IMPROVE- MENTS IN MAKING MOULDS POR CASTING
Year: 1858

page_text: LETTERS PATENT to Thomas Steven, Iron Founder, Thomas Reid, Foreman
Moulder, and Thomas Frew, Foreman Pattern Maker, all of Glasgow,
in the County of Lanark, North Britain, for the Invention of "IMPROVE-
MENTS IN MAKING MOULDS POR CASTING."
Sealed the 20th July 1858, and dated the 30th March 1858.
PROVISIONAL SPECIFICATION left by the said Thomas Steven, Thomas
Reid, and Thomas Frew at the Office of the Commissioners of Patents,
with their Petition, on the 30th March 1858.
We, THOMAS STEVEN, Iron Founder, THOMAS REID, Foreman Moulder, and
THOMAS FREW, Foreman Pattern Maker, all of Glasgow, in the County of
Lanark, North Britain, do hereby declare the nature of the said Invention
of "IMPROVEMENTS IN MAKING MOULDS FOR CASTING," to be as follows, that is
to say :-
This Invention relates to improvements in making moulds for casting,
whereby various articles, such as pipes, columns, pumps, gutters, the connections
appertaining to the preceding articles, cisterns, water closet pans, sink traps,
camp ovens, three-legged pots, kettles, boilers, & simular cast-metal articles,
can be manufactured more satisfactorily and economically than by the ordinary
process hitherto in use. In applying, the Invention in making moulds for
pipes and similar articles, not only is labour saved but the founder is also
enabled to use green sand cores instead of the more expensive stove dried
In the case of pipes and similar articles the Invention applies to the
making of the core; and in carrying it out according to one modification, the

page_text: core is made in a core box capable of separating in two halves as usual.
According to the common plan of making "pipe cores in a core box of this
kind, a bar is laid in the lower half box, and the sand rammed about it, the
upper half box is rammed full of sand and then turned over on the lower half
box, and the two half cores are compressed firmly together. The core bar
being necessarily of a comparatively small size so as not to project above the
surface of the lower half core, is not sufficiently strong to sustain the floating
pressure of the molten metal, and "thickness nails" or other contrivances have
to be used to prevent the shifting of the core whilst the casting is taking
place.
According to the modification of the present Invention now being described,
however, a core bar of sufficient strength is used to prevent any shifting of the
core, notwithstanding the absence of "thickness nails" or similar contrivances,
which are dispensed with. One or more narrow openings are made in the
upper half core box, and the ramming is effected through these openings, and
the core bar is prevented from shifting on the molten metal entering the mould,
by wedges inserted between its projecting ends and the top flask or mould box.
The usual air holes are formed in the core by means of rods rammed up
in the core, and afterwards withdrawn. According to another modification
the pipe core is rammed in two halves as usual, but the core bar used is of
extra size, and projects above the surface of the lower half core. The
two surfaces of the half cores which come together, are in this case shaped by
means of counterpart scrapers, the one applied to the upper half core, forming
a recess to receive the projecting portion of the core bar. In the case of
pipes which are of considerable length as compared with their diameter, the
core bar may be liable to bend & rise, although made as strong as the
diameter of the core will permit, and in such case a portion of dry sand may
be introduced at the longitudinal centre of the core or other places, and
thickness nails or similar contrivances may be used as heretofore. It will,
however, be obvious that even in such cases advantage will be derived from
making the core more or less according to the present Invention. In making
moulds for gutters and similar articles according to one modification of this
Invention, the gutter pattern is made with openings like the upper half core
box herein-before described, and it is placed in an inverted position. The core
portion of the mould is rammed through the openings in the pattern, and these
openings are closed by suitable pieces, and the outer mould rammed in the
usual way, after which the outer mould is lifted off and the pattern removed.
Or instead of this plan the core portion of the mould may be rammed through
openings in a plate upon which the gutter pattern is placed, the pattern and

