IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL, AND IN-APPARATUS TO BE EMPLOYED IN SUCH MANUFACTURE
Year: 1863

page_text: LETTERS PATENT to George Davies, of No. 1, Serle Street, Lincoln's
Inn, in the County of Middlesex, and No. 28, St. Enoch Square, in the
City of Glasgow, Civil Engineer and Patent Agent, for the Invention of
"IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL, AND IN-APPARATUS
TO BE EMPLOYED IN SUCH MANUFACTURE."—A communication from abroad
by William Gerhardt, of Philadelphia, Pennsylvania, United States of
America
Sealed the 1st March 1864, and dated the 18th September 1863.
PROVISIONAL SPECIFICATION left by the said George Davies at the
Office of the Commissioners of Patents, with his Petition, on the
18th September 1863.
I, GEORGE DAVIES, of No. 1, Serle Street, Lincoln's Inn, in the County of
Middlesex, and No. 28, St. Enoch Square, in the City of Glasgow, Civil
Engineer and Patent Agent,do hereby declare the nature of the said Invention
for "IMPROVEMENTS IN THE MANUFACTURE OF IRON AND STEEL, AND IN APPARATUS
TO BE EMPLOYED IN SUCH MANUFACTURE," (a communication to me from abroad
by William Gerhardt, of Philadelphia, Pennsylvania, United States of
America,) to be as follows:-
This Invention comprises several features all of which have, however, a
distinct connection or relation to each other and which may be classified as
follows:-
Firstly, making cast steel by heating cut wrought iron or scraps of the same
in crucibles, or their equivalents; to a high degree, and then introducing into
the crucibles oxyde of iron or other suitable substance containing oxygen,
and immediately after the introduction of the oxyde pouring a quantity of
melted pig iron upon the wrought iron in the crucibles.

page_text: Secondly, certain apparatus by which the above manufacture is carried
into effect.
Thirdly, modified apparatus for carrying out the said manufacture.
Fourthly, a peculiar manner of constructing and arranging furnaces for
heating the crucibles and melting the contents.
Fifthly, a peculiar manner of applying currents of magnetism in the manu-
facture of steel.
Sixthly, a method of introducing oxydes of iron or other solid substances
containing oxygen into molten iron, for the purpose of decarbonizing the
same in order to strengthen it or reduce it to cast steel or wrought iron.
Seventhly, a mode of producing sound test pieces and other castings of
malleable steel.
In carrying out the first part of this Invention the amount of oxyde of iron
is so proportioned that any excess of carbon which may exist in the cast iron
above that necessary to form the steel will combine with the oxygen gas
liberated from the oxyde and pass off with the products of combustion.
By increasing the proportion of oxide of iron the steel may be decarbonized
to such an extent as to reduce it to wrought iron.
The second part of the Invention may be described as follows:-
A reservoir of fire-proof materials supported on pillars is enclosed within a
furnace into which the blast is introduced at two points passing on through
corresponding outlets to the chimney at the opposite end of the furnace. The
covers of both the furnace and reservoir are detachable so that the scraps of
iron may be introduced into the latter, smaller openings being made in both
for introducing the oxyde and molten pig metal.
In a modification of the above (described as the third feature of this
Invention) intended for the manufacture of the finerqualitiesof steel;crucibles
are substituted for the reservoir, and above them is a conductor having an
opening over the mouth of each crucible through which the stream of molten
pig iron from the cupola falls into the wrought iron in the crucibles.
In carrying out the fourth feature of this Invention the crucibles are placed
in a series of furnaces (say four, for example) arranged in juxtaposition and
supported upon masonry. A passage from the top of the first furnace forms a
communication to the top of the second furnace, and a similar
passage from
the bottom of the second lends tothe bottom of thethird furnace, whilst a third
passage communicates from the top of the third furnace to the top of thefourth,
and a fourth passage leads from the bottom of the latter to the chimney, and
over this fourth passage and alongside of the chimney is an oven for drying
new crucibles.

