IMPROVE- MENTS IN THE MANUFACTURE OF CAST STEEL AND IN THE METHOD OF HARDENING THE SAME
Year: 1876

page_text: In the Matter of Letters Patent granted to JAMES LEDGER, Engineer and
Patent Agent, of 61, Fleet Street, London, for the Invention of "IMPROVE-
MENTS IN THE MANUFACTURE OF CAST STEEL AND IN THE METHOD OF
HARDENING THE SAME." A communication from abroad by Alexandre
Jullien, Engineer to the Foundries and Forges Company, of Terre Noire
La Voulte et Besseges, and President of the Manganesed Iron and Steel
Company, of Paris, in the French Republic, bearing date the 21st day of
November 1876, No. 4499.
DISCLAIMER AND MEMORANDUM OF ALTERATION as proposed to be
entered by Ferdinand Henri Valton, of the Société Anonyme des Fers et
Aciers, of Paris, in the French Republic, Civil Engineer, pursuant to the
Statutes in that case made and provided.
WHEREAS Her Majesty Queen Victoria by Her Letters Patent under the Great
Seal of the United Kingdom of Great Britain and Ireland, bearing date at West-
minster, the Twenty-first day of November 1876, in the fortieth year of Her reign,
did give and grant unto the said James Ledger, his executors, administrators, and
assigns, the sole privilege for the term of fourteen years thence next ensuing, of
making, using, exercising, and vending within the United Kingdom of Great
Britain and Ireland, the Channel Islands, and the Isle of Man, the said Invention of
IMPROVEMENTS IN THE MANUFACTURE OF CAST STEEL AND THE METHOD OF
HARDENING THE SAME." A communication from abroad by Alexandre Jullien,
Engineer to the Foundries and Forges Company, of Terre Noire La Voulte et
Besseges, and President of the Manganesed Iron and Steel Company, of Paris, in the
French Republic:
"
And whereas in pursuance of a proviso in the said Letters Patent contained, the

page_text: .said James Ledger did within six calendar months next after the date of the said
Letters Patent cause a Specification or instrument in writing under his hand and
seal, purporting to describe and ascertain the nature of the said Invention, and in
what manner the same was to be performed, to be duly filed in the Great Seal
Patent Office :
And whereas the said Letters Patent were assigned to and became and now are
vested in me the said Ferdinand Henri Valton:
And whereas since the filing of the said Specification, I, the said Ferdinand
Henri Valton, have ascertained that part of the Invention mentioned in the title
and claimed in the third claiming clause was not new at the date of the said
Letters Patent:
And whereas the first claiming clause might be objected to on the ground
that the Invention intended to be claimed thereby is not defined with sufficient
precision :
And whereas the second claiming clause might be objected to on the ground that
the nature of the Invention claimed thereby was not described in the Provisional
Specification :
And whereas portions of the text of the said Specification, and the Drawings
thereunto annexed, might be understood as describing and illustrating Inventions to
which no claim is intended to be made:
And whereas there are in the said Specification clerical errors which I desire to
have corrected:
For these reasons I hereby disclaim and alter the title and parts of the
Specification of the said Letters Patent in manner following, that is to say:-
In the title I omit all the words after "steel," and the title when so altered will
read "Improvements in the Manufacture of Cast Steel."
"
A
In the Specification, referring to the Queen's Printers' copy thereof, at page 3,
line 37, for the word "formed" I substitute "found;" at page 4, line 2; for
"ordinance" I substitute " ordnance," and for " railways" I substitute " railway
plant;" at page 4, line 4, I omit the words "this Invention further consists in," and
after the word "steel" I insert "may be effected;" at page 4, line 20, for
"ordinance I substitute "ordnance, at page 4, line 25, I omit the words
at page 4, line 39, for "ozydation" I substitute "oxidation."
"method of fusion and casting;" at page 5, line 18, for the word "in" after
" also " I substitute "into;" at page 5, line 46, I insert a comma after "fracture;"
at page 6, in lines 23, 24, and 25, I insert the marks "°" signifying "per cent."
after each of the three rows of numbers; at page 6, line 31, for "titane" and
"chrome" I substitute "titanium" and "chromium;" at page 6, line 34, for "dead
plates "I substitute beds;" at page 6, line 37, for "small" I substitute "smaller;"
at page 6, line 40, I omit the words "to take the samples," and insert "to take
samples" after the word "reversed" at page 6, line 43, for "wards" I substitute
"conversion;" at page 6, line 44, for "fusion" I substitute "fusing them;" in the
I insert
same line, for "whence" I substitute "and," and after the word "run
"from the converter;" at page 6, line 45, for "and in "I substitute "or;" at
page 6, line 54, for "present" I substitute "presents;" at page 7, in lines 30 and 31,
for "ordinance" I substitute "ordnance;" at page 7, line 35, and also in line 44,
for "cupella "I substitute "cupola;" at page 7, lines 41, 42, 45, and 48, for "heat"
I substitute "head;" at page 7, line 49, for "tappings" I substitute "runners;" at
page 7, line 53, for "4" I substitute "5;" at page 8, line 1, for "5" I substitute
"4" at page 8, line 4, for "place them "I substitute "cool it;" at page 8, lines 12
and 17, for "heat" I substitute "head;" at page 8, lines 23, 30, 32, and 33, for
"ordinance" I substitute "ordnance;" at page 8, lines 32, 34, and 35, for "trunions
I write "trunnions;" at page 8, line 32, for "mode" I substitute "modes;" at page 8,
line 38, for "moulds" I write "mould;" at page 8, line 50, I omit "and" before
the word "thus," and insert the word "to" after it; at page 8, line 53, I omit
the;" at page 8, line 55, for "15 and 16 "I substitute "14 and 15;" at page 9,
line 9, for "shell" I substitute "chills; at page 9, line 11, for "shell" I substitute
«
"

