Year: 1891

page_text: Date of Application, 17th Mar., 1891
Complete Specification Left, 11th Dec., 1891-Accented, 30th Jan., 1892
The objects of our invention are to secure economy by effecting
1. A great reduction in the cost of the plant required for casting.
2. Also in constructing and arranging the casting moulds.
3. In dispensing with skilled labour.
4. In simplifying the apparatus.
5. Effecting a saving in the weight of steel, iron, or other metal cast by reducing
its loss in the process of casting.
6. Also saving of labour in preparing for casting; and in separating the ingots or
pieces of metal when cast.
7. Also being able to run a larger quantity and weight of ingots in each cast
than has before been accomplished, with less risk of failure, and at a reduced cost
in every way.
In casting steel ingots (for example) according to our invention, we first place in
the casting pit, or elsewhere, a bed plate of suitable shape, in which are four
grooves, one of which is made for the main horizontal runner, in which we place
six runner bricks (having perforations in them for the running of the steel); on two
of these runner bricks we place a steel plate with a hole in the centre, over which
we put two open-topped runner moulds. Then in the other three grooves of the
casting plate, we insert a thin layer of firebricks. Upon each of these we place a
multiple mould, first inserting in the wall, or partitions of each, one of our
diaphragins (hereinafter described), then we put another multiple mould on the top
of it, having previously inserted in the top of the bottom mould, one for each ingot
of the diaphragms for the middle divisions, (means are provided for securing the
moulds together, if required); we have now a pit set for casting say 34 steel ingots
and 2 runner ingots. We then put the ladle with the hot inoften steel over the two
open-topped moulds, team the hot metal down these, whence it flows through the
runner bricks up into the first partition of each of the three sets of moulds, at the
same time. Then it runs on the top of the thin layer of firebricks, through
the diaphragms, placed in the walls of each
till the top of the bottom mould is reached, we; then the whole rises together
it meets with another contracted
feather-edged diaphragm, placed in the top of each of these cells, through which
the hot steel flows upwards until the whole are filled. Thus running, in a very short.
time, upwards of 8 tons of steel into 34 various sized ingots, and 2 sound runner
ingots; making a total of 36, so running a greater weight of steel, a larger number
of ingots, but with less than one-fourth the waste of steel, in less time than has been
previously accomplished. Also, with a fraction in the waste of materials, as compared
with Turner's or other modes of casting anything like the number or sizes of
ingots.
For casting double the above quantity, say 72 steel ingots and 4 runner ingots,
we place in the pit, two of the above-mentioned casting beds, placing in the few
runner bricks as above, putting on each central runner à steel plate, with a hole in
the centre. Over these we place one of our open topped moulds. Then we have
6 outlets for the hot steel to come up through. Over each one of these outlets, we

page_text: place one of the multiple moulds, first having prepared them as above stated with
diaphragms and so on. Then on the top of each of these, we put six other moulds,
having corresponding cells to those below. All is now ready for running a cast,
say of 15 tons without having used any skilled labour; and no extra plant,
moulding, or materials having been required. Our ladle is then put to the steel
furnace, and we run in the hot molten metal. After being filled, it is then placed
over two of the open-topped runner moulds, (we have 2 nozzles in our ladle
bottom). Then we lift the two nozzles, when the metal is at once teamed down,
pouring through the runner bricks at the bottom, meeting at the central outlet, up
into the centre multiple mould, while the same thing has taken place with the two
outside sets of moulds; all these filling at one and the same time: care having been
taken that the influx of metal from the ladle to the runner moulds, shall be just
sufficient to supply the three outlets, and keep a head of hot steel in the principal
runner moulds, till the whole are filled. The ladle is then moved over the other
2 open-topped rummer moulds, and the same number of moulds are again filled, this
completing what we call one set 64 ingots of various sizes, and 4 open-topped
runner ingots; giving a cast of about 15 tons of steel into 4x4-6x3-8×4-
7 x 7-16 x 4-and 11" x 11". This weight and quantity can be increased by adding
one-half, or as many whole sets to make up the weight required; or it can be
reduced at will; or any other combination of sizes and lengths can be used; or the
whole may be run from one runner mould.
=
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After the ingots have been east, the upper moulds may at once be removed; or,
what we think a better way, (as there is only one connecting runner to each block
of moulds, and this runner will readily break off) lift out each pair of moulds together
on to the bank, take out the pins or cramps which bind the two together, then lift
off the upper mould, and by this time, the effects of the feather-edged diaphragms
will be seen.