page_text: Beneath the first furnace is an ash-pit, into which the blast is introduced
and passes diagonally through each furnace to the chimney. The ash-pit
has an inclined floor, from the lower edge of which a plate projects to cou-
duct the ashes into a track running on rails in an arched way constructed
in the masonry. Nearly over this arched way is a casting pit for containing the
moulds. Above the furnaces and casting pit is suspended a railway, on which
runs a carriage from pulleys, on which are suspended automatic tongs for
carrying the crucibles from one furnace to another or to the casting pit.
In connection with the moulds used in the last-described apparatus or in
connection with separate moulds may be practised the mode of applying
maguetism in the manufacture of steel, which constitutes the fifth feature
of the Invention. When steel (or any other substance susceptible to
magnetic force) is magnetized while cooling in the mould, the crystals
wedge into each other in the direction of the magnetic current, and give
to the whole mass a longitudinal, lamellar, tough and strong texture.
Another advantage also is, that all lateral crystallization is prevented by the
action of the magnetic force, which maintains the molecules of the crystals
in a longitudinal direction. To obtain the desired effect a powerful electro-
magnet is applied to the flask containing the molten steel in such a manner
that a current of electricity passes continuously through the molten metal
during its cooling.
The sixth part of this Invention relates to the method of introducing
oxyde of iron and other solid substances containing oxygen into molten
iron, for the purpose of decarbonizing the same, in order to strengthen it
or reduce it to cast steel or wrought iron.
For this purpose a sheet-irou cylinder is used, to the head of which is
attached the end of a tube, through which (and also through the former)passes
a rod, to which are affixed two discs, one of which fits the inside of the
cylinder and occupies a position near the top of the same, and the other is
somewhat larger and closes the lower end of the cylinder. The space between
these two discs being filled with oxyde, the rod is grasped by the hand and
the cylinder passed through an opening in the crucible cover and immersed
in the molten metal. In a short time the lower disc will have burnt away,
and the rod is then pressed down causing the upper disc to expel all the
oxyde into the molten metal at the lower part of the crucible.
When a slower oxydation is desired, it is proposed to dispense with the
sheet-iron cylinder, and its adjuncts, and to employ a small vessel con-
structed of fire-clay or other fire-proof material, which,however, must be free
from any carbonaceous substance, such as plumbago or coke. This vessel

page_text: is perforated with numerous holes, and is to be filled with black oxyde of
manganese or other solid substance containing oxygen, and immersed in the
molten metal, the vessel being held submerged by the lid of the crucible.
The result will be that oxygen gass will pass off through the perforations,
and effect a gradual decarbonization of the metal.
The seventh feature of the Invention consists in a mode of producing test
pieces for ascertaining the quality of steel manufactured, the said mode
being also applicable to the production of sound steel castings for pistol
barrels and other like objects.
The moulds are prepared of the best fire-proof and refractory material,
as for instance, soapstone or fire-clay, and fixed to the lower end of a rod
for dipping them into the molten metal, and are so arranged as that they
will be filled through openings in the side near the top, having also a cavity
and openings for the escape of flux and gas. On dipping the mould below
the surface of the molten metal it flows into the openings, and entirely fills
the cavity. The moulds are then withdrawn from the crucibles and
allowed to cool gradually in an annealing oven.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said George Davies in the Great Seal Patent Office on the
18th March 1864.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, GEORGE
DAVIES, of No. 1, Serle Street, Lincoln's Inn, in the County of Middlesex,
and No. 28, St. Enoch Square, in the City of Glasgow, Civil Engineer and
Patent Agent, send greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Eighteenth day of September, in the year of our
Lord One thousand eight hundred and sixty-three, in the twenty-seventh
year of Her reiga, did, for Herself, Her heirs and successors, give and
grant unto me, the said George Davies, Her special liceuce that 1, the said
George Davies, my executors, administrators, and assigns, or such others as
I, the said George Davies, my executors, administrators, and assigns should
at any time agree with, and no others, from time to time and all times there-
after 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 "IMPROVE-
THE MANUFACTURE OF IRON AND STEEL, AND IN APPARATUS TO BE