page_text: kk
"
a chill" at page 9, line 17, for "21" I substitute " 25," and for "T, L," I substi-
tute "E, F" at page 9, line 23, for "heat" I substitute "head;" at page 9, line 28,
after "heavy" I insert "pieces;" at page 9, line 35, I omit "the;" at page 9,
line 47, for "quantity" I substitute "number;" at page 10, line 3, for "pieces " I
write "piece" at page 10, lines 21 and 22, I omit the words "and in the method
of hardening the same;" at page 10, line 23, between the words "that" and "what'
I insert the following sentence:-" Although I have mentioned various applications
" of the cast steel produced according to this Invention, and have described and
"shewn in the annexed Drawings various forms of pieces that might be cast in the
"said material, and apparatus for moulding and hardening the same, no claim is
"made to any of these applications, nor to any of the means or apparatus for
moulding and hardening herein set forth, but;" at page 10, line 25, I omit the
word "Firstly," and for "blown" I write "blow;" at page 10, line 26, before the
word "described " I insert "herein," and I omit all the rest of the line after
described." I omit also all the following lines of the Specification, being lines 27,
28, 29, 30, 31, 32, and 33 of page 10; and the Specification when so disclaimed,
altered, and amended will read as follows (omitting here the usual formal preamble
of Final Specification), that is to say:-
"
This Invention consists in certain improvements in the manufacture of cast steel,
whereby the metal may be obtained in large masses, without flaws, direct from the
furnace or crucible.
The following is the manner I propose to manufacture cast steel, without flaws,
in a Siemens-Martin furnace, for instance :-I form a metallic bath, by preference
of spiegeleisen, containing from 6 to 12 % of manganese, and 5 to 5 % of
carbon.
°
The spiegel eisen may be replaced by pig iron of good quality, in which manga-
nese is introduced to any desired proportion in the shape of rich ferro-manganese;
siliceous iron, containing 3% of silicon, could also be used, in which case it would
be necessary to add to the bath the proportion of manganese mentioned above; but
better results are obtained with manganesed iron. When the mass is in a perfectly
fluid state, and at its highest temperature, I add to it soft or hard scraps of iron,
or steel, puddled iron of various qualities, free from objectionable ingredients.
In order to bring the operation to a satisfactory result it should be performed
rapidly, and for that purpose the scraps are heated beforehand.
If it is desired to obtain hard steel, highly carburretted scraps should be used, but
in case of soft steel the said scraps should be of the softest kind. Samples are taken
from time to time from the melted mass until one is obtained answering to the
quality of steel it is desired to produce. The sample should stand hammering
without splitting or breaking at the edges, as this shows the small oxidation of the
metal. This is one of the features by which this process of manufacture differs from
others in which highly oxidised iron is first obtained and then reduced to the desired
state by manganese. The hammered samples are then bent in a cold state to an
extent which varies according to the degree of hardness or softness to which it is
desired to cast the steel. This point obtained, the operator ceases to introduce the
scraps into the mass.
The next operation consists in rendering the steel capable of being cast without
flaws or blown holes. I am aware that this has been performed in different ways,
such as adding to the molten mass (just before casting) a certain amount of silicon.
This operation has given certain good results, but the metal was not in a satisfactory
state of fluidity, difficult to cast, and very brittle when cooled.
I have found that by adding a certain proportion of manganese before casting, the
quantity of silicon can be reduced, and the result is a cast steel perfectly fluid, which
when cooled contains no flaws or blown holes, and is capable of resisting blows and
traction. The fact of adding manganese also helps in separating the metal from the
dross. It will thus be seen that to obtain cast steel possessing the above qualifica-
tions it is necessary to add to the bath of melted metal certain proportions of
carbon, silicon, and manganese.