page_text: plate being inverted for this purpose. In making moulds for three-legged pots
and similar articles according to this Invention, the outer portions of the
mould are rammed in a box which is divided into two halves by a central
vertical plate, having one half of the pattern on each side of it.
This vertical plate forms a parting, and the two halves of the outer mould are
removed from it horizontally, or nearly so, and brought together again over
the core previously formed on a separate plate.
The core is rammed in a box placed upon this plate, the box and plate being
inverted, and the ramming being effected through an opening in the plate.
Camp ovens and similar articles may be moulded in this way, or, the oven
being fixed to the plate, it may be inverted, and the internal portion be rammed
through an opening in the plate, after which the whole may be turned back,
and the outer part of the mould rammed upon the pattern and afterwards be
lifted off for the purpose of removing the pattern.
Another portion of the Invention relates to a mode of forming core boxes
from the pattern for the outer portion of the mould, or from a core box
corresponding to a larger size of article. If the pattern is used a half mould
is formed from it as for a casting, and a thin layer of clay or other suitable
flexible material is laid in the mould and applied uniformnly to it. Upon this
mould another half mould is made, from which the new half core box is cast.
If the half core box of the larger size is used, the clay or other material
is laid in it, and a half mould is formed upon it, from which the new half
core box is cast.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Thomas Steven, Thomas Reid, and Thomas Frew in the
Great Seal Patent Office on the 29th September 1858.
TO ALL TO WHOM THESE PRESENTS SHALL COME, we, THOMAS
STEVEN, Iron Founder, THOMAS REID, Foreman Moulder, and THOMAS FREW,
Foreman Pattern Maker, all of Glasgow, in the County of Lanark, North
Britain, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Thirtieth day of March, in the year of our Lord
One thousand eight hundred and fifty-eight, in the twenty-first year of Her
reign, did, for Herself, Her heirs and successors, give and grant unto us, the
said Thomas Steven, Thomas Reid, and Thomas Frew, Her special licence
that we, the said Thomas Steven, Thomas Reid, and Thomas Frew, our

page_text: executors, administrators, and assigns, or such others as we, the said Thomas
Steven, Thomas Reid, and Thomas Frew, our executors, administrators, and
assigns, should at any time agree with, and no others, from time to time
and at all times thereafter during the term therein expressed, should and
lawfully might make, use, exercise, and vend, within the United Kingdom
of Great Britain and Ireland, the Channel Islands, and Isle of Man, an
Invention for "IMPROVEMENTS IN MAKING MOULDS FOR CASTING," upon the
condition (amongst others) that we, the said Thomas Steven, Thomas Reid,
and Thomas Frew, our executors or administrators, by an instrument
in writing under our, or their, or one of their hands and seals, should
particularly describe and ascertain the nature of the said Invention, and
in what manner the same was to be performed, and cause the same to be
filed in the Great Seal Patent Office within six calendar months next and
immediately after the date of the said Letters Patent.
NOW KNOW YE, that we, the said Thomas Steven, Thomas Reid, and
Thomas Frew, do hereby declare the nature of our said Invention, and
in what manner the same is to be performed, to be particularly described and
ascertained in and by the following statement in writing, reference being had
to the accompanying Drawings, and to the letters and figures marked thereon,
that is to say :-
Our said Invention relates to improvements in making moulds for casting,
whereby various articles, such as pipes, columns, pumps, gutters, the con-
nections appertaining to the preceding articles, cisterns, water-closet paus,
sink traps, camp ovens, three-legged pots, kettles, boilers, and similar cast-iron
articles, can be manufactured more satisfactorily and economically than by the
ordinary processes hitherto in use.
And in order that our said Invention may be properly understood and
carried into effect, we shall particularly describe the same, having delineated
upon a Sheet of Drawings hereunto attached sundry explanatory figures, to
which we shall refer as we proceed.
It is an
In as far as our said Invention relates to pipes and and similar articles, it
applies to the making of "green sand" cores for such articles, and in carrying
it out according to one modification, the core is made in a core box capable of
separating in two halves in the ordinary way and such as is represented in
transverse vertical section in Figure 1, and in plan in Figure 2.
object of this part of the Invention to employ a core bar A, of such a size and
strength that it will not be necessary in most cases to employ" thickness pegs"
or similar contrivances to prevent the shifting or bending of the core by the
floating pressure of the molten metal when the casting is taking place. The

