AN IMPROVEMENT OB IMPROVEMENTS IN THE MANUFACTURE OF CAST STEEL
Year: 1861

page_text: LETTERS PATENT to Robert Mushet, of Coleford, in the County of
Gloucester, Metallurgist, for the Invention of "AN IMPROVEMENT OB
IMPROVEMENTS IN THE MANUFACTURE OF CAST STEEL.”
Sealed the 23rd April 1861, and dated the 22nd February 1861.
PROVISIONAL SPECIFICATION left by the said Robert Mushet at the
Office of the Commissioners of Patents, with his Petition, on the 22nd
February 1861.
I, ROBERT MUSHET, of Coleford, in the County of Gloucester, Metallurgist,
do hereby declare the nature of the said Invention for "AN IMPROVEMENT
OR IMPROVEMENTS IN THE MANUFACTURE OF CAST STEEL," to be as follows:-
When pig iron, cast iron, or refined iron, granulated in any convenient
manner, is mixed in suitable proportions with pulverized iron ores, consisting
essentially of peroxide or the magnetic oxides of iron, with the addition of
oxide of manganese, and the mixture thus obtained is heated in a melting pot
or crucible until melted, cast steel is produced, the quality of which said cast
steel partly depends upon the purity of the materials employed, that is to say,
upon the purity of the granular pig iron, cast iron, or refined iron, and of the
pulverized iron ore or oxides of iron; and partly upon the addition of the said
oxide of manganese to the said mixture of granular cast iron and pulverised
iron ores or oxides of iron. Cast steel is likewise produced by melting
granular cast iron, mixed with pulverized sparry iron ore or spathose iron ore,
A

page_text: in which case no addition of oxide of manganese to the mixture of granular
cast iron and pulverized spathose iron ore is required, because spathose iron
ores, called also sparry carbonates of iron, contain in themselves a considerable
proportion or per-centage of oxide of manganese.
When cast steel is manufactured from mixtures of granular pig iron, cast
iron, or refined iron with pulverized iron ores, with the addition of oxide of
manganese, or when cast steel is manufactured from mixtures of granular pig
iron, cast iron, or refined iron, and pulverized spathose or sparry iron ore
without the addition of oxide of manganese, excepting in so far as the said
oxide of manganese is contained in the said spathose iron ore, the said cast
steel when forged into bars or rods is more or less defective, and when these
bars or rods of cast steel are manufactured into tools, the said tools are apt to
crack in hardening them for tempering, and when they do not crack in the
hardening the tempered portions of the said tools which are manufactured from
the said steel are often brittle or coarse in the break. The degrees of hard-
ness also of the said cast steel cannot be regulated with uniformity or certainty,
and it often happens that the cast steel produced is hard in temper, brittle, and
what is called rash or wild, when it was intended to be of mild temper, soft,
and tough, and the reverse. To remedy these defects, or some of them, partially
or wholly, is the object of my Invention, and my Invention consists,-
Firstly, in adding to any mixture of granular pig iron, cast iron, or refined
iron, and pulverized iron ore, or oxide of iron and oxide of manganese,
pulverized or broken into pieces, which said mixture is intended to be melted
into cast steel, a quantity of pulverised titanium ore or titanic acid or oxide of
titanium, I thoroughly mix the said pulverized titanium ore or titanic acid, or
oxide of titanium with the said mixture of granular pig iron, cast-iron, or
refined iron, and pulverized iron ore, or oxide of iron and oxide of manganese,
pulverized or broken up into small pieces, but preferably pulverized. I intro-
duce the mixture thus obtained into a melting pot or crucible placed in a
suitable melting furnace, and I heat the said mixture in the said melting pot
until the said mixture is melted, and cast steel produced; I then withdraw
the melting pot from the furnace, and pour the cast steel into an ingot mould,
or into any other suitable mould.
My Invention consists, secondly, in adding to any mixture of granular pig
iron, cast iron, or refined iron, and pulverized iron ore, or oxide of iron and
oxide of manganese pulverized or broken into pieces, but preferably pulverised,
which said mixture is intended to be melted into cast steel a quantity of a
metallic compound of titanium. and. iron, or of titanium and iron containing
also carbon, and I effect the addition of the said metallic compound of titanium

page_text: and iron, or of titanium and iron containing also carbon to the said mixture of
granular iron, and pulverised iron ore, or oxide of iron, and pulverised oxide of
manganese in such a manner that the said substances may become melted and
combined together in the melting pot or crucible, into which the said substances
are introduced, and wherein they are heated in order to melt the said sub-
stances, and thereby produce cast steel. A metallic compound of titanium and
iron may be conveniently prepared by deoxidising compound ores of titanium
and iron, such as ilmenite and iserine, by heating these compound ores of
titanium in closed retorts or chambers in contact with carbonáceous matter.
A metallic compound of titanium and iron, containing also carbon, may be
conveniently prepared by smelting compound ores of titanium and iron, such
as ilmenite or iserine, in a blast furnace with coke or charcoal fuel. When
thus prepared, I term the metallic compound of titanium and iron containing
also carbon "titanic pig metal." Ilmenite is a compound ore of titanium and
iron containing according to published analyses, from 12 to 59 per-centum of
titanic acid, the residue being for the most part oxide of iron, with occasionally
a little oxide of manganese. Ilmenite is also termed titaniferous iron ore, or
iron ore rich in titanium. The ilmenite which I prefer to employ is that
variety which is rich in titanium, and the richer the said ilmenite is in titanium
the better it is suited for my process. Iserine is an ore of titanium and iron
containing, according to published analyses, from about eight to about twelve
per-centum of titanic acid, the residue consisting essentially of oxides of iron'
with occasionally some oxide of manganese.
Both ilmenite and iserine are cheap and abundant ores of titanium, and I'
therefore prefer to employ them for my process, and I prefer to employ such
ilmenites or iserines as are free or nearly free from sulphur, phosphorus, tin,
spar, and gangue, or veinstone.
In carrying into effect the first part of my Invention, I have found that
although various ores of titanium, such as rutile, anatase, iserine, and ilmenite,
and also titanic acid or oxide of titanium, separated or prepared by any con-'
venient method from ores of titanium, may be employed for my process, never-
theless that variety of titanium ore called ilmenite answers exceedingly well
for my purpose, and produces excellent and uniform results. I prepare the
ilmenite or titaniferous iron ore for my process in the following manner :-
I crush, stamp, or grind the ilmenite in any convenient manner, and pulverise
it so as to pass through a sieve of from 1,600 to 4,900 meslies per square inch.
When thus prepared the ilmenite or titaniferous iron ore is ready for my
process. I do not, however, confine myself to the use of sieves of the par-
ticúlar degrees of fineness herein set down, but I wish it to be understood