page_text: For hard steel-Silicon
-
from 0.005 to 0.006.
-
"
"
0.007 to 0.012.
0.002 upwards.
Carbon
Manganese
For soft steel-Silicon
-
-
Carbon
Manganese
from 0.002 to 0.004.
2
0.001 to 0.003.
»
"3
0.006 to 0.012.
Intermediate proportions would of course give intermediate qualities, but care
should be taken of the quantities absorbed by the dross.
The manner of introducing the carbon, silicon, and manganese may be varied
according to circumstances; for instance, by using silicious iron in suitable pro-
portions and adding ferro-manganese, or by means of an alloy of manganese, carbon,
and silicon.
In this last case the quantities may vary, but carbon should always enter in this
proportion of 3 to 5°, according to the quantity of silicon contained in the alloy.
The cast steel thus produced may be used to great advantage in casting large
masses of metal, such as for ordnance, armour plates, railway plant, and all parts of
machinery.
Hardening large masses of cast steel may be effected in the following manner:-
In a receptacle of sufficient dimensions, in which water is placed, I introduce a
second receptacle containing sand. The sides of this receptacle are perforated, so
as to place the sand in communication with the water aforesaid. The mass of cast
steel, after being heated to the desired temperature, is plunged in the damp sand
bath. The cooling of the mass takes place more or less rapidly, according to the
degree of coarseness or fineness of the sand. The mass of metal thus hardened can
then be tempered by heating it a second time, and allowing it to cool gradually so
as to bring it to the desired state of hardness.
And in order to explain this Invention more fully, I will now proceed to describe
the means whereby it may be effected and applied, reference being had to the
illustrative Sheets of Drawings accompanying these presents, and to the numeral
figures and letters of reference marked thereon respectively as follows :-
The object of this Invention is to obtain a metal casting without blown holes or
flaws, having the required qualifications which render it applicable (without ham-
mering, compression, or such like mechanical means) to all industrial purporses and
to ordnance. It is therefore important to introduce only in the metallic bath sub-
stances of the best quality, containing but the smallest traces of phosphorus and
sulphur. The castings could also be produced without blown holes or flaws,
although the materials used contained impurities, but the metal would be of an
inferior quality and its application would be limited.
The best metal for forming the bath is spiegel eisen, containing from 6 to 12% of
manganese and 5 to 5% of carbon. The spiegel eisen could be replaced by iron
of good quality, in which manganese would have been introduced in the desired
proportion, or by rich ferro-manganese. When the bath has arrived at a perfect
state of fusion, and at the highest temperature attainable, scraps or turnings, of iron
or steel, hard or soft, containing no impure elements are then added.
In order that the fusion may take place as quick as possible, the scraps or
turnings are heated before hand, and should be selected according to the quality of
metal it is desired to produce. Samples are taken from time to time from the
melted mass, which must stand the test of hammering without splitting or breaking
round the edges. When a sample has been obtained of the desired quality the
introduction of the scraps in the furnace is ceased, and the last additions which
constitute the important part of the operation begin. The object of these additions
is to give to the steel its final qualities, and care must therefore be taken that no
oxidation takes place in the bath, the object being to obtain cast steel without blown
holes or flaws; this result is arrived at by adding to the mass before casting a
certain quantity of manganese and silicon. This addition has also the advantage of

page_text: facilitating the separating of the metal from the slag. The metal being very fluid
and without blown holes possesses remarkable qualities of resistance to traction and
blows.
It is important in order to give to the cast steel the desired properties that the
proportions of carbon, silicon, and manganese should vary according to the circum-
stances. For hard steel 0·005 to 0.006 of silicon, 0·007 to 0.012 of carbon, and from
0.006 and upwards of manganese are added to the bath. For soft steel the pro-
portions of silicon must be reduced to minimum, about 0·003 to 0.004, carbon to
0.001 to 0.002, and manganese about 0·006 to 0-012.
The introduction of carbon, silicon, and manganese may be effected in different
ways, either by introducing separately a sufficient quantity of silicious iron, to which
is added the required quantity of manganese, or by introducing in the bath the
different substances mentioned above as an alloy containing manganese, carbon, and
silicon, the two last in various proportions, whilst the carbon remains in the limits
of 3 to 5%, according to the quantity of silicon contained in the alloy.
Supposing the metallic bath obtained in the conditions above stated, and the
sample having stood the test of hammering, and containing about 0·30 % of
carbon and 0-50 of manganese.
Two methods may be followed to make the final additions.
The first consists in adding for every 100 kilogs. contained in the bath 14 to 15
kilogs. of an iron of the following composition
The iron adds to the quantity already contained in the bath; then the carbon,
5 silicon, and manganese pass in large proportions also into the said bath, except a
small quantity absorbed by the slag, and a metal is obtained containing--
Carbon, from
Silicon
Manganese
0.65 to 0.70 %
0.48 to 0.50 "
1:30 to 1.50
""

