IMPROVEMENTS IN THE PROCESS OF MAKING MALLEABLE FERRO-NICKEL AND FERRO-COBALT AND COMBINATIONS OF THESE ALLOYS
Year: 1884

page_text: PROVISIONAL SPECIFICATION.
I ALEXANDER MELVILLE CLARK of the firm of A. M. and Wm Clark of
53 Chancery Lane in the County of Middlesex, Fellow of the Institute of Patent
Agents, do hereby declare the nature of the said invention for "IMPROVEMENTS IN
THE PROCESS OF MAKING MALLEABLE FERRO-NICKEL AND FERRO-COBALT AND
COMBINATIONS OF THESE ALLOYS" to be as follows:-
This invention relates to the manufacture of malleable ferro-nickel and ferro-
cobalt by the direct employment of pigs or matts of these metals (without that
part of the subsequent refining which would have for object the elimination of the
iron) which are combined at one and the same fusion with ferro-cyanide or cyanide
of potassium and one of the oxides of manganese (binoxide for example) adding, at
the moment of running, a small quantity of aluminium.
The proportions to be used, to ensure the products having the qualities of
malleability, ductility, tenacity etc which make them adaptable to the most varied
applications will be indicated hereafter.
The pigs or matts employed are obtained from the natural or oxidised ores
called hydrosilicates of nickel and magnesia, containing variable proportions of iron
and alumina, without any trace of arsenic, which are obtained in New Caledonia
and its dependencies, as well as the ores of cobalt and chromium of the same origin
and more generally the ores of nickel and cobalt of all countries. These pigs or
matts or mixed matts or pigs obtained by the simultaneous fusion of ores of nickel
and cobalt, as well as mixed matts or pigs which are obtained by the simultaneous
fusion of ores of nickel and chromium (or chrome iron) by the simultaneous fusion
of ores of cobalt and chromium, and the simultaneous fusion of ores of nickel,
cobalt and chromium using poor ores of nickel or cobalt with the addition of ores
of chromium when the products are to contain a small per centage of nickel or of
cobalt and a large per centage of iron; all these pigs or all these matts whether
simple or mixed containing a low per-centage of sulphur are what it is intended to
ID 431

page_text: utilise, with or without an addition either of soft or crude iron, according to
circumstances, before the final refining which has for its object the elimination of
the iron.
To obtain these alloys malleable, ductile, homogeneous and with non-oxidizing
qualities proportional to the per-centage of nickel or cobalt the pigs or the matts
above described are employed. Or these pigs or matts may have been previously
manufactured rich or poor in nickel or cobalt according to requirements or they
are impoverished more or less at will by the addition either of malleable iron or
pig iron (or crude iron) and we melt them directly with ferro-cyanide or cyanide
of potassium and one of the oxides of manganese (the binoxide for example) with
the addition at the moment of running of a small quantity of aluminium which
without altering the malleability of the product gives it a compactness and
homogeneity which it would not otherwise have.
These processes of malleabilization are entirely different from those which have
been heretofore invented not only in their nature but also especially in their
effects.
These processes for the direct malleabilization of the pigs or matts either simple
or mixed above enumerated with the optional addition of soft or cast iron, give the
alloys a special intrinsic character, a peculiar physical condition rendering them
permanently malleable even after a second fusion, which allows, on the one hand
the malleabilised ingots to be sent away to a distance to be worked up, and on the
other hand the waste jets or defective castings to be utilized either elsewhere or on
the spot.
The processes heretofore described and used on the contrary have only imparted
an unstable malleability necessitating after remelting a second operation for
malleabilisation.
.
The alloys obtained by this present process are tenacious, ductile and malleable
and adapted for casting, rolling, drawing, wire-drawing and hammering.
It should be remarked that in treating pigs or matts of nickel and of cobalt by
this process, the resulting ferro-nickel and ferro-cobalt can be forged much more
easily than the pure nickel and cobalt which would have been malleabilized in
their stead by the same means.
A peculiarity which is a property of this process of malleabilisation should be
observed. Whilst the soft iron loses by the second fusion its fibrous texture and
becomes crystalline and brittle like cast iron, this same soft iron preserves its
malleability after the second fusion if it had been previously mixed with a certain
quantity of the malleabilized products of the process of this invention whether
these products be the ferro-nickel or ferro-cobalt above mentioned or pure nickels
or pure cobalts malleabilised by the same process as described in a preceding
patent.
The fusion of these alloys can be effected either in a crucible furnace or an
open hearth furnace such as the ordinary reverbatory or Siemens furnace etc etc,
as well as in a cupola by employing appropriate fuel.
If one or other of the large apparatus above mentioned be used the considerable
wear and tear and the costliness of the crucibles is avoided and the alloys are
produced economically in large quantities, and in the easily transportable ingot or
granulated form or cast directly in metal or sand ingot moulds.
A sufficient quantity of carbon only for the preservation of the surfaces exposed
in some cases, to the action of the air carried along with the flame may be added.
The maximum proportions for a charge containing 70% of nickel and 30% of
iron containing a small amount of sulphur are the following.
Binoxide of manganese containing 03.30-12 parts
Ferro cyanide of Potassium
16
11
"
next
It is to be understood that these proportions are varied according to the intendeų
use of the alloy.
1