page_text: EMPLOYED IN SUCH MANUFACTURE," being a communication to me from abroad
by William Gerhardt, of Philadelphia, Pennsylvania, United States of America,
upon the condition (amongst others) that I, the said George Davies, my
executors or administrators, by au instrument in writing under my, 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 per-
formed, 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 I, the said George Davies, do hereby declare the
nature of the said Invention, and in what manner the same is to be per-
formed, to be particularly described and ascertained in and by the following
statement in writing, and on reference to the accompanying Drawings, that
is to say:-
This Invention comprises several features, all of which have, however, a
distinct connection or relation to each other, and which may be classified as
follows:-
Firstly, making cast steel by heating cut wrought iron, or scraps of the
same, in crucibles, or their equivalents, to a high degree, and then introducing
into the crucibles oxide of iron or other suitable substance containing oxygen,
and immediately after the introduction of the oxide pouring a quantity of
melted pig iron upon the wrought iron in the crucibles.
Secondly, certain apparatus by which the above manufacture is carried into
effect.
Thirdly, modified apparatus for carrying out the said manufacture.
Fourthly, a peculiar manner of constructing and arranging furnaces for
heating the crucibles, and melting the contents.
Fifthly, a peculiar manner of applying currents of magnetism in the manu-
facture of steel.
Sixthly, a method of introducing oxides of iron, or other solid substances
containing oxygen, into molten iron for the purpose of decarbonizing the
same in order to strengthen it or reduce it to cast steel or wrought iron.
Seventhily, a mode of producing sound test pieces and other castings of
malleable steel.
-
The first feature of the Invention is as follows: Wrought iron cuts or
scraps, already highly heated when the oxide is introduced, are nearly melted
by the increase in the intensity of the heat caused by the liberation of the
oxygen gas,and thecastiron on its introductioncombines almost instantaneously
with the wrought iron, the latter taking from the cast iron its carbon, so that

page_text: The
when distributed among the whole mass the latter will be carbonized.
amount of oxide is so proportioned that any excess of carbon which may exist
in the cast iron above that necessary to form the steel will combine with the
oxygen gas liberated from the oxide, and pass off with the products of com-
bustion. By increasing the proportion of oxide of iron the steel may be
decarbonized to such an extent as to reduce it to wrought iron. It will of
course be understood that the steel may be greatly varied in quality by the
introduction of other substances in connection with the oxide of iron, as for
instance by using the oxides of chrome, tungsten, or titanium, for producing a
hard steel or by simply increasing the amount of oxide of iron and wrought
iron for making a soft steel.
Although the above-described manufacture can be conducted in differently
constructed and arranged apparatus those which are about to be described
are to be preferred.
In the accompanying Drawing, Figure 1 illustrates apparatus for conducting
the manufacture on a large scale, and constitutes a second feature of the
Invention.
A is a reservoir of fire-proof material supported on pillars a, a, and enclosed
in a furnace B, into which the blast is introduced at two points through the
tuyere C; a, a, being the outlet openings through which the blast passes to
the chimney D. The covers both of the furnace and reservoir are detachable,
so that the scraps of iron may be introduced into the latter, sinaller openings
being made in both covers for introducing the oxide or molten pig metal.
After the introduction of the pig metal the entire mass is maintained in a
heated state for from one to two hours, according to the quantity of the metal
in the reservoir, and when the process is completed the steel is permitted to
run out through a tapping hole at the side of the furnace.
For the manufacture of finer qualities of steel it is preferable to use the
apparatus, which constitutes a third feature of the Invention, and which is
illustrated in Figure 2, where A, A, A, are crucibles enclosed in the furnace B,
and above these crucibles is a conductor D having an opening over the mouth
of each crucible through which the stream of inolten pig iron from the cupola E
falls on to the wrought iron in the crucibles. It is sometimes desirable that
the cupola shall be movcable, for which purpose flanged wheels running on
rails i are hung to the side of the supporting framework F of the furnace.
The fourth feature of this Invention, which consists in a peculiar manner
of constructing and arranging furnaces for heating the crucibles and melting
the contents, is illustrated in Figure 3. A, A, A, A111, are a series of
furnaces supported by the masonry B, in which are the arched way C and