page_text: The substances added in all by these two additions, are,-
Iron
-
Carbon
Silicon
Manganese
-
The cast steel will contain,―
Carbon
Silicon
Manganese-
which constitutes a soft steel.
5.88
0.27
0.30
1.05
0:32 to 0.37%
0.23 to 0.26°
1.10 to 1.30%
The above addition requires to be heated before hand, and introduced in the
furnace as soon as a suitable sample is obtained. The whole is mixed well together,
and when fluid is quickly run off, this being an important point for obtaining a
successful result. The quality of the metal thus obtained may be varied at will by
proportions of tungsten, titanium, chromium, and other elements, which can alter
and improve the quality of steel. It is only necessary to arrive at this result to
introduce in the alloys above described the elements which are required. This
process of fusion, chiefly applicable to furnaces, with fixed or moveable beds, may
also be carried out with suitable alterations by the Bessemer process, or in
crucibles.
In the case of the Bessemer process an iron containing a smaller quantity of
manganese is used, so as not to arrive at too high a temperature; this could also be
avoided by adding picked scraps or soft iron, the object being to obtain a metal as
little oxidized as possible. The converter is reversed to take samples in the same
way as with the Martin furnace; silicious iron may also be used, but it should
contain a certain proportion of manganese. The additions are made after conversion,
according to the method already described, either after reheating or after fusing
them in a Siemens or Ponsard furnace, and the metal may be run from the con-
verter into the ladle or the moulds.
To apply the process to the fusion in crucible, the proportions of the ingredients
placed in the said crucible are such as to obtain the desired color of cast metal, and
this being poured into the ladle the additions are then made as above described for
the Bessemer process, and the metal is run into moulds. Metallic moulds should be
used as often as possible, the rapid cooling being favorable to produce cast metal
without blown holes.
COMPOSITION AND QUALITY OF THE CAST STEEL.
The cast steel obtained by the above process of fusion and by the combination of
ingredients which have been described presents the following characteristics :-
1°. The metal is without blown holes in the whole of its mass.
2°. This cast steel, without compression or other mechanical means, has the
required density of 7-78 to 7.91.
3. The steel is malleable, and may be rolled and hammered without splitting.
4°. Its resistance to blows and traction varies in the same limits as those of rolled
and hammered steel.
In order to arrive at the above result the castings must be slowly tempered, and
cooled with care.
Trials made on tempered bars have given the following results, beginning with
hard and finishing with soft steel :-
Limit of Electinit
Runture
Stretching °1

page_text: i
All pieces of large size and of shape impossible to forge can be produced by
means of this new cast steel.
APPLICATION TO FIELD AND NAVAL ORDNANCE.
The application of this cast steel to field and naval ordnance are very numerous;
the following are some examples :-
1°. Shots and Shells for the Attack of Armour-plated Ships and Forts.-The shots
and shells are cast in metal moulds, having at the inside the desired shape, and the
casting is made from the cupola or ladle.
Direct casting is made as follows:-On the accompanying Sheet of Drawings
(Sheet 1) A, B, C, D, E, F, (Figure 1) shows the frames put together to receive the
metal in the sand, which must be well dried and heated. The two moulds G, H,
S, K, are intended to receive the principal part. The thickness must be such that
the cooling will be as rapid as possible. The frame J, K, L, M, is made to receive
the dead head, and is lined with dried fire-clay. The cooling being slower in this
part than in the mould, the metal in the dead head remains liquid and feeds the
centre of the projectile when the cooling takes place.
Figure 2 represents the arrangement for running the metal direct from the cupola
or ladle. The projectiles are cast with the point downwards with a dead head on
the top of the mould.
Figure 3 shows the mode of casting shells with a sand core. The parts A, B, C,
D, E, F, of the mould and frame of the dead head are arranged so as to receive two
runners, side by side. The core G, H, K, is made of fire-clay.
The gases escape
through a central tube L, M, but it will be found preferable to ram down the sand
with an outward shell of sheet iron, which in melting forms part of the casting, and
constitutes a cleaner chamber than with sand alone. This second method is shown
at Figure 5.
Figure 4 is a similar method of operating, with this difference, that the core is in
iron or steel.
bo
A
The projectile may also be made solid and bored out on the lathe.
cool it
It is necessary to anneal the projectile before being used, or better, A plaee-them it
in oil.
2°. Cannons of different sizes for Field and Naval Purposes.-The cast steel without
blown holes can be advantageously applied to the production of cannons of all sizes
which are bored or cast with a chamber. The casting is made direct in the mould
or otherwise.
Figure 6 shows the arrangements for casting a cannon of large dimensions. The
mould C, D, E, F, is made in rings placed one over the other. The frame A, B,
C, D, is intended to hold the dead head of sand. The casting is made in a cistern
L, M, and the metal enters the cistern in four streams N, N, N, N, along the core,
which is protected by a sheet-iron tube G, H, J, K, thin enough to be absorbed by
the melted metal.
Figure 7 shows the method of casting smaller cannons. A, B, C, D, is the mould ·

page_text: "
The watering is made by a series of pipes, in which water or steam is made
to pass.
Figure 43 shows the cooling of a piece in a bath of damp sand.
Figures 44 and 45 are two arrangements for cooling by means of a current
of air.
Having now described and set forth the nature and object of this Invention for
Improvements in the Manufacture of Cast Steel," as communicated to me by my
foreign correspondent, I would remark in conclusion that although I have mentioned
various applications of the cast steel produced according to this Invention, and have
described and shewn in the annexed Drawings various forms of pieces that might
be cast in the said material and apparatus for moulding and hardening the same, no
claim is made to any of these applications, nor to any of the means or apparatus
for moulding and hardening herein set forth, but what I claim as my Invention
and desire to secure by the herein in part recited Letters Patent is, producing cast
steel without flaws or blow holes in the manner and by the combinations and
proportions herein described.
In witness whereof, I, the said James Ledger, have hereunto set my hand and
seal, this Nineteenth day of May, in the year of our Lord One thousand
eight hundred and seventy-seven.
JAMES LEDGER. (L.S.)
In witness whereof, I, the said Ferdinand Henri Valton, have hereunto set my
hand and scal, this Nineteenth day of March, in the year of our Lord One
thousand eight hundred and seventy-eight.
I hereby grant my Fiat, giving leave to the above-named Ferdinand Henri
Valton (the assignee of the herein-before mentioned Letters Patent) to file in the
30 Great Seal Patent Office, with the Specification to which the same relates, the
above written Disclaimer and Memorandum of Alteration.
T
TG
1