page_text: that the finer the ilmenite or titaniferous iron ore is pulverised, the better it is
suited for my purpose.
*
Pig iron or other cast iron or refined iron, when granulated by any con-
venient method, may be employed for my process, but I prefer to use grey pig
iron, or cast iron smelted from rich and pure hematite, or other pure iron ores
with charcoal, coke, or coal fuel. I prefer to use such pig iron, cast iron, or
refined iron as is of good quality, and free or nearly free from sulphur,
posphorus, and other impurities. Though the pig iron or cast iron may
be granulated by any convenient method, I prefer to granulate the said pig
iron or cast iron for my process in the following manner, because when thus
granulated, the steel produced. from the said iron is more uniform than if the
said pig, cast, or refined iron had been otherwise granulated. I break the pig
iron or cast iron into pieces or lumps of from ten to forty pounds weight each
or thereabouts, and I heat the said lumps or pieces of pig iron or cast iron in
a, reverberatory or other suitable furnace to a temperature somewhat short of
their melting point. When thus heated the said pieces or lumps of pig iron
or cast iron will be found to be soft and friable. I now place the heated.
lumps of pig or cast iron in iron mortars, and I beat upon the said lumps of
pig or cast iron with heavy pestles until the said lumps of iron are broken.
down and reduced to the granular state. The pig iron or cast iron thus
granulated is ready for my process. I wish it to be understood that the finer
the pig iron or cast iron is granulated, the better it is suited for my process.
The iron ores suited for my procèss are the purest hematites, magnetic iron.
ores, hydrates, oxides of iron, and specular or micaceous iron ores. In
practice, however, I bave found that the purest red hematites of Cumberland
and Lancashire are especially well suited for my process, and afford when
employed the most uniform results, whilst they are to be obtained in any
quantity at a cheap rate. In order to prepare these iron ores for my process,
I select the purest portions of the Cumberland or Lancashire red hematite ores,
called kidney iron ore, and I crush, stamp, or grind the said kidney iron ore
so that it will pass through a sieve of from 1,600 to 4,900 meshes per square.
inch. When thus prepared the kidney iron ore is ready for my process. I do
not, however, limit myself to the use of sieves of the degrees of fineness herein
set down, but I wish it to be understood that the finer the hematite or kidney:
iron ore is pulverized, the better it is suited for my purpose. The oxide of
manganese I prefer to employ for my process is the purest oxide of manganese
of commerce, and I prefer to pulverize the said manganese, though it may,.
nevertheless, be employed when in the state of small lumps or fragments...
Though I prefer to use the purest oxide of manganese of commerce, I have

page_text: found that the more common varieties of the oxide of manganese may also be
employed with good effect. The proportions of the granular pig iron or cast
iron, the pulverized hematite iron ore, the pulverized ilmenite, and the
pulverized oxide of manganese, which I employ in my mixture, which it is
intended to melt into cast steel will be best shewn by examples as follows:-
To produce cast steel of medium hardness:-
Good grey pig iron, granulated as herein-before described -
Good red hematite iron ore, pulverized
Pulverized ilmenite
-
Pulverized oxide of manganese
40 Ibs.
8 lbs.'
1 lb.
from 8 oz. to 12 oz.
I mix these substances thoroughly, and I introduce them into a melting pot
or crucible placed in a suitable melting furnace, and I heat the said substances.
therein until the granular pig iron is melted, and the iron and titanium in the
iron ores, and in the titanium ores are respectively reduced and melted, and
combined with the granular pig iron; I then withdraw the melting pot from
the furnace, and I pour the cast steel contained in the said melting pot into
ingot mould or into any other suitable mould. I do not limit myself to the
relative proportions of the granular pig iron, the pulverized hematite iron. ore,
the pulverised ilmenite, and the pulverized oxide of manganese herein set.
down, for these proportions may be varied without departing from the nature
of my Invention, but I wish the following remarks to be particular attended.
to:-
1st. When the granular pig iron, cast iron, or refined iron employed contains
a large per-centage of carbon, the relative proportions of pulverized hematite
iron ore added to the said granular iron must be greater than when the said
granular iron contains a smaller per-centage of carbon.
2dly. When the hematite iron ore employed is very pure, the relative pro-
portion of oxide of manganese added to the mixture may be diminished, and
in general I regulate the proportion of oxide of manganese added to the
mixture, so as to produce with the scoria and impurities which are separated
during fusion, from the granular pig or cast iron and the pulverised iron ore,
a liquid slag or glass. When the proportion of oxide of manganese added is
insufficient, the slag will be found of a refractory scoriaceous character, not at
all liquid, and so viscid as to retain in itself grains or globules. of steel. When
the proportion of oxide of manganese, added to the mixture is sufficient, the
slag, during the melting operation, will separate in a liquid, but moderately,

