Improvements in the Methods and Apparatus employed in the Heating, Melting, and Working of Metals, Alloys, and Metalloids by the Application of Electric Currents.
Year: 1889

page_text: Date of Application, 10th Dec., 1889
Complete Specification Left, 29th Aug., 1890-Accepted, 22nd Nov., 1890
PROVISIONAL SPECIFICATION.
Improvements in the Methods and Apparatus employed in the
Heating, Melting, and Working of Metals, Alloys, and Metalloids
by the Application of Electric Currents.
We, JOHN CHRISTIAN WERNDLEY of 173 Tamworth Road, Newcastle-upon-Tyne,
Electrician, and HENRY FOSTER of 92 Dilston Road, Newcastle-upon-Tyne Engineer,
both in the County of the same City do hereby declare the nature of this invention
to be as follows:-
Our invention relates to improvements in the methods and apparatus employed
in the direct application of electric currents for the following purposes :-
1st. The beating, melting and working of metals, alloys and metalloids.
2nd. The union of metals and alloys, either in layers or otherwise, to themselves
separately, or to each other.
3rd. The superheating of fluid metals and alloys, either during or immediately
before or after the operation of casting, in order to prevent the formation of
cavities in the interior of the castings made.
In carrying out our invention we make use of a dynamo or other suitable
electrical generator for the formation of a voltaic arc where required, and we
further introduce into the electrical circuit the metal, alloy or other article to be
heated, melted, or otherwise operated upon in such a manner that a voltaic arc can
be formed at any desired point on the article, either by the approach to each other
of two or more carbons or other suitable bodies forming the positive and negative
pole of the circuit respectively, or, the metal or other article to be heated, melted or
otherwise operated upon may itself form one pole of the circuit, while one or more
carbons or other suitable body forms the other pole.
In the union of metals, or alloys either in layers or otherwise, to themselves
separately or to each other, we connect a cable or other suitable conductor to the
article to be operated upon and also to the negative pole of the dynamo or other
electrical generator used. We then connect one end of a similar cable or other
conductor to the positive pole of the dynamo or other electrical generator, and to
the other end of this cable we fix a carbon or other suitable body having an insulated
handle attached, and by which it can be moved about as desired without danger to
the operator.
If now the carbon attached to the cable or other conductor in connection with the
positive pole of the dynamo or other electrical generator in motion, be presented to
the article connected to the negative pole a voltaic are will be formed at the point to
which the carbon is presented, and the article will be heated or melted as the case
may be at that point, depending upon the strength of the current generated.
By using a current of sufficient strength, the article operated upon can be readily
mounted at the point where the voltaic are is thus formed, and small pieces of metal
or alloy placed in the region of the arc will be melted and form one with the article
operated upon when the carbon is withdrawn, and the voltaic are broken.
Another method of carrying out this particular part of our invention consists in
introducing the metal or alloy which is required to be joined to the article operated
upon, into the region of the voltaic arc in a highly heated or molten state; or, in
cases where it is required to unite one article to another, or one part of an article to
its other part, the articles or pieces may be heated at the junction required, previous
to the voltaic aro being formed, and afterwards highly heated molten metal or alloy
introduced into the region of the voltaic arc, so as to securely join the articles
together.
Another part of our invention relates to the superheating of molten metals and
allovs