page_text: LETTERS PATENT to James Ledger, Engineer and Patent Agent, of 61, Fleet
Street, London, for the Invention of "IMPROVEMENTS IN THE MANUFACTURE
OF CAST STEEL AND IN THE METHOD OF HARDENING THE SAME."-A communi-
cation from abroad by Alexandre Jullien, Engineer to the Foundries and
Forges Company of Terre Noire La Voulte et Besseges, and President of the
Manganesed Iron and Steel Company, of Paris, in the French Republic.
PROVISIONAL SPECIFICATION left by the said James Ledger at the Office
of the Commissioners of Patents on the 21st November 1876.
"IM-
JAMES LEDGER, Engineer and Patent Agent, of 61, Fleet Street, London.
PROVEMENTS IN THE MANUFACTURE OF CAST STEEL AND IN THE METHOD OF
HARDENING THE SAME."-A communication from abroad by Alexandre Jullien,
Engineer to the Foundries and Forges Company of Terre Noire La Voulte et
Besseges, and President of the Manganesed Iron and Steel Company, of Paris, in
the French Republic.
This Invention consists in certain improvements in the manufacture of cast steel,
whereby that metal may be obtained in large masses, without flaws or blown holes,
direct from the furnace or crucible.
The following is the manner I propose to manufacture cast steel without flaws
in a Siemens-Martin furnace for instance:-I form a metallic bath, by preference
of spiegel eisen, containing from 6 to 12% of manganese, and 5 to 5% of
carbon. The spiegel eisen may be replaced by pig iron of good quality, in which
manganese is introduced to any desired proportion in the shape of rich ferro-
manganese; silicious iron, containing 3% of silicon, could also be used, in which
case it would be necessary to add to the bath the proportion of manganese men-
tioned above, but better results are obtained with manganesed iron. When the .
mass is in a perfectly fluid state and at its highest temperature I add to it soft or
hard scraps of iron or steel, puddled iron of various qualities, free from objectionable
ingredients.
In order to bring the operation to a satisfactory result it should be performed
rapidly, and for that purpose the scraps are heated beforehand.
-
If it is desired to obtain hard steel, highly carburetted scraps should be used, but

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed by
the said James Ledger in the Great Seal Patent Office on the 19th May
1877.
JAMES LEDGER, Engineer and Patent Agent, of 61, Fleet Street, London. "IM-
PROVEMENTS IN THE MANUFACTURE OF CAST STEEL AND IN THE METHOD OF

page_text: HARDENING THE SAME."-A communication from abroad by Alexandre Jullien,
Engineer to the Foundries and Forges Company of Terre Noire La Voulte et
Besseges, and President of the Manganesed Iron and Steel Company, of Paris, in
the French Republic.
This Invention consists in certain improvements in the manufacture of cast steel,
whereby the metal may be obtained in large masses, without flaws, direct from the
furnace or crucible.
The following is the manner I propose to manufacture cast steel without flaws
in a Siemens-Martin furnace for instance :-I form a metallic bath, by preference
of spiegel eisen, containing from 6 to 12% of manganese and 5 to 5% of
carbon. The spiegel eisen may be replaced by pig iron of good quality, in which
manganese is introduced to any desired proportion in the shape of rich ferro-
manganese; silicious iron containing 3° of silicon could also be used, in which
case it would be necessary to add to the bath the proportion of manganese men-
tioned above, but better results are obtained with manganesed iron. When the
mass is in a perfectly fluid state and at its highest temperature I add to it soft or
hard scraps of iron or steel, puddled iron of various qualities, free from objectionable
ingredients.
In order to bring the operation to a satisfactory result it should be performed
rapidly, and for that purpose the scraps are heated beforehand.
If it is desired to obtain hard steel, highly carburetted scraps should be used, but
in case of soft steel the said scraps should be of the softest kind. Samples are
taken from time to time from the melted mass until one is obtained answering to
the quality of steel it is desired to produce. The sample should stand hammering
without splitting or breaking at the edges, as this shows the small oxidation of the
metal. This is one of the features by which this process of manufacture differs
from others in which highly oxidized iron is first obtained and then reduced to the
desired state by manganese. The hammered samples are then bent in a cold state
to an extent which varies according to the degree of hardness or softness to which
it is desired to cast the steel. This point obtained, the operator ceases to introduce
the scraps into the mass.
The next operation consists in rendering the steel capable of being cast without
flaws or blown holes. I am aware that this has been performed in different ways,
such as adding to the molten mass (just before casting) a certain amount of silicon.
This operation has given certain good results, but the metal was not in a satisfactory
state of fluidity, difficult to cast, and very brittle when cooled.
I have formed that by adding a certain proportion of manganese before casting
the quantity of silicon can be reduced and the result is a cast steel perfectly fluid,
which when cooled contains no flaws or blown holes, and is capable of resisting
blows and traction. The fact of adding manganese also helps in separating the
metal from the dross. It will thus be seen that to obtain cast steel possessing the
above qualifications it is necessary to add to the bath of melted metal certain pro-
portions of carbon, silicon, and manganese.
The following shows the proportions which can be used:-
For Hard Steel. Silicon from
0.005 to 0.006.
Carbon
Manganese
0.007 to 0.012
رو
"
0.002 upwards.
For Soft Steel.--Silicon
from
0.002 to 0.004.
"
0.001 to 0.003.
0.006 to 0.012.
33
Carbon
Manganese
Intermediate proportions would of course give intermediate qualities, but care
should be taken of the quantities absorbed by the dross.
The manner of introducing the carbon, silicon, and manganese may be varied
according to circumstances, for instance, by using silicious iron in suitable proportions
and adding ferro-manganese, or by means of an alloy of manganese, carbon, and silicon.
In this last case the quantities-may-vary, but carbon-should-always-enter-in-this
renortion of 2 to 20% socording to the quantity of silicion contained in the allox.