page_text: viscid state, and will be free from globules of steel. If an excess of oxide of
manganese be added to the mixture, a very thin and liquid slag is separated
by the melting process, and this slag acts destructively upon the inside of the
melting pot. When the pulverised iron ore used is of a highly siliceous
nature, more oxide of manganese will be required to produce a liquid slag
than when a pure iron ore, free or nearly free from silica, is employed. When
magnetic iron ores containing protoxide of iron are employed in the mixture
in place of the red hematites, very much less oxide of manganese will be
required, but the results are not so certain and uniform as when the red
hematite iron ores of Cumberland and Lancashire are employed.
3dly. If the quantity of pulverised ilmenite added to forty pounds of granular
pig, cast, or refined iron is increased beyond the quantity set down in the
examples herein-before given, then the quantity of pulverised iron ore used
must be diminished by a like amount below the quantity set down in the
several examples. And if the amount of pulverised ilmenite added to forty
pounds of pig, cast, or refined iron- be less than the quantity set down in the
examples herein-before given then the quantity of the iron ore used must be
increased by a like amount, and the quantity set down in the examples, that is
to say the sum of the quantities of pulverised ilmenite and iron ore employed
must be preserved the same or nearly the same, any increase in the amount of
either of them being accompanied by a corresponding diminution in the
amount of the other.
In order to illustrate these remarks, and to enable the steel maker to
understand them more readily and fully, I subjoin the following examples:

page_text: Pulverised ilmenite containing oxide of manganese..
9 lbs.
The mixtures herein set down in examples No. 2, No. 3, and No. 4, produce
when melted, cast steel of medium hardness; and in examples No. 3 and No. 4,
the oxide of iron contained in the ilmenite acts as a substitute for the oxide of
iron in the hematite iron ore and replaces the said oxide. In practice however
I find it more convenient and economical to employ a mixture of pulverised!
iron ore and pulverised ilmenite, and I also find that to every forty pounds of
granular pig iron operated upon and mixed with from six to eight pounds or
thereabouts of pulverised hematite iron ore it is sufficient to add one pound
of pulverised ilmenite in order. to obtain an excellent result, though I do not
confine myself to these proportions which may be varied without departing from
the nature, of my Invention.
4thly. I regulate the hardness of the cast steel produced in the following
manner. If on trial the cast steel produced by melting the mixture, the
proportions of which I have herein-before set down in Example No. 1, prove
too hard, I increase the quantity of pulverised hematite iron ore, or I diminish
the quantity of granular pig iron, but I usually prefer to increase the quantity
of the pulverised hematite whilst the quantity of the granular pig iron remains
the same. *
If the cast steel produced by melting the mixture, the proportions of which
I have set down in example No. 1, prove too soft, I either diminish the quantity
of pulverised hematite ore employed, or I increase the quantity of granular pig
iron; but in practice it is simplest to diminish the quantity of pulverised
hematite ore.
EXAMPLE No. 5.
To produce a cast steel harder than that set down in Example No. 1.
Good grey pig iron, granulated
40 lbs.
Good red hematite iron ore, pulverised
Ilmenite, pulverised
Oxide of manganese
-
7 lbs.
.
1 lb.
from 8oz. to 12 oz.
EXAMPLE No. 6.
To produce a cast steel softer than set down in Example No 1.
Good grey pig iron, granulated
Good red hematite iron ore, pulverised
Ilmenite, pulverised
Oxide of manganese
40 lbs.
8 lbs.
1 lb.
from 8 oz to 12 oz.

page_text: titanium artificially separated from titanium ores or titanium compounds may
be employed in place of ilmenite; nor do I confine myself to the use of the
red hematite ores of Lancashire and Cumberland, for other iron ores or
oxides of iron may be employed, but I have herein set down and enumerated
the particular materials which I have hitherto found best suited for my
process.
Scrap iron or scrap steel, or both these substances, may be added to the
mixtures I have herein described, and may be melted with the said mixtures,
but such addition forms no part of my Invention. Borax and other alkalinė.
fluxes may be added to the mixtures of steel-producing materials herein-before
described, but the addition of such fluxes forms no part of my Inventioni,
neither is the said addition essential to the success of my. process.
When I carry into effect the second part of my Invention, which, as herein-
before described, consists in adding to any mixture of granular pig iron, cast
iron, or refined iron, and pulverised iron ore or oxide of iron, and pulverised
oxide of manganese, which said mixture it is intended to melt into cast steel, a
quantity of a metallic compound of titanium- and iron, cr of titanium and iron
containing also carbon, and heating these substances together in a melting
pot or crucible, so that they shall be melted, mixed, and combined in order to
produce cast steel of improved quality, I proceed in the following manner,
and by methods which I now proceed to illustrate by examples

page_text: therein until it, is partially or wholly melted. I then remove the lidior cover
.of the melting pot or crucible, and I drop into, the said melting pot the
requisite quantity of the, titanic pig metal. The said titanic pig metal may
be thus introduced either in the cold state, or in a heated state, or in a
melted state, but in practice I find that it answers very well to drop the said
titanic pig metal, when in the cold state, into the melting pot containing the
partially or wholly melted mixture of granular pig iron, pulverised iron ore,
and oxide of manganese. In either case I suffer the melting pot to remain in
the furnace until the, said mixture, and the said titanic. pig metal, are both
.completely melted and coinbined. .I then withdraw the melting pot: from the
furnace, and I pour; the cast steel produced into an ingot mould, or into any
other suitable mould. I do not confine myself to the relative. proportions of
granular pig iron, pulverised iron ore, and oxide of manganese, and ititanic. pig
metal set down in this example, for these proportions. may be varied without
departing from the nature of my Invention.