page_text: arched passage D. A passage or flue a forms a communication between the
top of the furnace A, and that of the furnace A', a similar flue a³ forming a
communication between the lower end of the furnace A¹ and that of the
furnace A, and a third flue a", forming a communication between the upper
portion of the furnace A" and that of the furnace A1, while a fourth flue a"!
communicates from the lower portion of the furnace A to the chimney F.
Beneath the furnace A is an ash-pit E, into which, through an opening e, the
blast is introduced, the ash-pit having an inclined floor, from the edge of which
projects a plate c into the arched way C. A drying oven G with perforated
shelves d, is erected directly over the flue a¹, and so that the chimney F
shall pass up one side of the oven, an opening g, near the top of the oven,
communicating with another chimney F. Over the furnaces A, &c., is
suspended the railway H, slightly inclined downwards from the chimney F,
and on this railway runs a car I from pulleys on which are suspended the
automatic tongs J. Near one end of the masonry B is a casting pit K for
containing the moulds. C' is a truck having wheels adapted to rails laid ou
the bottom of the arched way C.
By the arrangement of furnaces above described many advantages are
obtained, one of the most important of which is the saving of fuel by utilizing
the heat which passes from the first furnace A, and which, instead of imme-
diately escaping to the chimney, is conducted through the flue a to the top of
the furnace A', through which it passes in the direction of the diagonal line x
to the flue a', which conducts it to the bottom of the furnace A", and through
which it passes upwards to the flue a" and to the top of the furnace A¹¹¹, and
out of the latter into the flue a, and thence into the chimney. The products
of combustion thus taking a diagonal course through the several furnaces a
gradual heat will be conducted through the same and communicated to the
crucibles, and finally impart heat to the oven G for drying new crucibles.
When it is necessary to remove a crucible from one furnace and deposit it
in another, a cover 6 is removed and the car I brought over the furnace so
that the automatic tongs J can be lowered to grasp the crucible. When the
latter is raised it can easily be moved to another furnace by pushing the car I.
By this means also the crucibles containing the molten metal from the furnace
may be conveyed to the pit K which contains the moulding flasks for the
reception of the molten metal. The ashes are removed from beneath the
furnace by opening the door y and permitting them to slide down the inclined
floor on the plate e into the truck C'. By combining and arranging the
furnaces as thus described, not only is there a great saving effected in the
amount of fuel by utilizing the heat which generally passes up
the chimney,