page_text: The cast steel thus produced may be used to great advantage in casting large
masses of metal, such as for ordinance, armour plates, railways, and all parts of
machinery.
This Invention further consists in hardening large masses of cast steel in the
following manner:-In a receptacle of sufficient dimensions in which water is
placed I introduce a second receptacle containing sand. The sides of this receptacle
are perforated so as place the sand in communication with the water aforesaid.
The mass of cast steel after being heated to the desired temperature is plunged in
the damp sand bath. The cooling of the mass takes place more or less rapidly
according to the degree of coarseness or fineness of the sand. The mass of inetal
thus hardened can then be tempered by heating it a second time, and allowing it to
cool gradually so as to bring it to the desired state of hardness.
.
And in order to explain this Invention more fully I will now proceed to describe
the means whereby it may be effected and applied, reference being had to the
illustrative Sheets of Drawings accompanying these presents, and to the numeral
figures and letters of reference marked thereon respectively as follows:-
The object of this Invention is to obtain a metal casting without blown holes or
flaws, having the required qualifications which render it applicable (without
hammering, compression, or such like mechanical means) to all industrial purposes
and to ordinance. It is therefore important to introduce only in the metallic bath
substances of the best quality containing but the smallest traces of phosphorus and
sulphur. The castings could also be produced without blown holes or flaws,
.although the materials used contained impurities, but the metal would be of an
inferior quality, and its application would be limited.
The best method of fusion and casting metal for forming the bath is spiegel eisen
containing from 6 to 12% of manganese, and 5 to 5% of carbon. The spiegel
eisen could be replaced by iron of good quality in which manganese would have
been introduced in the desired proportion or by rich ferro-manganese. When the
bath has arrived at a perfect state of fusion, and at the highest temperature
attainable, scraps or turnings of iron or steel, hard or soft, containing no impure
elements are then added. In order that the fusion may take place as quick as
possible the scraps or turnings are heated beforehand, and should be selected
according to the quality of metal it is desired to produce. Samples are taken from.
time to time from the melted mass which must stand the test of hammering without
splitting or breaking round the edges. When a sample has been obtained of the
desired quality the introduction of the scraps in the furnace is ceased, and the last
additions which constitute the important part of the operation begin. The object
of these additions is to give to the steel its final qualities, and care must therefore
be taken that no ozydation takes place in the bath, the object being to obtain
cast steel without blown holes or flaws; this result is arrived at by adding to the
mass before casting a certain quantity of manganese and silicon. This addition has
also the advantage of facilitating the separating of the metal from the slag. The
metal being very fluid and without blown holes possesses remarkable qualities of
resistance to traction and blows.
It is important in order to give to the cast steel the desired properties that the
proportions of carbon, silicon, and manganese should vary according to the cir-
cumstances. For hard steel 0·005 to 0.006 of silicon, 0·007 to 0.012 of carbon, and
from 0.006 and upwards of manganese are added to the bath. For soft steel the
proportions of silicon must be reduced to minimum about 0.003 to 0.004 carbon
to 0.001 to 0.002, and manganese about 0.006 to 0.012.
The introduction of carbon, silicon, and manganese may be effected in different
ways, either by introducing separately a sufficient quantity of silicious iron to
which is added the required quantity of manganese, or by introducing in the bath
the different substances mentioned above as an alloy containing manganese, carbon,
and silicon, the two last in various proportions, whilst the carbon remains in the
limits of 3 to 51/2, according to the quantity of silicon contained in the alloy.
Hard Cast Steel-Supposing the metallic bath obtained in the conditions above

page_text: stated, and the sample having stood the test of hammering and containing
about 0.30° of carbon and 0·50 of manganese.
Two methods may be followed to make the final additions. The first consists in
adding for every 100 kilogs. contained in the bath 14 to 15 kilogs. of an iron of
the following composition :-
14.50
The iron adds to the quantity already contained in the bath; then the carbon,
silicon, and manganese pass in large proportions also in the said bath, except a
small quantity absorbed by the slag, and a metal is obtained containing
Carbon from 0.65 to 0.70%
Silicon
Manganese,
0.48 to 0.50
"
1:30 to 1.50
دو
"
The second method consists in adding to every 100 kilogs. 11 kilogs. of iron of