The top ingots only require pushing off, they being already separated
from the effects of contraction, guided, and concentrated to one point by the use of
the said diaphragms. Then lift up the bottom mould, when the ingots will be
found left on the ground. These, if not already parted at the runner, will be found
to require but little trouble, as the effects of the diaphragms for separating the
bottom parts, will at once be apparent and effectual, and a level face left on the
side of the ingots; these all being ready for the mills without further trouble. By
using the diaphragms in the middle or dividing walls, the risk of stopping as in
other long moulds is avoided.
"
By the adaptation and use of our combination of rummer moulds, and in the
setting of the same a distinct advantage is attained over what is called "Turner's
special runner, and his mode of preparing and setting the same; thereby greatly
reducing the cost of the plant, etc., in constructing and arranging the casting moulds,
dispensing with all skilled labour, and simplifying the whole method of casting
multiple ingots, thereby enabling the apparatus to be fixed in any ordinary casting
pit, or any other convenient place for casting without any special provision or
extra cost whatever, over the ordinary pit or plant.
Our improved perforated diaphragms are made of fireclay and require no extra
cost in making; but by their use the separation of the ingots is practically assured,
as the effects of contraction (in the hot metal) is guided and concentrated upon one
point of the diaphragm; this point being a feather-edged one, thus greatly reducing
the cost of labour, for, if not broken off by its own contraction, it will be found to
be partly so, and the effects of the feather or chisel-pointed edge all round the
runner will enable them to be broken off with little or no trouble. The feather or
cutting edge of our diaphragms can be used on all diaphragms in perfectly dividing
inguts into two or more parts, by being placed in the moulds at the required
distances from each other, or these diaphragms may form part of the mould
A steel perforated plats which we place at the bottom of the runner mould is
provided for preventing the destruction of the casting bed, by the impact of the hot
stucl.
Our runner moulds will need no bolting to the casting bed; the moment they

page_text: are lowered on it they are ready for use, which is a distinct advantage over
"Turner's" special runner.
Dated this 16th day of March 1891.
BRISTOW HUNT, R.P.A.,
Aline Chamber-, Sheffield. Agent for the Applicants.
COMPLETE
SPECIFICATION.
Improved Means and Apparatus for Casting Multiple Ingots in Steel.
Iron, or other Metals.
We FITZ-HERBERT WRIGHT, Managing Director, and THOMAS HILL,
Engineer, of Codnor Park Iron and Steel Works in the County of Derby do
hereby declare the nature of this invention and in what manner the same is to be
performed, to be particularly described and a-certained in and by the following
statement in writing and on reference to the accompanying drawings:-
Our invention relates to and consists in providing improved means and more
useful and effective apparatus to be employed in casting multiple ingots in steel,
iron, or other metals; and the objects we attain by the application and use of our
said invention are:-The securing of greater economy in producing multiple ingots
by effecting, (1) a great reduction in the cost of the plant required for casting;
(2) greater economy in constructing and arranging the casting moulds; (3) dis-
pensing with skilled labour; (4) simplifying the apparatus; (5) effecting a saving
in the weight of steel, iron, or other metal cast,-by reducing its waste and loss in
the process of casting; (6) saving labour in preparing for casting and in separating
the ingots or pieces of metal when cast: (7) al-o being able to run a larger
quantity and weight of inguts in each east than has been accomplished before, with
less risk of failure and at a reduced cost in every way.
In order that our invention, and the method and means of carrying it out in
practice, may be fully understood it is illustrated on the accompanying two sheets
of explanatory drawings which are marked with figures and letters of reference
corresponding with those in the following description, like reference letters indicating
similar parts in all the figures containing such parts.
Figure 1 is a general plan in section, made on the line A-B in Figure 2, of our
multiple ingot casting apparatus, showing one block of four runner moulds and
six sets of multiple ingot moulds as placed in position for casting, say, about 15 tons
of various sized ingots at one and the same time.
Figure 2, is a sectional elevation made on the line (-D in the plan view
Figure 1, the ingot moulds being in position, and showing the runner bricks, the
perforated steel plate for preserving the bed plate and our special feather-edged
diaphragms, all as fixed in their respective places.
Figure 3 is an end view section made on the line E-F in the plan view
Figure 1.
Figure 4, comprises and shows enlarged plans and sectional elevations of our
diaphragms i and j. And
Figure 5, comprises and shows a side view, a plan, and a sectional elevation of
our diaphragm h, shown in Ligures 2 and 3, but of enlarged size.