page_text: 1st. During the operation of casting and
2nd. Immediately before or after the casting has been performed.
In carrying out the first part of this operation we connect the ladle or other
vessel holding the molten metal or alloy with one pole of the dynamo by means of
a suitable conductor, and form a voltaic arc in the manner already described at
the point where the molten metal or alloy is being discharged from the ladle and
thus give to the molten metal or alloy an excess of heat in order to render it more
fluid.
"
In carrying out the second part of this operation, before the metal or alloy is cast,
we may form a voltaic are as already described, so as to superheat the metal or alloy in
the ladle; or after the operation of casting has been performed the voltaic arc may be
formed at the "git" or runner of the casting in order to render the metal or alloy
more fluid, and thus enable the metal or alloy in the "git" to more readily "feed
the casting and thereby prevent the formation of cavities in the interior of the casting.
But if the processes herein before set forth were carried on alone as described the
voltaic are formed would be unsteady and not sufficiently continuous to effect the
desired purpose. To obviate this defect and to render the processes herein described
capable of being successfully carried out we divide the cable or other conductor
leading from the positive pole of the dynamo or other electrical generator used, to
the place where the voltaic arc is formed, at any convenient point, and introduce
into the circuit at the division so made a number of resistance coils resistance frames
or resistance blocks arranged in parallel, or in series, or in both parallel and series
combined, depending upon the nature of the current used, and the object to be
attained.
Or in cases where two or more distinct operations are required to be carried on at
the same time, we may divide the cable or other conductor leading from the positive
pole of the dynamo (or other electrical generator used) into two or more branches,
having the resistance coils or resistance coils, resistance frames or resistance blocks,
arranged as above described, in the respective branches into which the cable or other
conductor is divided; the number of resistance coils or resistance frames to be used
in any particular case depending upon the amount and strength of the current
generated.
In performing the various operations herein before set forth, it is not necessary
that the article to be operated upon should be transferred to the source of power,
but on the other hand, the power together with all the necessary apparatus may be
taken to the place required.
In cases where the article to be operated upon is on land, we may arrange the
dynamo or other electrical generator used, together with the engine for driving it,
and all necessary resistance coils, resistance frames, or resistance blocks, and other
apparatus required upon a suitable carriage capable of being moved about from place
to place as required.
Or we may arrange the dynamo together with all the necessary apparatus upon a
locomotive steam engine capable of propelling itself to the place required, and after-
wards use the engine for driving the dynamo (or other electrical generator used)
whilst the various operations are being performed.
In cases where the article to be operated upon constitutes part of the cargo of a
ship or other vessel floating on water, or itself constitutes part of the ship or other
vessel, we arrange our dynamo or other electrical generator used, together with all
the necessary resistance coils, resistance frames, or resistance blocks, and other
apparatus required, on a steam launch, or other suitable vessel capable of propelling
itself or being propelled to the place required; and afterwards perform any of the
various operations herein before set forth while the steam launch or other suitable
vessel used, lies alongside of the ship on which the operations are being performed.
Dated this 9th day of December 1889.

page_text: COMPLETE SPECIFICATION.
Improvements in the Methods and Apparatus employed in the
Heating, Melting, and Working of Metals, Alloys, and Metalloids.
by the Application of Electric Currents.
We JOHN CHRISTIAN WERNDLEY of 173 Tamworth Road, Newcastle-upon-Tyne,
Electrician, and HENRY FOSTER of 92 Dilston Road, Newcastle-upon-Tyne, Engineer,
both in the County of the same City, do hereby declare the nature of this inven-
tion and in what manner the same is to he performed, to be particularly described
and ascertained in and by the following statement :-
"
Our invention relates to improvements in the methods and apparatus employed
in the direct application of electric currents for the following purposes:-
1st. The heating, melting and working of metals, alloys and metalloids.
2nd. The union of metals and alloys, either in layers or otherwise, to themselves
separately, or to each other..
3rd. The superheating of fluid metals and alloys, either during or immediately.
before or after. the operation of casting, in order to prevent the formation of cavities
in the interior of the castings made..
In carrying out our invention, we make use of a dynamo, or other suitable
electrical generator for the formation of a voltaic are where required, and we further
introduce into the electrical circuit, the metal, alloy or other article to be heated,
melted, or otherwise operated upon in such a manner that a voltaic arc can be formed
at any desired point on the article, either by the approach to each other of two or
more carbons, or other suitable bodies forming the positive and negative pole of the
circuit respectively, or, the metal or other article to be heated, melted, or otherwise
operated upon may itself form one pole of the circuit, while one or more carbons or
other suitable body forms the other pole...
"
In the union of metals,, or alloys either in layers or otherwise, to themselves
separately, or to each other, we connect a cable or other suitable conductor to the
article to be operated upon, and also to the negative pole of the dynamo or other
electrical generator, used. We then connect one end of a similar cable or other con-
ductor to the positive pole of the dynamo or other electrical generator, and to the
other end of this cable we fix a carbon or other suitable body having an insulated
handle attached, and by which it can be moved about as desired without danger to
the operator.
If now the carbon attached to the cable or other conductor in connection with the
positive pole of the dynamo or other electrical generator in motion be presented to
the article connected to the negative pole, a voltaic arc will be formed at the point
to..which the carbon is presented, and the article will be heated, or melted as the
case may be at that point, depending upon the strength of the current generated.
By using a current of sufficient strength the article operated upon can be readily
melted at the point where the voltaic arc is thus formed, and small pieces of metal
or alloy placed in the region of the arc will be melted, and form one with the article
operated upon when the carbon is withdrawn, and the voltaic are broken.
Another method of carrying out this particular part of our invention consists in
introducing the metal or alloy which is required to be joined to the article operated
upon, into the region of the voltaic arc in a highly heated or molten state; or, in
cases where it is required to unite one article to another, or one part of an article
to its other part, the articles or pieces may be heated at the junction required
previous to the voltaic arc being formed, and afterwards highly heated or molten
metal or alloy introduced into the region of the voltaic arc, so as to securely join the
articles together.
Another part of our invention relates to the superheating of molten metals and
allova
".
I