page_text: If when working this process the crucible is used the broken pig or matt is put
in the crucible with the binoxide of manganese previously mixed with the ferro
cyanide or cyanide of potassium, and the whole is melted together, allowing it to
slightly exceed the melting point in order to facilitate all the reactions, and lastly
in order to render the alloy more homgeneous the aluminium is added at the
moment of casting. If there is any trace of sulphur, a few grammes of hydro
chlorate of ammonia will suffice for each kilogramme of the material under
treatment.
The introduction of a certain quantity, variable according to circumstances of
the pigs or matts above mentioned malleabilized by this process in the place of
pure refined nickel, in the binary alloy nickel and copper is especially reserved as
well as in the place of pure refined nickel, in the triple alloy of nickel, copper and
zine of old german silver in order to constitute new compounds both more
economical and possessing special qualities.
The pigs or matts above mentioned malleabilized by this process may be used
also in various proportions in the manufacture of malleable cast iron and in the
various manufactures of iron and steel.
These malleable alloys may be used in lock and gun making, for navy purposes,
for minting, for gold and silver-smiths work and specially for the manufacture of
covers in which is combined with the process of malleabilising the alloys the
casting in sand the covers of ferro-nickel and ferro-cobalt followed by stamping
and polishing according to circumstances.
:

page_text: I, ALEXANDER MELVILLE CLARK, of the firm of A. M. and Wm. Clark, of
53, Chancery Lane, in the County of Middlesex, Fellow of the Institute of Patent
Agents, do hereby declare the nature of the said Invention for "IMPROVEMENTS
IN THE PROCESS OF MAKING MALLEABLE FERRO-NICKEL AND FERRO-COBALT AND
COMBINATIONS OF THESE ALLOYS," and in what manner the same is to be
'performed, to be particularly described and ascertained in and by the following
.statement :-
This Invention relates to the manufacture of malleable ferro-nickel and ferro-
cobalt by the direct employment of pigs or matts of these metals (without that
part of the subsequent refining which would have for object the elimination of the
iron) which are combined at one end and the same fusion with ferro-cyanide or
cyanide of potassium and one of the oxides of manganese (binoxide for example)
adding, at the moment of running, a small quantity of aluminium.
The proportions to be used, to ensure the products having the qualities of
malleability, ductility, tenacity, etc: which render them suitable for the most
varied applications, will be indicated hereafter.
The pigs or matts employed are obtained from the natural or oxidised ores
(called hydrosilicates of nickel and magnesia) containing variable proportions of
iron and alumina, without any trace of arsenic, which are obtained in New
Caledonia and its dependencies, as well as the ores of cobalt and chromium of the
same origin and more generally the ores of nickel and cobalt of all countries.
These pigs or matts or mixed matts or pigs obtained by the simultaneous fusion
of ores of nickel and cobalt, as well as mixed matts or pigs which are obtained by
the simultaneous fusion of ores of nickel and chromium (or chrome iron) by the
simultaneous fusion of ores of cobalt and chromium, and the simultaneous fusion
of ores of nickel, cobalt and chromium, using poor ores of nickel or cobalt with
the addition of ores of chromium when the products are to contain a small per-
centage of nickel or of cobalt and a large per-centage of iron; all these pigs or all
these matts whether simple or mixed containing a low per-centage of sulphur aro
what it is intended to utilize, with or without an addition either of soft or crude
iron, according to circumstances, before the final refining which has not for its object
the elimination of the iron.