In applying our invention to the casting of steel and other ingots we proceed as
follows: :-
We first place in the casting pit, or in other suitable position or place, a bed
plate a, made preferably of cast iron, in which are four grooves one of which is
made for the main horizontal runner b, in which we place six runner bricks, two of
them being shown at e, Figure 2; they have perforations in them for running the
steel or other metal through. On two of the runner bricks we place a steel plate d,
having a hole in its centre, over which we put two open-topped runner moulds e,

page_text: (see Figure 2) then in the other three grooves of the casting or bed plate a, we
insert a thin layer of firebricks . Upon these we place a multiple mould g, first
inserting, in the walls or partitions of each, one of our diaphragins h, as shown in
Figure 5, then we put another multiple mould on the top of it, having previously
inserted in the top of the bottom mould one for each ingot of the special
diaphragms i, for the middle divisions, means being provided for securing the moulds
together if required.
We have now a pit set for casting, say, 34 steel ingots and two runner steel
ingots, we then put the ladle with the hot molten steel (or other metal) over the
two open-topped moulds e, and team the hot metal down them, whence it flows
through the rummer bricks e, up into the first partition of each of the three sets of
moulds at the same time, the directions of the flow being indicated by the arrows
marked on Figure 2, of the drawings. Then the hot metal runs on the top of the
thin layer of firebricks, through the diaphragms h, placed in the walls of each
space; the whole then rises together until the top of the bottom mould is renched
when it meets with another contracted feather-edged diaphragm, placed in the top
of each of these cells through which the hot steel flows upwards until the whole
cells are filled, the air and gases escaping through the diaphragms j, and thus
running in a very short time upwards of eight tons of steel into 34 various sized
ingots and two sound runner ingots, making a total of 36 ingots, so running a
greater weight of steel and a larger number of ingots but with less than one fourth
the waste of steel and in less time than has been previously accomplished, also with
a fraction in the waste of material as compared with any other modes of casting
anything like the number or sizes of ingots.
For casting double the above quantity, say, 72 steel ingots and 4 runner ingots
we place in the pit two of the beforementioned casting beds or bed plates a, placing
in the runner bricks c, as before named, and putting on cach central runner a
perforated steel plate d. Over these we place one of our open-topped runner
moulds e; we have then six outlets for the hot steel to come up through. Over
each one of these outlets we place one of the multiple moulds, having first prepared
them as before stated with diaphragms and so on. Then on the top of these moulds
we put six other moulds having corresponding cells to those below. All is now
ready for running a cast, say, of 15 tons (as provided for by the apparatus
illustrated in Figure 1,) without having used any skilled labour, and no extra
plant, or moulding, or materials, having been required.
Our ladle which has two nozzles in the bottom of it is then put to the furnace and
we run in the hot molten steel; after the ladle has been filled it is placed over two
of the open-topped runner moulds e, (see Figure 2,) then we lift the two nozzles of
the lndle when the hot metal is at once teamed down, pouring through the runner
bricks at the bottom,-meeting at the central outlet,-up into the centre multiple
mould, while the same thing has taken place with the two outside sets of moulds,
all these filling at one and the same time, care having been taken that the influx
of metal from the ladle to the runner moulds shall be just sufficient to supply the
three outlets and keep a head of hot steel or other metal in the principal runner
moulds till the whole are filled. The ladle is then moved over the other two open-
topped runner moulds and the same number of moulds are again filled, this com-
pleting what we call 1 set = 64 ingots of various sizes and four open-topped runner
ingots giving a cast of about 15 tons of steel into 4 x 4-6 x 5-8 x 4-7 x 7-
16 x 4 and 11" x 11". This weight and quantity can be increased by adding
one half or as many whole sets to make up the weight required; or it can be
reduced at will, or any other combination of sizes and lengths can be used, or the
whole may he run from one runner mould placed in the centre.
After the ingots have been cast the upper moulds can at once be removed, or,
what we think a better way (as there is only one connecting runner to each block
of moulds and this runner ingot will readily break off) we lift out each pair of
moulds together onto the bank then take out the pins or cramps which bind the

page_text: two together, then we lift off the upper mould and by this time the effects of our
specially formed feather-edged diaphragms i, will be seen. The top ingots only will
require pushing off they being already separated from the effects of the contraction
guided and concentrated to one point by the use of the said feather-edged
diaphragms. Then the bottom mould is lifted up when the ingots will be found -lippe i
out of the moulds and left on the ground or floor. These ingots if not already
parted at the runner will be found to require but little trouble as the effects of the
diaphragms h, for separating the bottom parts will at once be apparent and effectual,
and a level face left on the side of the ingots, these all being ready for the mil
without further trouble.