page_text: without departing from the nature of my Invention. If the steel produced
by melting the mixtures of materials described in Examples A. and B. prove
too hard; I increase the quantity of the pulverised hematite iron ore employed,.
and if the steel proves too soft, I diminish the quantity of the said pulverised
hematite iron ore in the mixture. Borax and other alkaline fluxes may be
added to the mixtures of steel-producing materials herein-before described,
but the addition of such fluxes forms no part of my Invention, neither is the
said addition essential to the success of my process.
Although, for convenience of description, I have described the kinds of iron
which, I employ as pig, or cast iron, and refined iron, yet I wish it to be under
stood that in place of granular, pig, or, cast iron, or granular refined iron, used
singly or separately, mixtures of these varieties of iron may be employed with
similar effects,, due allowance being made from the smaller per-centage of
carbon contained in refined iron than is usually found contained in pig or cast
iron of good quality. The melting pots or crucibles I employ, and the melting
furnaces in which I heat them are such as are ordinarily employed by steel
manufacturers.
Having thus described the nature of my Invention, and the methods by
which I carry the said Invention into effect, I declare that my Invention
consists, in the first place, in adding to any mixture of granular pig iron, cast
iron, or refined iron, and pulverized iron ores, or oxides of iron and oxide of
manganese, which said mixture is intended to be melted into cast steel, a
quantity of pulverized titanium ore, or titaniferous iron ore, or titanic acid, or
oxide of titanium, and I then mix the said substances thoroughly, and when
mixed I introduce the mixture thus obtained into a melting pot or crucible
placed in a melting furnace, and I heat the said mixture therein until the
granular, pig, cast, or refined iron is melted, and the iron and the titanium in
the pulverised ores or oxides of iron and titanium are respectively reduced
and melted and combined with the melted granular, pig, cast, or refined iron,
producing cast steel of an improved quantity alloyed with titanium...
And, secondly, my Invention, further consists in adding to any mixture of
granular pig iron, cast iron, or refined iron, and pulverized iron ores or oxides
of iron, and oxide of manganese, which said mixture is intended to be melted
into cast steel a quantity of a metallic compound consisting essentially of
titanium and iron, such as deoxidised ilmenite or iserine, or a quantity of a
metallic.compound composed essentially of iron and titanium, and containing
also carbon, and either melting these said compounds together with the said
mixture of granular pig iron, cast iron, or refined iron, or dropping the said
metallic compounds of titanium and iron, or the said metallic compounds of

page_text: titanium and iron, containing also carbon, into the melting pot containing the
'mixture of granular pig iron, cast iron, or refined iron, and pulverised iron ore,
or oxide of iron and oxide of manganese when the said mixture is in a par-
'tially or wholly melted state, so that the said metallic titanium compounds
'may become melted, dissolved, and alloyed with the said mixture of granular,
pig, cast, or refined iron, in order to produce cast steel of an improved quality
alloyed with titanium.
I wish it to be clearly understood that I do not claim the manufacture of
'cast steel from any mixture of granular pig iron, cast iron, or refined iron,
and pulverised iron ore, or oxide of iron, except when to a mixture of three
substances there is added either a quantity of pulverized titanium ore,
titaniferous iron ore or titanic acid, or oxide of titanium, or a quantity of a
metallic compound of titanium and iron, such, for instance, as deoxidised
ilmenite or iserine, or a quantity of a metallic compound of titanium and iron
containing also carbon, which I call titanic pig metal.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed
by the said Robert Mushet in the Great Seal Patent Office on the
25th July 1861.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, ROBERT
MUSHET, of Coleford, in the County of Gloucester, Metallurgist, send
greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Twenty-second day of February, in the year of our Lord
One thousand eight hundred and sixty-one, in the twenty-fourth year of Her
reign, did, for Herself, Her heirs and successors, give and grant unto me, the
said Robert Mushet, Her special licence that I, the said Robert Mushet, my
executors, administrators, and assigns, or such others as I, the said Robert
Mushet, my, 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 "AN IMPROVEMENT OR IMPROVE-
MENTS IN THE MANUFACTURE OF CAST STEEL," upon the condition (amongst
others) that I, the said Robert Mushet, my executors or administrators, by an
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,

page_text: 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 I, the said Robert Mushet, do hereby declare.
the nature of the said Invention, and in, what manner the same is to be
performed, to be particularly described and ascertained in and by the following
statement thereof, that is to say:-
+
When pig iron, cast iron, or refined iron granulated in any convenient
manner, is mixed in suitable proportions with pulverised iron ores, consisting,
essentially of peroxide or the magnetic oxides of iron, with the addition of
oxide of manganese, and the mixture thus obtained is heated in a melting pot.
or crucible until melted, cast steel is produced, the quality of which.said cast.
steel depends mainly upon the purity of the materials employed, that is to say,
upon the purity of the granular pig iron, cast iron, or refined, iron, and of the
pulverised iron ore or oxides of iron, and also partly upon the addition of
the said oxide of manganese to the said mixture of granular cast iron and,
pulverised iron ores or oxides of iron. Cast steel is likewise produced by melting,
granular cast iron mixed with pulverised sparry iron ore or spathose iron ore,,
in which case no addition of oxide of manganese to the mixture of granular,
cast iron and pulverised spathose iron ore is required, because spathose iron.
ores, called also sparry carbonates of iron, almost always contain in themselves.
a considerable proportion or per-centage of oxide of manganese..
'
When cast steel is manufactured from mixtures of granular pig iron, cast;
iron, or refined iron, with pulverised iron ores or oxides of iron, with the.
addition of oxide of manganese; or when cast steel is manufactured from
mixtures of granular pig iron, cast iron, or refined iron, and pulverised spathose.
or sparry iron ore without the addition of oxide of manganese, excepting in so,
far as the said oxide of manganese is contained in the said spathose iron ore,
the said cast steel when forged into bars or rods is frequently found to be more,
.or less defective; and when these bars or rods of cast steel are manufactured.
into tools, the said tools are apt to crack in hardening them for tempering, and
when they do not crack in the hardening, the tempered portions of the said,
tools which are manufactured from the said steel are often brittle or coarse in
the break. The various degrees of hardness also of the said cast steel cannot.
be regulated with uniformity or certainty, and it often happens that the cast:
steel produced is. hard in temper, brittle, and what is called rash or wild, when,
it was intended to be of mild temper, soft and tough, and the reverse.
To remedy these defects, or some of them, partially or wholly, is the object of
my Invention; and my Invention consists, firstly, in adding to any mixture of,
:

