Improvements in the Manufacture of Wrought Metal Headers for Sectional Steam-generators.
Year: 1896

page_text: Date of Application, 12th Feb., 1896-Accepted, 21st Mar., 1896
[Communicated from abroad by THE BABCOCK AND WILCOX COMPANY, of
New York, in the United States of America, Steam Boiler Manufacturers.]
Improvements in the Manufacture of Wrought Metal Headers for
Sectional Steam-generators.
I, WALLACE FAIRWEATHER, C.E., of 62 Saint Vincent Street, in the County
of the City of Glasgow, Chartered Patent Agent, do hereby declare the nature of
this invention and in what manner the same is to be performed, to be particularly
described and ascertained in and by the following statement :-
This invention relates to the manufacture of those parts of a sectional steam-
generator known as the headers, to which parts the ends of the inclined water-
tubes are connected. The invention consists in a header composed of four parts
joined together.
In the accompanying drawings,
Figure represents, in perspective, the two main parts of the header, which
have been formed by dies, the upper half (in the view) being provided on its
face with projecting, circular flanges surrounding the hand-holes, and the lower
half having a face which is zigzag in contour for a purpose hereinafter
described.
Figures 2 and 3 represent, in perspective, the two plates which are to be
secured into the respective ends of the header.
Figure 4 shows, on a smaller scale, an end view of the two halves of the header
placed together in readiness to be secured to each other.
Figure 5 represents, on the same scale as Fig. 4, a face view of the plate shown
in Fig. 2.
Figure 6 shows, in plan, a view of the hand-hole face of the header.
Figure 7 represents a side view of the header.
Figure 8 shows a transverse section of the header on line x-x of Fig. 7.
Figure 9 shows, in central, vertical section, a press in which the main parts of
the header may be formed.
Figures, 10, 11, 12, 13, 14 and 15 represent, in transverse section, the two
revoluble dies for forming one of the main parts of the headers, the said views
also representing the position of the dies in the successive steps in the formation of
such part, and the upper die being shown in section on line Y Y of Fig. 17.
Figure 16 shows a side view of such completed part of the header.
Figure 17 represents a plan view of one of the dies for bending up the sides of a
part of the header, with such part of the header therein.
Figure 18 shows such die and its fellow in longitudinal section, and in a closed
position.
Figure 19 represents in transverse section the two dies in a closed position, the
section through the same being on line 2-, of Figs. 18 and 19.
Figures 20, 21, 22, 23, 24 and 25 show, in transverse section, the two dies for
forming the other main part of the header, the said views representing, also, the
successive steps in the formation of such header-part.
Figure 26 represents a longitudinal section of such dies in a closed position.
Figure 27 showe a plan view of one of the dies for producing the hand-holes and
flanges on a part of the header.

page_text: ery, a top view, a side view, and a
transverse section of this completed part of the header.
Figure 31 shows, iu vertical, longitudinal section, the furnace in which the
header-parts may be heated prior to welding; and in side elevation an apparatus
in which the welding may be performed, and means for pushing such header-parts
out of the furnace into the welding-apparatus.
Figure 32 represents a horizontal section of the furnace and a top view of the
welding apparatus.
Figure 33 represents, in transverse section, the apparatus for welding the parts
of the header to each other, the blocks or rams of the apparatus being in normal
position.
Figure 34 represents a similar view of said apparatus with all the blocks in a
closed position.
Figure 35 shows, in transverse section, the two main parts of the beader placed
together prior to being welded.
Figure 36 represents a transverse section of the header after the parts have been
welded.
The header A, shown in Figs. 1 to 8, is of the variety which is designed to
occupy a vertical position, and its tube-face a is made zigzag in contour, as
particularly shown in Fig. 7, so that the inclined faces a¹ (which are provided
with tube-receiving holes a², indicated by dotted lines in said figure) shall be at
right angles to the inclined boiler-tubes that said face receives. The sides of the
header are sinuous in outline as shown in Fig. 6, in order to connect the boiler-
tubes in a staggered relation, which is well understood.