page_text: a cover or covers
lower half core box B is or may be precisely the same as an ordinary one, but
the upper half core box C is formed with one or more narrow longitudinal.
openings D. The forming of the core is effected by the following operations:
Some sand being placed in the lower half core box B, the core bar A is placed.
in or on it in a central or nearly central position, and sand is rammed or
compressed in on each side of the latter; the upper half-core box C is then
turned over upon the lower half core box B, and sand is rammed through the
narrow opening or openings D, and at the extreme ends at the latter, to give
firmness to the core bearings; and, finally, the part of the core exposed by the
opening or openings D is shaped by means of tools, such as "scrapers." or
" and "sleekers," ordinarily used by moulders in like cases. Or the
sweeps'
part at the opening or openings D being sweeped or scraped nearly down to
its proper shape, may be pressed quite down thereto by
fitting in such opening or openings. By these means the core is rendered
more uniform in consistency, and better suited for use than by any other
means with which we are acquainted. When the core E is placed in the
mould F, represented in end elevation in Figure 3, and in vertical longitudinal
section in Figure 4, wedges G are inserted between the projecting ends of
the core bar A and the top flask or mould box H, to prevent the core bar and
core from shifting when the molten metal enters the mould. According to
another modification the two half core boxes are rammed up separately, the
core box being open, as shown in Figure 5; the core bar A, however, is of extra
size, and projects above the level of the lower half core box B. The surfaces
of the half cores which come together when the core box is closed to compress
the half cores together, and thus complete the core, are shaped by means of
counterpart scrapers, such as are represented in Figure 6. The scraper I,
intended for the lower half core box B, is made with a recess fitting upon the
core bar A, and with horizontal edges for shaping the sand on each side of the
core bar. The scraper J intended for the upper half core box C is made with a
projection corresponding to the cross section of the core bar A; and by this.
projection a recess is formed in the sand in the upper half core for the
reception of the core bar when the core box is closed, the scraper being guided
in the ordinary way on the sides of the core box. The parts of the scrapers
I, J, by which the surfaces of the sand are shaped, may be of various counter-
part forms, provision being always made for the projection of the core bar into
both halves of the core. Thus the scrapers may be of the modified forms
indicated by dotted lines in Figure 6, the resulting shapes of the portions of
the core being indicated by dotted lines in Figure 5. The practical moulder
will of course understand that the two portions of the core must, as usual, bo

page_text: Suaped signty in excess to insure complete contact and union when com-
pressed together.
In the case of pipes, the cores of which are of small diameter as compared
with their length or thickness, the corebar may be liable to bend and shift,
although made as strong as the diameter of the core will permit, and in such
case a portion of dry sand may be introduced into the green sand core at the
longitudinal centre or other parts of the core, or a metal plate may be embedded
in the core, and thickness nails may be used as heretofore to keep the core in
the centre of the mould; or other known contrivances may be adopted to the
same end. It will, however, be obvious, that even in such cases advantage
will be derived from making the core more or less according to the present
Invention.
In making moulds for gutters and similar articles according to one modifi-
cation of this Invention, the gutter pattern K is made with openings D, as
shown in the transverse section of a gutter mould box, Figure 7, and it
is placed in an inverted position, being arranged by preference, as shown in
the Figure, that is to say, with its extreme or outer corner edges barely in
contact with corner edges formed in the frame or plate M. This arrangement
avoids the necessity of forming a sand "parting." On commencing to make
the mould, the pattern K is supported in its proper position by several skids
or supporting blocks N, and the interior of the pattern is first rammed through
the opening or openings D. Each opening D is then filled by a piece,
rendering the pattern complete, and also shaping the surface of the inner part
of the mould at the opening; after which the outer portion of the mould is
rammed up in the ordinary way in the top flask O. When the outer mould
is formed, it is lifted off with the top flask O for the removal of the pattern.
The skids or supports N may be removed after sufficient sand is rammed
inside the pattern to support it, and before the ramming of the inside is com-
pleted; or they may be removed afterwards through openings in the frame M,
the cavities left by them being filled with sand.
Or instead of operating according to the plan last described, the interior or
core portion of the mould for a gutter or similar article may be rammed
through openings in a frame or plate upon which the pattern is placed.
Figures 8 and 9 are transverse sections explanatory of this plan of moulding.
The gutter pattern K being laid upon a "board" or block P, as shown in
Figure 8, and the frame or plate M being placed upon it in an inverted posi-
tion, the core portion is rammed through an opening or openings D, provided
in the frame M for that purpose. The frame M, with the pattern K, is then
turned over, as shown in Figure 9; and the top flask being adjusted, the