page_text: but the arrangement is such that both labor and time are-economized by
bringing all the parts necessary to carry on the operations intimately together,
It will also be apparent that a series of furnaces constructed as described may
be arrranged side by side, the arched chamber 1) and arched way C extending
under the entire series, thus greatly increasing the facilities for carrying on
extended operations within a contracted space.
In connection with the moulds used in the last-described apparatus, or in
connection with separate moulds, may be practised the mode of applying
magnetism in the manufacture of steel, which constitutes the fifth feature of
the Invention. The molecular structure of steel will be altered by passing
through the same (while in a molten state in the moulding flask, and before it.
has cooled) a current of magnetism. This is not only the case with steel
while in a molten state, but even the solid armatures kept for a length of
time in contact with the poles of a powerful magnet have changed their mole-
cular texture under the influence of the magnetic forces. When steel (or any.
other substance susceptible to magnetic force) is magnetized while cooling in
the mould, the crystals wedge into each other in the direction of the magnetic
current and give to the whole mass a longitudinal, lamellar, tough, and strong
texture. Another advantage also is that all lateral crystallization is prevented
by the action of the magnetic force which maintains the molecules of the
crystals in a longitudinal direction. To obtain the desired effect a powerful
electro-magnet is applied to the flask containing the molten steel, as shewn in
Figures 4 and 5, where Figure 4 is a side view of the car supporting the
magnet and battery; Figure 5 is a front view of the same.
A is a truck, to which are hung the wheels a, a, and to the top of this
truck is secured a standard b, and to the upper edge of the latter is jointed,
so as to revolve readily, a plate B, in each end of which is cut a longitudinal
slot c. Through each slot projects the screwed end of a bar C of soft iron,
around which is coiled an insulated copper wire, the latter leading to one of
the poles of a battery D on the truck. The bars C are held in their position
by nuts, which may be loosened to allow the bars to be adjusted on the plate.
The flask E containing the casting is mounted on a block G, so that the ends
of the bar C may be each as near to its end of the flask as possible. The
connection between the two bars being thus established by the flask, the mag-
Detism generated in the bars by the current of electricity passing through the
coils which surround them passes also through the molten steel which lies
within the circuit. By means of the moveable plate B and the slots in the
same which permit, the adjustment of the bars C, they may be applied readily
to almost any form of flask.

page_text: The sixth feature of this Invention relates to the method of introducing
oxides of iron and other solid substances containing oxygen into molten iron
for the purpose of decarbonizing the same in order to strengthen it or reduce
it to cast steel or wrought iron. Figures 6 and 7 illustrate apparatus for
accomplishing this result. In Figure 6, A is the crucible containing the
molten metal to be decarbonized; B is a sheet-iron cylinder, to the head of
which is attached the end of the tube a, through which and through the
cylinder passes a rod b. To this rod is attached a disc or plate d, which fits
the inside of the cylinder, and occupies a position at the upper end of the
same, and to the lower end of the rod a is secured a somewhat larger plate ď.
The space in the cylinder between the two discs d and d' is filled with the oxide,
and the rod a grasped with the hand, and the entire cylinder forced into the
molten metal in the crucible. In a few moments the lower disc will have
burnt away,
when the wire b is pushed down so as to force the disc d along
the cylinder, and expel from it the oxide into the metal at the lower part of
the crucible, so that it may become thoroughly incorporated with the same.
The cylinder B may be dispensed with, and a solid cylinder of oxide of iron
may be introduced into the crucible, the oxide being solidified by a small
portion of clay and lime.
The advantages which result from this feature of the Invention are
manifold. As it is very important to obtain cast iron of great strength and
close texture,many means have been resorted to to increase its tenacity. The
most successful of all divices heretofore invented for this purpose (that of
abstraction of carbon by injection of air)requires complicated apparatus, and
consequently great outlay. In the present instance the same result is accom-
plished in much less time, with a mere nominal expense, without danger, and
with a precision that none of the known processes present. The amount of
carbon that has to be oxidized in order to obtain iron of a certain strength
can be previously ascertained, and its corresponding quantity of oxygen
required may be calculated and introduced in the form of oxides. When the
process is applied to steel,the same can be rendered softer even during the last
heating moments in the crucible, because the reducing material, as well as that
to be reduced, can be fully controlled and exactly calculated, an advantage that
has never been obtained heretofore. When the iron or steel to be decarbonized
contains sulphur or other impurities, such substance or substances should
be mixed with the oxides as can combine with the same, pass off as vapour,
or unite with the covering flux. For instance, if a small portion of chloride
of sodium, or calcium, or lime, or any other substance having the desired
properties be mixed with the oxides, the chlorine will abstract the sulphur,