The complete header is made of four parts, 1, 2, 3, 4, (Figs. 1, 2 and 3), the
parts 1 and 2 being cut out of, and stamped up from plates into the forms shown;
and the part 2 is furnished with holes a³, that are surrounded by projecting,
circular flanges a, upon. which the hand-hole plates are to be clamped. The
parts 3 and 4, which form the respective ends of the header, are cut out of metal
plates, and have the proper outline to fit into the ends of the troughs, the part 3
having a hole a to receive a nipple or pipe for connecting the header to the steam-
and-water drum of the boiler, or to a transverse box.
The die blocks B and C, which may be employed to form the part 1, are shown
in Figs. 9, 10, 11, 12, 13, 14, 15, 18 and 19. These blocks may be used in any
suitable press, but an hydraulic press D, in which such die-blocks may be used,
is shown in Fig. 9. Each of the blocks B, C, has two acting die-faces b, b,
and c, c', respectively, which are oppositely located on the same, and in order that
such faces may conveniently be brought into action, the blocks are mounted in
any suitable manner so as to be revoluble, as on trunnions 62 and 3, which may
project into and be guided by slots 1, (one only being shown in Fig. 9) in the sides
of the press D.
of
The die-blocks B, C, being in the positions, relatively to each other, shown in
Figs. 9 and 10, a plate of metal E, is placed on that surface of the block C
which has the die-face c, and the ram d' of the press is caused to rise to bring
the die-blocks together, as shown in Fig. 11, and thereby produce on said plate a
series of depressions, which form the inclined faces a'. The blocks are now allowed
to separate; the block C is turned to bring its die-face c uppermost; the same
plate is placed upon the block, as in Fig. 12; and the die-blocks are again brought
together to cause the edges 3 of the block B, in conjunction with the edges
the block C, to cut out the blank e from the plate, as shown in Fig. 13,
preparatory to bending up the sides of the blank to form the side-portions of part 1
of the header. The dies are again allowed to separate, and the block B is turned
to bring its die-face & lowermost, as shown in Fig. 14, when the blocks are again
brought together, as shown in Figs. 15 and 19, to bend up the sides of the blank
and complete part 1 of the header, as shown in side view in Fig. 16, which completed
part is a trough having serpentine sides and a bottom with a zigzag contour, as
shown in Fig. 1. The tube-receiving holes a² may be punched in the bottom of

page_text: this trough after it has been struck up, but they are preferably formed after the
parts of the header have been welded together, so as to avoid any possible distortion
of the holes during the welding operation.
The part 2 of the header is made from a plate of metal, and in its formation the
die blocks F, G, Figs. 20 to 27 inclusive, are designed to be employed in a suitable-
press for instance, like that shown in Fig. 9. The die-block F has three die-
faces f,,, and is to be mounted so as to be revoluble, as on trunnions F', Fig. 26,
in order that said faces may each be brought into action. The die-block G has
but one die-face g.
The blocks F, G, being in the relative position shown in Fig. 20, a plate of
metal H is placed upon the block G, and the dies are brought together to cause
the edges of the die-face, in conjunction with the edges of the die-face g, to
cut a blank from the plate, as shown in Fig. 21. The die-blocks are now separated,
and the block F is turned one-third of a revolution to bring the dic-faces f¹ into
position for action, as shown in Fig. 22, when the blocks are again brought together
to bend up the sides of the blank, as shown in Fig. 23, the trough thus formed
having serpentine sides. In the bottom of the die-face g is a staggered series of
upwardly projecting punches 2; and in the die-face is a series of cavities 5, for
receiving said punches, as particularly shown in Fig. 23. When the die-faces f¹
and g are brought together, as just described, not only the sides of the blank h will
be bent up, but a series of holes will be punched in the blank, which are subsequently
expanded to form the hand-holes a³ in part 2 of the header. The blocks are again
separated, and the block F is turned another third of a revolution to bring the
die-face into position for action, as shown in Fig. 24. This die-face is composed
of a series of circular projections 6, in which are circular cavities 7, the latter
of which idly receive the punches 92 which are idlers, also, in the next operation.
