
manner described, or in cases where the slot is only required to be short may be
trusted to hold itself, with reference to Figures 17 and 18. The mould is made taper
to prevent the ingot adhering thereto, and the grippers are applied to the ingot in
the manner shewn in the Drawing to effect its removal from the mould. Figs. 19
and 20 shew polygonal and cylindrical forms of moulds constructed with openings
for the grippers, as above described.
When a number of moulds is arranged in close proximity for the purpose of being
charged I propose to effect the casting operation by means of a travelling ladle or
travelling trough, which improvement constitutes the last head of my Invention.
The Figures in Sheet IV. illustrate the use of the travelling ladle, Figure 21 being
an elevation of the travelling ladle arrangement, and Fig. 22 a plan view of the
same. In these Figures A is a series of horizontal moulds placed parallel to each
other on the ground, and transversely of a pair of rails on which a carriage B runs
bearing a ladle C charged with the molten metal. This ladle is filled froin the steel
melting furnace or from a Bessemer converter, the metal being guided into the ladle
by means of suitable troughs or gutters D; it is then brought opposite or over the
moulds in succession, and the metal is discharged therefrom into the moulds by the
spout E.
Fitted to the ladle is a sliding stopper F, by the depression of which the discharge
opening in the bottom of the ladle is closed. This is brought into use on every
shifting of the ladle.
The travelling trough arrangement is shewn in Sheet V., Fig. 23 being a trans-
verse section of a foundry arrangement according to this part of my Invention;
Fig. 24, a partial longitudinal elevation; and Fig. 25, a partial plan view. In these
Figures A, A, are trucks running upon railways, and carrying each a series of
horizontal moulds placed side by side. B is the tapping hole of the smelting
furnace discharging metal into the fixed trough C. Immediately below the
discharging end of this trough is the travelling trough D, which is a long
inclined channel mounted on wheels, and provided at its lower end with a spout
that extends at right angles therefrom, or nearly so, so as to run the metal direct
from the steel melting furnace into the moulds E on the truck A as the trough
travels slowly along either above or parallel to the moulds. The fixed trough C is

page_text: fitted at its discharge and with a stopper like that with which the ladle is fitted, and
thus the flow of the metal is regulated, the discharge being stopped at each shifting
of the trough or shute. By moving the travelling trough or shute over some six
or more moulds in succession, and then shifting the truck to bring another batch of
inoulds within range of the travelling trough or shute, the casting of the ingots
may be effected with a minimum expenditure of labour.
When a third truck laden with moulds is used, as indicated in the plan view
Fig. 25, the travelling trough or shute cannot be used for the filling of those
moulds, I therefore rely on the traverse motion of the truck to bring the moulds
in succession in line with a fixed trough or shute D*, which trough or shute extends
over the line of rails adjacent to the smelting furnace. I also propose when casting
ingots in vertical_moulds to arrange them on a travelling truck, as shewn in
Sheet III., where Fig. 20 is a cross section of a truck so fitted and brought under
a fixed trough or teening box, fitted with the usual nozzle and swan-neck stopper
arrangement or other suitable device for regulating the flow of the metal in con-
nection with the smelting furnace; Fig. 27 is a longitudinal side elevation of the
same partly in section; Fig. 28 is a plan view of the saine.
In this case also the
moulds are supplied with metal by being traversed under a fixed trough or teeming
box C.
Having now set forth the nature of my Invention, and explained the manner of
carrying the same into effect, I wish it to be understood that under the above in
part recited Letters Patent I claim,―
First. When casting ingots in the manner above described, that is, in moulds of
greater area at the top than at the bottom (and of any desired depth), mixing
with the molten metal a definite proportion of silicon and ferro-manganese, as above
explained, for preventing the boiling of the metal in the moulds.
Second. The means above described, with reference to Sheets I., II., and III.,
whereby the ingot may be withdrawn from the mould by grippers or by rods or
hooks appended to lifting chains or their equivalent.
Third. The means above described, with reference to Sheets IV., V., and VI., for
facilitating the filling of the ingot moulds.
In witness whereof, I, the said William Henry Osborne Taylor, have hereunto
set my hand and seal, the Eighth day of April, in the year of our Lord One
thousand eight hundred and seventy-nine.
T ANTARKT
MAYTON