page_text: pass off partially as chloride of sulphur, while the rest will be kept by the flux
covering the steel or iron.
A modification to be used when a slower oxidation is desired is shewn in
Figure 7 of the Drawing. It consists of the vessel A', covered with a lid a,
of convenient shape and size, constructed of fire-clay or other fire-proof
material, which, however, must be free from any carbonaceous substance, such
as plumbago, coke, &c. This vessel or crucible is pierced with numerous
holes, and is filled with black oxide of manganese or other solid substance
containing oxygen, and submerged in the steel. The lid of the crucible
containing the molten metal will hold the small vessel below the surface of the
metal, allowing the slow escape of the oxygen through the small holes into
the molten steel, whereby a gradual decarbonization is effected. The advan-
tage of this apparatus consists in using the pure oxygen gas, keeping the
remaining substances from coming in contact with the steel or iron.
The seventh feature of this Invention consists in a mode of ascertaining the
quantity of steel manufactured, the said mode being also applicable to the pro-
duction of sound steel castings of pistol barrels and other like objects. One
form of apparatus for carrying out this mode is illustrated in Figure 8, where
A is the clay mould screwed to a rod a; x, x, are the openings through which
the metal contained in the crucible A' runs into the mould. The moulds are
prepared of the best fire-proof and refractory material, as, for instance, soap-
stone, fire-clay, &c., in the same manner as ordinary-fire-bricks and crucibles
are prepared. The moulds thus prepared are arranged so that they will be
filled through openings in the side near the top, and have also a cavity and
air-holes for the escape of flux and gas. On dipping the mould below the
surface of the molten metal it flows into the opening and entirely fills the
cavity, the moulds are then withdrawn from the crucibles and allowed to
cool gradually in an annealing oveu.
The importance of obtaining accurate test proofs is well known to those
engaged in the manufacture of steel. These tests have been heretofore
obtained by taking a proof out of the crucible by introducing a cold iron bar
to which the molten steel adheres, the steel having to be tried by a hammer.
The instantaneous absorption of heat causes a. strong contraction of the
exterior crystalline particles of the steel, and an uneven interior texture of
the test piece.
By the above described mode of obtaining test pieces, no sudden con-
traction of the exterior particles takes place, the mould being filled with the
metal while in its most liquid state, and the metal being allowed to cool
gradually and equally, a proceeding which results in the obtaining of accurate

page_text: test pieces. It will be readily observed, that the mode of obtaining accurate
test pieces may be applied to the production of steel castings of a variety of
objects, such, for instances, as pistol and rifle barrels.
Having now described the nature and object of the said Invention for
"Improvements in the Manufacture of Iron and Steel, and Apparatus to be
employed in such Manufacture," together with the manner in which the
same is to be or may be performed or carried into practical effect, I would
remark, in conclusion, that I claim as the Invention (communicated to me by
the above-named William Gerhardt,
First, making cast steel by heating strips or scraps of wrought iron in
crucibles, or their equivalents, and introducing into the latter oxide of iron or
other suitable substance containing oxygen, and then pouring a quantity of pig
iron into the crucibles.
Second, the apparatus substantially as herein described and illustrated in
Figure 1 for carrying said manufacture into effect.
Third, the modified apparatus, substantially as herein described and illus-
trated in Figure 2, for carrying the same manufacture into effect.
Fourth, a series of furnaces arranged to communicate with each other,
substantially as herein described and illustrated in Figure 3.
Fifth, the combination of a series of furnaces with a drying oven, sub-
stantially as described in reference to Figure 3.
Sixth, the combination of a series of furnaces with traversing tongs, sub-
stantially as described in reference to Figure 3.
Seventh, the within described mode, substantially as described, of employing
magnetism in the manufacture of steel.
Eighth, the modes herein described, or any equivalent to the same, of
introducing oxides of iron and other substances containing oxygen into molten
steel for the purpose set forth.
Ninth, the mode, substantially as herein set forth, of producing sound test
pieces and other castings of malleable steel.
In witness whereof, I, the said George Davies, have hereunto set my
hand and seal, this Eighteenth day of March, in the year of our Lord
One thousand eight hundred and sixty-four.
GEORGE DAVIES. (L.s.)