page_text: outer portion of the mould is rammed as before; or the outer portion of the
mould may be rammed first, the pattern being placed with its concavity down-
wards on a flat board, and the flask O over it; the flask, with the pattern in it,
may then be inverted, the frame M, Figure 8, be placed on, and the inside
be rammed through the opening or openings D. Or again, the parts may be
at the commencement, as shown in the transverse section, Figure 10, and
whereas in the two plans last described, a narrow sand "parting" is formed,
with the arrangement shown in Figure 10, this is not necessary, the edges of
the pattern K just meeting corresponding edges in the lower frame or plate
M (as shown in Figure 7). The pattern K (Figure 10) is supported in
position by the skids or supports N, whilst the outer portion of the mould is
being rammed, the whole is then turned over, and the supports N being
removed, the interior or core portion is rammed through the opening or
openings D in the lower frame or plate M.
In making moulds for three-legged pots and similar articles according to
this Invention, the outer portions of the mould are rammed in two half-boxes
adjusted upon opposite sides of a central vertical plate which has one-half of
the pattern attached to each side of it.
Figure 11 is a transverse vertical section through the vertical plate Q, the
two half "gate" patterns Z, the two half pot patterns R, with their supporting
frame or plate S, and the two half mould boxes T. The vertical plate Q
forms a parting surface on each half mould, and when these are rammed, they
are removed from it horizontally or nearly so, and brought together again
over the core U, (previously formed upon a separate frame or plate V,) as
shown in Figures 12 and 13, the former being a transverse vertical section,
and the latter a plan of the complete mould. The core is rammed in a core
box W, Figure 14, divided vertically into two halves. The frame or plate V
is placed upon the mouth of the core box W in an inverted position, and the
ramming is effected through an opening D in the frame or plate V. In
making the patterns for three-legged pots and similar articles, we prefer to.
form them in two halves, which, for the purpose of being turned to their
proper shape are accurately joined and held together, the exterior patterns by
means of internal snugs, and the interior patterns or core boxes by means of
external snugs. It will be seen from Figure 12, that conical parting surfaces
are formed in the outer mould and on the core at X, by which the parts of the
mould are accurately guided and adjusted together. We prefer to form the
corresponding portions of the pattern, Figure 11, solid with the main body
R of the pattern; but old pot patterns or such as are used in the ordinary,
way of moulding these articles may be adapted to our improved system by

page_text: providing balf rings corresponding to the part x. The legs of pots, camp
ovens, and similar articles may be moulded in the ordinary way, and the ears or
spouts may be moulded by means of half patterns attached to the vertical plate Q.
Camp ovens, range ovens, boilers, cisterns, and similar articles may be
moulded according to this Invention, as shown in Figure 15, or as shown in
Figures 16 and 17, the latter mode being preferred. Figure 15 is a vertical
section showing a camp oven pattern K in a mould in the position in which
the internal portion a is rammed. The external portion 6 of the mould is
first rammed in the usual way, the pattern K being placed on a board with
the flask O over it; the whole is then turned over into the position in which
it is represented in Figure 15, and the frame or plate M being placed on it
the internal portion a is rammed through the opening or openings D. Figures
16 and 17 are vertical sections showing the one a range oven pattern K, and
the other a frying pan pattern K in their moulds in the positions in which the
outer portions of the moulds are rammed. In these cases the outer portions
b of the moulds are first rammed, the patterns being supported by skids or
supports N with their extreme or outer corner edges barely in contact with
corner edges formed in the lower frames or plates M. The outer portion 6 of
the mould being rammed in each case, the whole is turned over, and the skids
or supports N being removed, sand is rammed into the inside of the pattern
through the opening or openings D in the frame or plate M. A sand "parting"
is needed in the plan illustrated by Figure 15, but no sand parting is
required in the plan illustrated by Figures 16 and 17. The same mould
boxes and frames O, M, Figures 16 and 17, may be made to serve for different
sizes of articles by employing loose frames or rings fitting in the recessed part
of the frames M, such frames or rings having their inside corner edges shaped
each to a different size or form of article.
In Figures 9, 10, 13, 15, 16, and 17, the "gates" for the entrance of the
molten metal, and which may be moulded in the ordinary way or by means of
patterns, are marked z.
Another portion of our said Invention relates to a system or mode of form-
ing core boxes from the pattern for the outer portion of the mould or from a
core box corresponding to a larger size of article. If the pattern for the
outer mould is used a half mould is formed from it as for a casting, and a
layer of the required thickness of a flexible or plastic material, such as clay,
is laid in the half mould and applied uniformly to it. This layer of clay
answers as the pattern for the half core box and a second flask is rammed
upon it to form the portion of the mould corresponding to the inside of the
half core box. In the transverse vertical section, Figure 18, is shown the