page_text: granular pig iron, cast iron, or refined iron, and pulverised iron ore or oxide
of iron, and oxide of manganese, pulverised or broken into pieces, which said
'mixture is intended to be melted into cast steel; a quantity of pulverised tita-
nium ore, or titanic acid, or oxide of titanium. I thoroughly mix the said
pulverised titanium ore, or titanic acid, or oxide of titanium with the said
mixture of granular pig iron, cast iron, or refined iron, and pulverised iron ore
or oxide of iron and oxide of manganese, pulverised or broken up into small
pieces, but preferably pulverised. I introduce the mixture thus obtained into
a melting pot or crucible placed in a suitable melting furnace, and I heat the
said mixture contained in the said melting pot until the said mixture is melted,
and cast steel produced. I then withdraw the melting pot from the furnace
and pour tlie cast steel into an ingot mould or into any other suitable
mould.
My Invention consists, secondly, in adding to any mixture of granular pig
iron, cast iron, or refined iron; and pulverised iron ore or oxidé of iron, and
oxide of manganese, pulverised or broken into pieces, but preferably pulverised,
which said mixture is intended to be melted into cast steel, a quantity of a
metallic compound of titanium and iron, or of titanium and iron containing
also carbon, and I effect the addition of the said metallic compound of tita-
nium and iron, or of titaniumi and iron containing also carbon to the said
mixture of granular iron and pulverised iron ore or oxide of iron, and pulve-
rised oxide of manganese, in such a' manner that the said substances may
become melted and combined together in the melting pot or crucible into
which the said substances are introduced, and wherein they are heated, in order
to melt the said substances, and thereby produce cast steel. A metallic com-
pound of titanium and iron may be conveniently prepared by deoxidising
compound ores of titanium and iron, such as ilmenite and iserine, by heating
these compound ores of titanium in closed retorts or chambers in contact with
carbonaceous matter, such for instance, as charcoal, which I find answers very
well. A metallic compound of titanium and iron, containing also carbon, may
be conveniently prepared by smelting compound ores of titanium and iron, such
as ilmenite or iserene, in a blast furnace with coke or charcoal fuel.. When
thus prepared, I term the metallic compound of titanium and iron, containing
also carbon, "titanic pig metal." Ilmenite is a compound ore of titanium and
iron, containing according to published analyses, from 12 to 59 per-centum of
titanic acid, the residue being for the most part oxide of iron, with occasionally
a little oxide of manganese. Ilmenite is also termed titaniferous iron ore or
iron ore' rich in titanium. The ilmenite which I prefer to employ is that
variety which is rich in titanium, and the richer the said ilmenite is in tita

page_text: nium, the better it is suited for my process. Iserine is an ore of titanium and
iron, containing according to published analyses from about eight to about
twelve per-centum of titanic acid, the residue consisting essentially of oxides of
iron, with occasionally sonie oxide of manganese. Both ilmenite and iserine
are cheap and abundant ores of titanium, and I therefore prefer to employ
them for my process, and I prefer to employ such ilmenites or iserines as are
free or nearly free from sulphur, phosphorus, tin spar, and gangue or vein-
stone, and ilmenite being found in large masses nearly perfectly pure, is the
cheapest and most convenient. material for my process.
In carrying into effect the first part of my Invention, I have found that
various ores of titanium, such as rutile, anatase, iserine, and ilmenite, and also
titanic acid, or oxide of titanium, separated or prepared by any convenient
method from ores of titanium, may be advantageously employed for my process,
and that that variety of titanium ore, called ilmenite, also answers exceedingly
well for my process, and produces excellent and uniform results. I prepare
the ilmenite or titaniferous iron ore for my process in the following manner:
I crush, stamp, or grind the ilmenite in any convenient manner, and pul
verise it as to make it pass, through a sieve of from 1600 to 4900 meshes
per square inch. When thus prepared the ilmenite or titaniferous iron ore is
ready for my process. I do not, however, confine myself to the use of sieves
of the particular degree of fineness herein set down, but I wish it to be under-
stood that the finer the ilmenite or titaniferous iron ore is pulverised the better
it is suited for my purpose.
Pig iron or other cast iron, or refined iron, when granulated by any con-
venient method, may be employed for my process; but I prefer to use grey
pig iron or cast iron smelted from rich and pure hematite, or other pure iron'
ores, with charcoal, coke, or coal fuel. I prefer to use such pig iron, cast iron,
or refined iron as is of good quality, and free or nearly free from sulphur,
phosphorus, and other impurities. Though the pig iron or cast iron may be
granulated by any convenient method, I prefer to granulate the said pig iron
or cast iron for my process in the following manner :-I break the pig iron or-
cast iron into pieces or lumps of from ten to forty pounds weight each, or
thereabouts, and I heat the said lumps or pieces of pig iron or cast iron in a
reverberatory or other snitable furnace to a temperature somewhat short of
their melting point. When thus heated the said pieces or lumps of pig iron
or cast iron will be found to be soft and friable. I now place the heated
lumps of pig or cast iron in iron mortars, and I beat upon the said lumps of
pig or cast iron with heavy pestles -until the said lumps of iron are broken.
down and reduced to the granular state. The pig iron, or cast iron- thus