page_text: 500 of ferro-manganese, containing,
Iron
Carbon
Manganese
-
24.50 say 0:37 added
-
5.50
0.08
"
"
70-
1.05
دو
"
100.
1.50.
The substances added in all by these two additions are,-
Iron
Carbon
Silicon
Manganese
The cast steel will contain,-
Carbon
Silicon
Manganese
which constitutes a soft steel.
5.88
0.27
-
0.30
1.05
0.32 to 0:37
0.23 to 0.26
1.10 to 1.30
The above addition requires to be heated beforehand, and introduced in the
furnace as soon as a suitable sample is obtained. The whole is mixed well together,
and when fluid is quickly run off. This being an important point for obtaining a
sucessfull result. The quality of the metal thus obtained may be varied at will
by proportions of tungsten, titane, chrome, and other elements which can alter and
improve the quality of the steel. It is only necessary to arrive at this result to
introduce in the alloys above described the elements which are required. This
process of fusion, chiefly applicable to furnaces with fixed or movable dead plates,
may also be carried out with suitable alterations by the Bessemer process or in
crucibles.
In the case of the Bessemer process an iron containing a small quantity of
manganese is used so as not to arrive at too high a temperature; this could also be
avoided by adding picked scraps or soft iron, the object being to obtain a metal as
little oxidized as possible. To take the samples the converter is reversed in the
same way as with the Martin furnace. Silicious iron may also be used, but it
should contain a certain proportion of manganese. The additions are made after-
wards according to the method already described, either after reheating or after
fusion in a Siemens or Ponsard furnace, whence the metal may be run into the
ladle and in the moulds.
To apply the process to the fusion in crucible the proportions of the ingredients
placed in the said crucible are such as to obtain the desired color of cast metal, and
this being poured into the ladle the additions are then made, as above described, for
the Bessemer process and the metal is run into moulds. Metallic moulds should be
used as often as possible, the rapid cooling being favourable to produce cast metal
without blown holes.
COMPOSITION AND QUALITY OF THE CAST STEEL.

page_text: 2°. This cast steel, without compression or other mechanical means, has the
required density of 7.78 to 7.91.
3°. The steel is malleable and may be rolled and hammered without splitting.
4°. Its resistance to blows and traction varies in the same limits as those of rolled
and hammered steel.
In order to arrive at the above result the castings must be slowly tempered and
cooled with care.
Trials made on tempered bars have given the following results, beginning with
hard and finishing with soft steel :-
Limit of Elasticity.
1. 42 to 45 kilogs.
Rupture.
85 to 90 kilogs.
75 84
"
Stretching..
2.5 to 40
4.5 7.0
""
7.5 10.0
"2
2. 37., 39
3. 34, 36
"
"
72 78
"
»
"
4. 33 35
71
75
11.
14.
"
532 34
"3
دو
"
13
"
70 74
15°
17.5
"
"
وو
37
6. 25 31
60 70
18.
20°
"
"
دو
"
5°. Before tempering, the six above pieces of steel have properties very similar
to each other, the principal of which are as follows:-
Limit of Elasticity
28 to 25 kiloca
The application of this cast steel to field and naval ordinance are very numerous;
the following are some examples:
1°. Shots and Shells for the Attack of Armour Plated Ships and Forts.-The
shots and shells are cast in metal moulds, having at the inside the desired shape,
and the casting is made from the cupella or ladle.
Direct casting is made as follows:-On the accompanying Sheet of Drawing
(Sheet 1) A, B, C, D, E, F, (Figure 1,) shows the frames put together to receive the
metal in the sand, which must be well dried and heated. The two moulds G, H,
S, K, are intended to receive the principal part. The thickness must be such that
the cooling will be as rapid as possible. The frame J, K, L, M, is made to receive the
dead heat, and is lined with dried fire-clay. The cooling being slower in this part
than in the mould, the metal in the dead heat remains liquid, and feeds the centre
of the projectile when the cooling takes place.
Figure 2 represents the arrangement for running the metal direct from the cupella
or ladle. The projectiles are cast with the point downwards, with a dead heat on
the top of the mould.
4
Figure 3 shows the mode of casting shells with a sand core. The parts A, B, C,
D, E, F, of the mould and frame of the dead heat are arranged so as to receive two
tappings side by side. The core G, H, K, is made of fire-clay. The gases escape
through a central tube L, M, but it will be found preferable to ram down the sand
with an outward shell of sheet iron, which in melting forms part of the casting, and
constitutes a cleaner chamber than with sand alone. This second method is shown
at Figure 4.