The blocks are now finally brought together as shown in Figs. 25 and 26, when the
rings 6 will expand the holes that were punched in the trough by the last operation,
and will throw up on the face of the trough the circular flanges a (which are to
receive the band-hole covers) thereby completing part 2 of the header-an interior
plan view of which is shown in Fig. 28, a side view in Fig. 29, and a transverse
section in Fig. 30..
Apparatus in which the parts of the header may be heated and then welded
together is shown in Figs. 31 and 32. The heater K is a furnace of proper
construction, having an opening k through which the header can be inserted,
another opening through which the header can be pushed into the welding-
apparatus M, and a third opening k², through which a push-rod L can work for such
purpose.
The parts 1, 2, 3 and 4 of the header are assembled in proper relation, and are
then placed in the heater K, in the position shown by dotted lines in Fig. 32, and
are afterwards pushed forward to the position shown by full lines in said figure,
by rods inserted through the openings ka, so as to be in the path of movement of
the push-rod L. After the header-parts have been brought to a welding-heat, the
rod L is caused to move forward, as by hydraulic pressure, to push the heated
mass through the opening k¹ into the welding-apparatus. In this apparatus M, is
located a bed-block m, Figs. 33 and 34, upon which the header rests after it has
been inserted; and said block is arranged to move vertically between two walls n,
the distance apart of which is slightly greater than the width of the header. The
upward movement of the block m is preferably produced by hydraulic pressure
acting upon a series of pistons, as m¹ depending from the block and working in
cylinders, as m², Fig. 34, the block being preferably guided by rods m³.
upper part of the apparatus is a stationary head-block N, having its lower face
adapted to fit the top-surface of the part 2. Against this block the header is pressed
by the block m, thereby welding the top and bottom edges of the parts 3 and 4 to
the parts
and 2, and welding together, also, the inner edges 8, of the sides of
the parts 1 and 2, which sides are slightly inclined in opposite directions, when
they come from the dies, as shown in Fig. 35.
In the

page_text: When the header is completed, it is intended that the said sides shall be at right
angles to the faces of the leader, as shown in Fig. 33. In order to bring said sides
into such position and to complete the welding together of the parts 1, 2, 3 and 4,
the welding-apparatus is provided with two laterally-movable blocks O, the adjacent
faces of which are shaped to conform to the sides of the completed header. Each
of these blocks is preferably provided with a series of pistons o, working in
cylinders o, Fig. 34, so that the blocks can be moved toward each other by
hydraulic pressure. Such pressure is immediately applied after the block m has
received its full upward movement, and the inclined sides of the parts 1 and 2 arc
brought into a vertical position, and the edges of said sides completely welded to
each other-the V-shape openings 9, Fig. 35, between said edges being closed from
the apex outward, during the welding, thereby squeezing out any slag or impurity
that may be between said edges. At the same time, the lateral sides of the
ends 3 and 4 are welded to the sides of the parts 1 and 2, by the movement of the
blocks.
Instead of welding together the parts of the headers by the application of
furnace heat the joints may be made by welding them by electrical means in a
manner well understood.
Having now particularly described and ascertained the nature of my said inven-
tion, and in what manner the same is to be performed, I declare that what I
claim is :-
1. A wrought metal header composed of two rectangular, joined troughs, each
having a bottom and two sides, and two end pieces secured within such joined
troughs, substantially as set forth.
2. In a machine for forming headers, the combination of two revoluble die-
blocks each provided with a multiple number of co-acting die-faces, substantially
as set forth.
Dated this 11th day of February 1896.
WALLACE FAIRWEATHER.