page_text: granulated is ready for my process, and consists partly of small knobs and
partly of fine metallic granules and dust. When well granulated by the
method I have herein described, good grey pig iron will be so far pulverised
or comminuted that out of every three tons of pig iron thus granulated, two
tons, or thereabouts, will pass through a riddle of four meshes per square inch,
and one ton, or thereabouts, in the state of knobs or pieces. will not pass
through the riddle. When refined cast iron, or very strong bodied cast iron
or pig iron is thus granulated, about one-half of the quantity operated upon
will consist of knobs or pieces which will not pass through a riddle of four
meshes per square inch, and the remaining moiety of the said iron will pass
through the said riddle. I wish it to be understood that the finer the pig iron
or cast iron is granulated the better it is suited for my process.
"
When the pig iron, cast iron, or refined iron, as the case may be, has been
prepared by granulating it in the manner. herein-before described, I find it
convenient before weighing the said granulated iron, to separate the knobs
or larger pieces of iron from the smaller pieces and the metallic dust or
powder of which the granulated iron consists. This is readily effected by
riddling the granulated iron, and I usually employ a riddle of four meshes per
square inch for this purpose, when thus riddled and separated into two
kinds, one of which passes the meshes of the said riddle,, whilst the other kind
does not pass through the said meshes.. I call the former kind "fine iron,"
and the latter. kind "rough iron," and in weighing up the requisite quan-.
tities of the granular pig iron, cast iron, or refined iron which are to be
employed in my process, I prefer to weigh up a fair proportion of "fine iron
to "rough iron." Thus, if the granulated pig iron consists of two parts of
"fine iron" to one part of "rough iron" for every three pounds of granulated.
iron weighed up, I take two pounds of "fine iron" and one pound of "rough
iron; or, if the granulated refined iron consists of equal parts of "fine iron "
and "rough iron," then in weighing up the quantity of granulated refined iron
required, I take equal parts of "fine iron " and of "rough iron." I thus
secure a due or just proportion of fine and rough iron in every instance, and
this is of advantage, inasmuch as it promotes uniformity of quality in the cast
steel produced by my process. The iron ores suited for my process are the
purest hematites, magnetic iron ores, bydrated oxides of iron, and specular or
micaceous iron ores.
In practice, however, I have found that the purest red hematite iron ores
of Cumberland and Lancashire are especially well suited for my process, and
afford, wlem employed, the most uniform results; whilst they are to be
obtained in any required quantity at a cheap rate. In order to prepare these:

page_text: iron ores for my process, I prefer to select the purest portions of the Cumber-
land or Lancashire red hematite iron ores, called kidney iron ore, or the purest
varieties of the small or gravelly red ore, or hematite iron ore, and I crush,
stamp, or grind the said kidney iron ore, or the said hematite iron ore, so that
it will pass through a sieve of from 1600 to 4900 meshes per square inch.
When thus prepared the kidney iron ore, or the small or gravelly hematite iron
ore is ready for my process. I do not, however, limit myself to the use of sieves
of the degrees of fineness herein set down;; but I wish it to be understood that
the finer the hematite or kidney iron ore, is pulverized the better it is suited
for my purpose. The oxide of manganese; I prefer to employ for my process
is the purest oxide of manganese of commerce, and I prefer to pulverise the
said oxide of manganese, though it may, nevertheless, be employed when in
the state of small lumps or: fragments. Though I prefer to use the purest
oxide of manganese of commerce, I have found that the more common
varieties of the oxide of manganese may also be employed with good effect.
The proportions of the granular pig iron or cast iron, the pulverized hematite
or kidney iron ore, the pulverized ilmenite, and the pulverized, oxide of man-
ganese which I employ in my mixture which it is intended to melt into cast steel,
will be best shewn by example: as follows:-

page_text: :
down, for these proportions may be varied without departing from the naturė
of my Invention; but I wish the following remarks to be particularly
attended to:-
7
1st. When the granular pig iron, cast iron; or refined iron employed contains
a large per-centage of carbon, the relative proportions of pulverized hematite
iron ore added to the said granular iron must be greater than when the said
granular iron contains a smaller per-centage of carbon.
2nd. When the hematite iron ore employed is very pure, the relative pro-
portion of oxide of manganese added to the mixture may be diminished, and
in general I regulate the proportion of oxide of manganese added to the
mixture, so as to produce with the scoria and impurities which are separated
during fusion from the granular pig or cast iron, and the pulverized iron ore a
moderately liquid slag or glass. When the proportion of oxide of manganese
added is insufficient, the slag will be found of a refractory scoriaceous
character, not at all liquid, and so viscid as to retain in itself grains or globules
of steel. When the proportion of oxide of manganese added to the mixture
is sufficient, the slag during the melting operation will separate in a liquid
.but moderately viscid state, and it will be free from globules of steel. . If an
excess of oxide of manganese be-added to the mixture, a very thin and liquid
slag is separated by the melting process, and this kind of slag acts destructively
upon the inside of the melting pot.
When the pulverized iron ore used is of a highly siliceous nature, more
oxide of manganese will be required to produce a liquid slag than when a pure
iron ore free or nearly free from silica is employed. When magnetic iron ores
containing protoxide of iron are employed in the mixture, in the place of the red
hematites, very much less oxide of manganese will be required, but the results
when magnetic iron ores, or the lower oxides of iron are employed are not so
certain and uniform as when the red hematite iron ores of Cumberland and
Lancashire are used for my process.
3dly. If the quantity of pulverized ilmenite added to forty pounds of
granular pig, cast, or refined iron is increased beyond the quantity set down
in the examples herein given, then the quantity of pulverized iron ore used
must be diminished by a like amount below the quantity set down in the
several examples. And if the amount of pulverized ilmenite added to forty
pounds of pig, cast, or refined iron be less than the quantity set down in the
examples herein given, then the quantity of the iron ore used must be
increased by a like amount; and the quantity set down in the examples, that
is to say, the sum of the quantities of pulverized ilmenite and iron ore

page_text: employed must be preserved, the same, or nearly the same, any increase in the
amount of either of them being accompanied by a corresponding diminution
in the amount of the other. In order to illustrate these remarks, and to
enable the steel maker. to understand them more readily and fully, I subjoin
the following examples:-