page_text: formation of the half mould c from the pattern d. In the transverse vertical
section Figure 19, the half mould c is shown turned over and the layer of clay e
is applied to it, the half mould f being rammed on the clay e for the inside of
the half core box: The core box casting is shown complete in Figure 20,
each half being moulded in the way just described. The lugs g, Figure 20,
for the connecting pins are moulded by means of separate patterns, shown in
Figures 18 and 19. In cases in which from the size of core required tho
core box would not be of sufficient thickness if the half mould c taken directly
off the pattern & were used in casting it, the half mould for the outside of each
half core box may be obtained by applying a layer of flexible or plastic
material such as clay to the pattern and then ramming up thereon, or the mould
taken directly off the pattern may scraped to give sufficient thickness. If the
core box is to be moulded from a core box of a larger.size than that required,
the layer of clay or other material is laid in such larger half core box and the
half mould for the inside of the new half core box is rammed up thereon.
Such half mould is then turned over and the pattern half core box being
removed, leaving the layer of clay on the half mould, the second half mould
for the outside of the new half core box is rammed up thereon. The system
or mode of moulding just described, as applied to core boxes, may obviously
be adopted for moulding a variety of articles (including metal patterns) in a
rapid and economical manner, and will in many cases save the expense of
getting up entirely new patterns, when patterns somewhat differing in sizo
from what is wanted happen to be in the ironfounder's possession. According
to a convenient way of making lagers of clay of a uniform or nearly uniform
thickness for the purposes of this part of the Invention, two strips of wood
of the thickness to be given to the clay are fixed on a flat board, and the
clay, previously brought to a proper consistency, is placed between them and
spread out by means of a roller, the strips gauging the thickness to which it is
reduced.
Having thus particularly described our said Invention, and the manner in
which the same is or may be used or carried into effect, we have to state that
we do not restrict ourselves to the precise details herein-before described or
delineated, that we do not claim to have invented every separate detail herein-
before described and delineated; and that what we believe to be novel and
original and therefore claim as the Invention secured to us by the herein-before
in part recited Letters Patent is,-
First, the several combinations of processes in mould making herein-before
described.

page_text: Second, the system or mode of ramming up green sand cores for pipes and
similar articles, through narrow or contracted openings in the upper half core
boxes as herein-before described.
Third, the entirely or partially dispensing with "thickness pegs" or similar
contrivances in casting pipes and similar articles, by aid of the herein-
before described modes of forming cores so as to contain core bars of increased
strength in themselves.
Fourth, the system or mode of making green sand cores for pipes and
similar articles, wherein a core bar of such a size as to occupy portions of
both halves of the core is used, such core bar being partly embedded in the
sand or core material in the lower half core box, whilst a recess is formed by
means of a scraper in the sand or core material in the upper half core box,
for the reception of the projecting part of the core bar, when the core box is
closed as herein-before described, more particularly with reference to Figures
5 and 6, on the Sheet of Drawings hereunto attached.
Fifth, the system or mode of ramming up the portions of moulds for the
insides of gutters and similar articles, through narrow or contracted openings
in the tops of the patterns as herein-before described.
Sixth, the system or mode of ramming up the portions of moulds for the
insides of gutters, camp ovens, boilers, cisterns, and similar articles through
contracted openings in the under frames or plates, or bottom portions of the
mould boxes, the portions of the moulds for both the insides and outsides of
the articles being formed from the same patterns as herein-before described,
together with the herein-before described contrivances for dispensing.with sand
"partings" in such moulds.
Seventh, the system or mode of forming the outer portions of moulds for
pots and similar articles, in half mould boxes adjusted on opposite sides of a
vertical plate to which the pattern is attached, one half being on each side of
it as herein-before described, more particularly with reference to Figure 11,
on the Sheet of Drawings hereunto attached.
Eighth, the system or mode of forming the cores for pots and similar articles,
in core boxes divided vertically into two complete halves, the sand or core
material being ramined in through a plate or frame fitted into the conical
mouth of the core box, such plate or frame retaining the core, and serving as
the bottom portion of the complete mould box, as herein-before described,
more particularly with reference to Figures 12 and 14, on the Sheet of
Drawings hereunto attached.
Ninth, the system or mode of producing moulds for articles of sizes differing

page_text: from those of the original patterns employed, by the aid of layers of a flexible
or plastic material such as clay, as herein-before described, more particularly
with reference to Figures 18, 19, and 20, on the Sheet of Drawings hereunto
attached.
In witness whereof, I, the said Thomas Steven, on behalf of myself,
and of the said Thomas Reid and Thomas Frew, have hereunto set
my hand and seal, this Twenty-seventh day of September, One thou-
sand eight hundred and fifty-eight.
o Witness,
EDMUND HUNT, Patent Agent,
28, St. Enoch Square, Glasgow.
THOMAS STEVEN. (L.S.)