By applying and using the diaphragms, in the middle or dividing walls the risk
of stopping the flow of the molten steel or other metal, as in other long moulds, is
avoided.
By the adaptation and use of our improved combination runner moulds and in
the setting of the same a distinct advantage is attained over any other runner or
mode of preparing and setting the same, thereby greatly reducing the cost of the
plant &c. in constructing and arranging the casting moulds, dispensing with all
skilled labour and simplifying the whole method of casting multiple ingots, thereby
enabling the apparatus to be fixed in any ordinary casting pit or in any other
convenient place for casting without any special provision or extra cost whatever
over the ordinary pit or plant,
Our improved and specially perforated diaphragms are made of ordinary or
common fireclay and require no extra cost in making, but by their use the very
ready separation of the ingots is practically assured as the effect of contraction
(in the hot metal) is guided and concentrated upon one poiut of the diaphragm
this point being the internal feather or sharp-cutting edged one, thus greatly
reducing the cost of labour for if not broken off by its own contraction it will be
found to be partly so, and the effect or impression of the feather or chisel-pointed
edge all round the runner metal or ingot will enable the ingots to be broken off*
with little or no trouble.
The feather or chisel-pointed cutting edge of our diaphragms can be applied to
and used on all diaphragms in perfectly dividing ingots into two or more parts by
being placed in the moulds at the required distances from each other, or the
diaphragms may form part of the mould itself.
With reference to our improved specially perforated diaphragins we would here
remark that we are aware that perforated diaphragms with smoothly curved
surfaces internally have been used in moulds for casting ingots and therefore we lay
no claim to the use of such diaphragms, for example, those described and shown
in Turner's Complete Specification No. 12,795, nor do we claim the application
and use of perforated diaphragms of any other forms than our improved specially
formed internally feathered or chisel-cutting edged diaphragms, the construction
and especially useful advantages of which we have already described, because we
have found that where diaphragms having smoothly curved internal surfaces have
been used the ingote cannot be readily separated from each other after being
cast, which defect is effectually remedied by means of our specially formed
diaphragms.
The perforated steel plate d, which we place at the bottom of the runner
moulds and which is another important feature of our invention, is provided for
preventing the destruction of the casting bed by the impact of the hot steel.
Our runner moulds need no bolting to the casting bed as the moment they are
lowered onto it they are ready for use which will be found an important and a
distinct advantage over other modes of casting multiple ingots.
In applying our invention to the casting of multiple ingots of iron or other metals
the only difference will be in the weights of metal and the weights of ingots
produced, which will vary according to the metal required to be cast, whether it be
iron brass or other metal.

page_text: Having now particularly described and ascertained the nature of our said inven-
tion, and in what manner the same is to be performed, we declare that what we
claim is :―
1. The special construction, arrangement, and use of vertical runners or runner
mould for casting multiple ingots in steel, iron, or other metals,-whereby the
steel or other metal in the main runner mould becomes an ingot at the finish of
the casting operation substantially as hereinbefore described and illustrated on
the accompanying drawings.
2. The peculiar combination and arrangement of the casting moulds and the
double runner or runner mould for the purpose set forth and as illustrated on the
drawings.
3. The construction application and use of the specially formed internally
feathered or cutting-edged perforated diaphragms, and 7; the same being arranged
and fitted as shown on the accompanying drawings.
4. The application and use of the perforated steel plate d, and arranging one at
the bottom of each vertical runner mould, for the purpose of protecting the casting
bed, substantially as set forth.
5. The general combination and arrangement of the whole of the aforesaid
component parts of our multiple ingot casting apparatus, constituting improved
and more useful means for casting such multiple ingots in steel, iron, or other metals;
substantially as herein before described and as illustrated on the accompanying
drawings.
6. Effecting with greater facility than heretofore the running and utilizing of a
greater number of columns or piles of casting moulds with a larger number of ingots
in each block of moulds, at a less cost and with less waste than hitherto, substantially
as herein before described.
7. Effecting greater simplicity than heretofore in the method of and means or
apparatus for casting multiple ingots and effecting a great reduction in the cost of
the plant required for casting, with a minimum of wear and tear of the apparatus,
also dispensing with skilled labour and effecting an easier separation of the ingots
or pieces when cast substantially as hereinbefore described."
8. Effecting a great reduction in the loss of steel, iron, or other metal, in the
process of casting, and increasing the quantity and weight of ingots in each cast as
hereinbefore described.
Dated this 10th day of December 1901
BRISTOW HUNT, R.P.A.,
Aldine Chambers, High Street, Sheffield, Agent for the Applicants.