To obtain these alloys malleable, ductile, homogeneous and with non-oxydising
qualities proportional to the per-centage of nickel or cobalt, the pigs or the matts
above described are employed. Or these pigs or matts have been previously
manufactured rich or poor in nickel or cobalt according to requirements; or they
may be impoverished more or less at will by the addition either of malleable iron
or pig iron (or crude iron) and melted directly with ferro-cyanide or cyanide of
potassium and one of the oxides of manganese (the binoxide for example) with the
addition, at the moment of running, of a small quantity of aluminium which, without
altering the malleability of the product, gives it a compactness and homogeneity
which it would not otherwise have.
These processes for the direct malleabilization of the pigs or matts either simple
or mixed above enumerated, with the optional addition of soft or cast iron, give
the alloys a special intrinsic character, a peculiar physical condition rendering them
permanently malleable even after a second fusion, which allows, on the one hand,
the malleabilised ingots to be sent away to a distance to be worked up, and on the
other hand the waste jets or defective castings to be utilized either elsewhere or on
the spot

page_text: The alloys obtained by this present process are tenacious, ductile, and malleable
and adapted for casting, rolling, drawing, wire-drawing and hammering.
It should be remarked that in treating pigs or matts of nickel and of cobalt by
this process the resulting ferro-nickel and ferro-cobalt can be forged still more
easily than the pure nickel and cobalt which might have been malleabilized in
their stead by the same means.
:
A peculiarity which is a property of this process of malleabilisation should be
observed. Whilst the soft iron loses by the second fusion its fibrous texture and
becomes crystalline and brittle, like cast iron, this same soft iron preserves its
malleability after the second fusion if it had been previously mixed with a certain
quantity of the malleabilized products of the process of this invention whether
these products be the ferro-nickel or ferro-cobalt above mentioned or pure nickels'
or pure cobalts malleabilised by the same process as described in a preceding
patent.
The fusion of these alloys can be effected either in a crucible furnace, or an open
hearth furnace, such as the ordinary reverberatory or Siemens furnace, etc: etc.;
as well as in a cupola, by employing appropriate fuel.
If one or other of the large apparatus above mentioned be used, the considerable
wear and tear and the costliness of the crucibles is avoided and the alloys are
produced economically in large quantities, and in the easily transportable ingot
or granulated form, or cast directly in metal or sand ingot moulds.
A quantity of carbon sufficient only for the preservation of the surfaces exposed
in some cases to the action of the air carried along with the flame, may be added.
The maximum proportions for a charge containing 70%. of nickel and 30%. of
iron containing a small amount of sulphur are the following:-
Binoxide of manganese containing 63·30 °
-
-
12 parts.

page_text: The pigs or matts above mentioned malleabilized by this process may be used
also in various proportions in the manufacture of malleable cast-iron and in the
various manufactures of iron and steel.
Having now particularly described and ascertained the nature of the said
Invention, and in what manner the same is to be performed, I declare that what
I claim is
The herein described process of manufacturing malleable ferro-nickel and ferro-
cobalt by the direct employment of pigs or matts of these metals (refined only to
the point at which the elimination of the iron would begin) which are combined
at one and the same fusion with ferro-cyanide, or cyanide of potassium and one
of the oxides of manganese adding, at the moment of running, a small quantity of
aluminium, as herein specified.