page_text: Figure 5 is a similar method of operating, with this difference, that the core is in
iron or steel.
The projectile may be also made solid, and bored out on the lathe.
It is necessary to anneal the projectile before being used, or better, to place them
in oil.
2°. Cannons of Different Sizes for Field and Naval Purposes.-The cast steel
without blown holes can be advantageously applied to the production of cannons of
all sizes, which are bored or cast with a chamber. The casting is made direct in the
mould or otherwise.
Figure 6 shows the arrangements for casting a cannon of large dimensions. The
mould C, D, E, F, is made in rings placed one over the other. The frame A, B, C, D,
is intended to hold the dead heat of sand. The casting is made in a cistern L, M,
and the metal enters the cistern in four streams N, N, N, N, along the core, which
is protected by a sheet-iron tube G, H, J, K, thin enough to be absorbed by the
melted metal.
Figure 7 shows the method of casting smaller cannons. A, B, C, D, is the mould
made of several parts. A, B, G, H, is the frame, which receives the dead heat in
sand. A tube of thin sheet iron J, K, perforated along its length to allow the metal
to pass, is placed in the centre of the mould. It is held in position by discs or cross
pieces L, M, N. The whole is made of sheet iron sufficiently thin to be absorbed
by the melted metal. The casting is made by a funnel O lined with fire-clay.
Figure 8 shows a method of direct casting for cannons of similar sizes.
Figure 9 is an arrangement for casting large pieces of ordinance, which is per-
formed by means of a central core in fire-clay covered with thin sheet iron absorbed
by the metal.
Figure 10 shows an arrangement similar to that of Figure 9 for direct casting in
the mould by means of a funnel O, and by the centre of the core made of fire-clay
covered with thin sheet iron.
The quality of cast steel used varies according to circumstances:
3°. Internal Tubes for Large Pieces of Ordinance.-These tubes are cast in a
similar way as the cannons.
4°. Hoops and Trunions for Ordinance of all Sizes.-The mode of casting these are
the same as those employed for casting ordinance and tubes. For small hoops and
trunions the mould is made specially with depressions for the trunions.
Figure 11 shows the details of the process used for casting hoops and trunions.
The inould A, B, C, D, is made of two parts, divided by the line E, F, resting on
the bed plate C, D, and covered by a plate A, B, supporting the dead head mould.
The casting is made by a receiver communicating with the moulds by channels J, K.
The quality of steel is similar to that used for the cannons, and tempering is
necessary.
ARMOUR PLATES.
This cast steel applied to armour plates for ships and fortifications offers great
resistance to shocks, and allows the said plates to be made of less thickness than
heretofore, which in the case of ships is a great advantage.
The outer surface may be of various patterns, such as diamond, spherical, or
hollow shapes, inclinations of all kinds and at every angle, so that the shot shall
not strike the plate in a straight direction.
The interior of the casting may also be made to suit the shape of the ship.
By means of this process the armour plates may be hollowed out so as to obviate
the necessity of passing the bolts right through, and thus be exposed to the blow of
the shot or shell.
The casting of these armour plates is made in a similar way as above described.
Figures 12 and 13 show the surfaces, which can be obtained by making armour
plates by means of this cast steel.
Figures 15 and 16 show plates also obtained by this process.
Figure 16 represents plates hollowed out by means of cores.

page_text: The steel can also be applied to the production of all kinds of appliances for iron
works, such as cages, rollers, gearing, steam hammers, and such like heavy work.
METHOD OF HARDENING.
This method consists in replacing, tempering, and hardening by oil by means of a
bath of damp sand.
A
A receptacle of a sufficient capacity for receiving the piece it is intended to
harden is used, and filled with cold or warm water, according to circumstances.
second receptacle filled with sand is placed in the first receptacle. The sand, which
can be of fine or coarse quality, is placed in communication with water by means of
a large quantity of small apertures.
The receptacle containing the sand may be made of perforated sheet iron.
The piece to be hardened is heated to a temperature which varies according to its
degree of hardness or composition and the result it is desired to attain, and then

page_text: plunged in the above described sand bath. Cooling takes place more or less rapidly,
according to the fineness or coarseness of the sand.
It may be easily understood that the pieces placed at a red heat in the bath heats
and produces evaporation of the water contained in the sand; this water being
replaced more or less quickly, according to the quality of the sand used.
A harder or softer degree of hardness, and even temper, may be given by varying
the coating of the sand used between the piece to be hardened and the water.
Coatings of different qualities of sand may also be used in case certain parts
require to be made harder than others.
If the pieces taken out of the sand be too hard, they may be tempered; if they
should be too soft, they should be heated over again and placed a second time in the
bath of sand, the quality of which is altered.
Figure 41 shows a shell in the sand bath surrounded by water.
Figure 42 is an arrangement of a similar piece, but of another shape.
The watering is made by a series of pipes, in which water or steam is made
to pass.
Figure 43 shows the cooling of a piece in a bath of damp sand.
Figures 44 and 45 are two arrangements for cooling by means of a current
of air.
Having now described and set forth the nature and object of this Invention for
Improvements in the Manufacture of Cast Steel and in the Method of Hardening
the same," as communicated to me by my foreign correspondent, I would remark
in conclusion that what I claim as my Invention and desire to secure by the
herein in part recited Letters Patent is,-
Firstly. Producing cast steel without flaws or blown holes in the manner and
by the combinations and proportions described and set forth in the first part of this
Specification, and the mode of melting and casting the same, substanstially as
described and represented.
Secondly. The apparatus and methods of casting, substantially as described and
represented.
Thirdly. The method of hardening by means of a wet sand bath, and the means
of cooling, substantially as described and represented in Figures 41, 42, 43, 44,
and 45.
In witness whereof, I, the said James Ledger, have hereunto set my hand
and seal, this Nineteenth day of May, in the year of our Lord One
thousand eight hundred and seventy-seven.
JAMES LEDGER. (L.S.)