page_text: 4th. I regulate the hardness of the cast steel produced in the following
manner-If on trial the cast steel produced by melting the mixture, the pro-
portions of which I have herein-before set down in Example No. 1, prove too
hard, I increase the quantity of pulverized hematite iron ore, or I diminish
the quantity of granular pig iron, but I usually prefer to increase the quantity
of the pulverized hematite, whilst the quantity of the granular pig iron remains
the same. If the cast steel produced by melting the mixture, the proportions
of which I have set down in Example No. 1, prove too soft, I either diminish
the quantity of pulverized hematite iron ore employed, or I increase the
quantity of granular pig iron, but in practice it is simplest to diminish the
quantity of pulverized hematite ore.
To produce a cast steel softer than that set down in Example No. 1.
Good grey pig iron, granulated, as herein-before described - 40 lbs.
Good red hematite iron ore, pulverized
Ilmenite pulverized
8 lbs.
1 lb

page_text: In each Example, Nos. 5, 6, 7, and 8, the materials, the proportions of
which are set down in the said examples, are to be carefully mixed, after
which in each case I introduce the mixture into a melting pot or crucible
placed in a melting furnace, and I heat the said mixture in the said melting
pot until the said mixture is melted, as described with reference to Example
No. 1. I then withdraw the melting pot from the furnace, and I pour the
steel into an ingot mould, or into any other suitable mould...
Pulverized ilmenite
Pulverized oxide of manganese
1 lb.
from 4 oz. to 8 oz.
These substances I mix thoroughly, and treat the mixture in the same manner
as described with reference to examples Nos. 1, 5, 6, 7, and 8. Examples Nos. 7..
8, and 9, produce cast steel of good quality and average hardness. I wish it to be
clearly understood that I do not confine myself. to the relative proportions of
the materials I employ, as herein-before set down in Examples Nos. 1, 2, 3, 4}
5, 6, 7, 8, and 9, for the proportions may be varied without departing from
the nature of my Invention; but I have found that these proportions, or
nearly similar proportions, afford excellent results. I wish it also to be under-
stood that I do not limit my Invention to the use of any 'specific kinds or
varieties of pig iron, for other varieties of cast iron, besides grey pig iron may
be employed. Neither do I limit myself to the use of that particular ore of
titanium, called ilmenite, for other ores of titanium or titanic acid, or oxide of
titanium artificially separated from titanium ores or titanium compounds may
be employed in place of ilmenite; nor do I confine myself to the use of the
red hematite iron ores or kidney iron ores of Lancashire and Cumberland, for
other iron ores or oxides of iron may be employed. But I have herein set
down and enumerated the particular materials, which I have hitherto found
best suited for my process. Scrap iron or scrap steel or both these substances
may be added to the mixtures I have herein-before described, and may be
melted with the said mixtures, but such addition forms no part of my In-
vention. When, however, mixtures of scrap iron or scrap steel, that is,
pieces of malleable iron or steel cut or broken up for the convenience of
packing into the melting pots are employed, the following examples will best
illustrate how I proceed.

page_text: Good grey pig iron, granulated, as herein-before described
Red hematite iron ore, pulverized
Ilmenite, pulverized
Oxide of manganese, pulverized
12 105.
-
33 lbs.
-
5 lbs.
-
1 lb.
12 oz.
These substances are to be thoroughly mixed before they are introduced
into the melting pot.
In each case, viz., in Examples Nos. 10, 11, 12, 13, and 14 respectively, the
mixtures are to be introduced into a melting pot or crucible placed in a
suitable melting furnace, and the said mixtures are to be heated therein until
they are reduced, and the steel is melted. I then withdraw the melting pots
from the furnace and pour the steel into ingot moulds, or into other suitable
moulds.
The grey pig iron or pig irons, which I prefer to employ for my process are
those smelted with coke fuel in the blast furnace from the red hematite iron
ores of Cumberland and Lancashire, such pig irons being commercially known
as hematite pig iron. These pig irons are exceedingly cheap, and afford excel-
lent results when employed in my process. Very good results may also be
obtained with the best grey pig irons of the Forest of Dean.
Borax and other alkaline fluxes may be added to the mixture of steel-pro-
ducing materials, herein-before described, but the addition of such fluxes forms
no part of my Invention, neither is the said addition essential to the success of
my process.
Titanic acid or oxide of titanium may be substituted for titanium ore in the
several mixtures herein-before described. When I employ either titanic acid
or oxide of titanium, the said acid or oxide may be employed in the same pro-
portions and in the same manner as described with reference to titanium ore,
excepting that as the said acid and oxide are separated from their natural com-
pounds in the form of an impalpable powder, they do not require to be
pulverized.
In carrying into effect the second part of my Invention, which as herein-
before described, consists in adding to any mixture of granular pig iron, cast
iron, or refined iron, and pulverized iron ore or oxide of iron and pulverized
oxide of manganese, which said mixture it is intended to melt into cast steel a
quantity of a metallic compound of titanium and iron, or of titanium and iron

page_text: containing also carbon, and heating these substances together in a melting pot
or crucible, so that they shall be melted, mixed, and combined in order to
produce cast steel of improved quality. I proceed in the following manner, and
by methods which I now proceed to illustrate by examples.
Grey pig iron, of good quality, granulated, as herein-before
described
Rich red hematite iron ore, pulverized
Oxide of manganese
-
40 lbs.
9 lbs.
from 4 oz. to 12 oz.
I mix these substances well together, and I add to the mixture thus
obtained from one to five pounds of a compound of titanium and iron con-
taining also carbon which I call titanic pig metal, and which said titanic
pig metal I have herein-before described. I introduce the said mixture and
the said titanic pig metal into a melting pot or crucible placed in a melting
furnace, and I heat the said mixture and the said titanic pig metal therein
until these substances are melted and combined.. I then withdraw the melting
pot from the furnace, and I pour the steel produced into an ingot mould or
into any other suitable mould; or I first introduce the mixture of granular pig
iron, pulverized iron ore, and pulverised oxide of manganese into the melting
pot or crucible placed in a melting furnace, and heat the said mixture therein
until it is partially or wholly melted. I then remove the lid or cover of the
melting pot or crucible, and I drop into the said melting pot the requisite
quantity of the titanic pig metal, the said titanic pig metal may be thus intro-
duced either in the cold state or in a heated state or in a melted state, but in
practice I find that it answers very well to drop the said titanic pig metal
when in the cold state, or when heated to a red heat into the melting pot
containing the partially or wholly melted mixture of granular pig iron,
pulverized iron ore, and oxide of manganese. In either case I suffer the
melting pot to remain in the furnace until the said mixture and the said
titanic pig metal are both completely melted and combined. I then withdraw
the melting pot from the furnace, and I pour the cast steel produced into
an ingot mould or into any other suitable mould. I do not confine myself
to the relative proportions of granular pig iron, pulverized iron ore and
oxide of manganese, and titanic pig metal set down in this example, for these
proportions may be varied without departing from the nature of my
L..
Invention.
.

page_text: Grey pig iron of good quality granulated as herein-before
described
-
Rich red hematite iron ore, pulverized
Pulverized oxide of manganese
40 lbs.
8 lbs.
-
from 4 oz. to 12 oz.
I mix these substances well together, and I add to the mixture thus
obtained from eight ounces to two pounds of deoxidised ilmenite or iserine, but
preferably deoxidised ilmenite, and I introduce the said mixture and the said
deoxidised ilmenite into a melting pot or crucible placed in a melting furnace,
and I then proceed as described in reference to Example A. Or I first intro-
duce the mixture of granular pig iron, pulverised iron ore, and oxide of
manganese into the melting pot and I heat the said mixture therein until the
said mixture is partially or wholly melted. I then introduce the requisite
quantity of the deoxidized ilmenite by removing the cover of the melting pot
and dropping the said deoxidized ilmenite into the said partially or wholly
melted mixture. I then proceed in the manner I have herein-before described
with reference to Example A. The deoxidized ilmenite may be dropped into
the melting pot when the said deoxidized ilmenite is in either the cold state or
in a heated state, but in practice I find that it answers very well when
employed in the cold state. I do not confine myself to the particular relative
proportions of granular pig iron, pulverized iron ore, oxide of manganese, and
deoxidized ilmenite which I have set down in Example B, for these pro-.
portions may be varied without departing from the nature of my Invention..
If the steel produced by melting the mixtures of materials described in
Examples A. and B. proves too hard, I increase the quantity of the pulverised.
hematite iron ore employed in the mixtures, and if the steel proves too soft I
diminish the quantity of the said pulverised hematite iron ore in the mixture.
Borax and other alkaline fluxes may be added to the mixtures of steel-pro-
ducing materials herein-before described, but the addition of such fluxes.
forms no part of my Invention, neither is it essential to the success of my
process.
:
Although for convenience of description I have described the kinds of iron
which I employ as pig or cast iron and refined iron, yet I wish it to be under-,
stood that in place of granular pig or cast iron, or granular refined iron,
used singly or separately, mixtures of these varieties of iron may be employed.
with similar effects, due allowance being made for the smaller per-centage of

page_text: carbon contained in refined iron than is usually found contained in pig or cast
iron of good quality. The melting pots or crucibles I employ, and the melting
furnaces in which I heat them, are such as are ordinarily employed by, steel
manufacturers.
Having thus described the nature of my Invention, and the methods by
which I carry the said Invention into effect, I declare that my Invention
consists in the first place in adding to any mixture of granular pig iron, cast
iron, or refined iron, and pulverized iron ores or oxides of iron and oxide of
manganese, which said mixture is intended to be melted into cast steel, a
quantity of pulverised titanium ore, or titaniferous iron ore, or titanic acid or
oxide of titanium, and I then mix the said substances thoroughly, and when
mixed I introduce the mixture thus obtained into a melting pot or crucible
placed in a melting furnace, and I heat the said mixture therein until the
granular, pig, cast, or refined iron is melted, and the iron and the titanium in
the pulverised ores or oxides of iron and titanium are respectively reduced and
melted and combined with the melted granular pig, cast, or refined iron,
producing cast steel of an improved quality alloyed with titanium.
-
And, secondly, my Invention further consists in adding to any mixture of
granular pig iron, cast iron, or refined iron, and pulverised iron ores or oxides
of iron, and oxide of manganese, which said mixture is intended to be melted
into cast steel, a quantity of a metallic compound. consisting essentially of
titanium and iron, such as deoxidised ilmenite or iserine, or a quantity of a
metallic compound composed essentially of iron and titanium, and containing also
carbon, and either melting these said compounds together with the said mixture
of granular pig iron, cast iron, or refined iron, or dropping the said metallic
compounds of titanium and iron, or the said metallic compounds of titanium and
iron containing also carbon into the melting pot containing the mixture of
granular pig iron, cast iron, or refined iron, and pulverized iron ore or oxide of
iron and oxide of manganese when the said mixture is in a partially or wholly
melted state, so that the said metallic titanium compounds may become melted,
dissolved, and alloyed with the said mixture of granular, pig, cast, or refined
iron, in order to produce cast steel of an improved quality alloyed with
titanium.
.
I wish it to be clearly understood that I do not claim the manufacture of
cast steel from any mixture of granular pig iron, cast iron, or refined iron, and
pulverised iron ore or oxide of iron, except when to a mixture of these sub-
stances there is added either a quantity of pulverised titanium ore, titaniferous
iron ore, or titanic acid or oxide of titanium, or quantity of a metallic com-

page_text: pound of titanium and iron, such for instance as deoxidized ilmenite or iserine, or
a quantity of a metallic compound of titanium and iron containing also carbon
such as I have herein-before described and called "titanic pig metal."
In witness whereof, I, the said Robert Mushet, have hereunto set my
hand and seal, this Twentieth day of July, in the year of our Lord One
thousand eight hundred and sixty-one.
Witnesses,
EDW. M. MUSHET,
Coleford, Gloucestershire.
BROOKLYN MUSHET,
Coleford, Gloucestershire.
ROBT. MUSHET. (L.S.)