page_text: 1st. During the operation of casting and
2nd. Immediately before or after the casting has been performed.
In carrying out the first part of this operation, we connect the ladle or other vessel
holding the molten metal or alloy with one pole of the dynamo by means of a suitable
conductor, and form a voltaic arc in the manner already described, at the point
where the molten metal or alloy is being discharged from the ladle, and thus give
to the molten metal or alloy an excess of heat in order to render it more fluid.
In carrying out the second part of this operation, before the metal or alloy is cast,
we may form a voltaic are as already described so as to superheat the metal or alloy
in the ladle; or after the operation of casting has been performed, the voltaic are
may be formed at the "git" or runner of the casting in order to render the metal or
alloy more fluid and thus enable the metal or alloy in the "git" to more readily
"feed" the casting, and thereby prevent the formation of cavities in the interior of
the casting.
But if the processes herein before set forth were carried on alone as described, the
voltaic are formed would be unsteady & not sufficiently continuous to effect the
desired purpose. To obviate this defect and to render the processes herein described
capable of being successfully carried out, we divide the cable or other conductor
leading from the positive pole of the dynamo or other electrical generator used, to
the place where the voltaic arc is formed, at any convenient point, and introduce into
the circuit at the division so made a number of resistance coils, resistance frames, or
resistance blocks, arranged in parallel, or in series, or in both parallel and series
combined, depending upon the nature of the current used, and the object to be
attained.
Or in cases where two or more distinct operations are required to be carried on at
the same time, we may divide the cable or other conductor leading from the positive
pole of the dynamo (or other electrical generator used) into two or more branches
having the resistance coils, resistance frames or resistance blocks arranged as above
described in the respective branches into which the cable or other conductor is
divided; the number of resistanee coils or resistance frames to be used in any
particular case depending upon the amount and strength of the current generated.
In performing the various operations herein before set forth, it is not necessary
that the article to be operated upon should be transferred to the source of power, but
on the other hand, the power together with all the necessary apparatus may be taken
to the place required.
In cases where the article to be operated upon is on land, we may arrange the
dynamo or other electrical generator used, together with the engine for driving it,
and all neceasary resistance coils, resistance frames or resistance blocks, and other
apparatus required upon a suitable carriage capable of being movea about from place
to place as required. Or we may arrange the dynamo-together with all the
necessary apparatus upon a locomotive steam engine capable of propelling itself to the
place required, and afterwards use the engine for driving the dynamo, or other
electrical generator used while the various operations are being performed.
In cases where the article to be operated upon constitutes part of the cargo of a
ship, or other vessel floating on water, or itself constitutes part of a ship or other
vessel, we arrange our dynamo or other electrical generator used, together with all the
necessary resistance coils, resistance frames, or resistance blocks & other apparatus
required, on a steam launch, or other suitable vessel capable of propelling itself or
being propelled to the place required; and afterwards perform any of the various
operations herein before set forth, while the steam launch cr other suitable vessel used
lies alongside of the ship on which the operations are being performed.
Having now explained the nature of our invention, we will now proceed to
particularly describe in what manner the same is to be carried into effect by the aid
of the following drawings..
In Figs. 1 and 2 the dynamo (or other electrical generator) (A) for generating the
necessary current is shown in connection with the engine (B) in plan and elevation,
and from the negative pole of the dynamo, a cable or other suitable conductor (C) is

page_text: taken direct to the article (D) which is intended to be heated, melted, or otherwise
operated upon; while from the positive pole of the dynamo a similar cable or other
suitable conductor (E) is led to the resistance coils, resistance frames, or resistance
blocks (F) arranged in parallel, or in series. or in both parallel and series combined
(depending upon the nature of the current) and from thence to the article D, where
the operation is to be performed in the manner hereafter described.
Firstly-In the union of similar or dissimilar metals or alloys either in layers or
otherwise to themselves separately or to each other, we connect the cable or other
suitable conductor (C) Fig. 3-leading from the negative pole of the dynamo (or
other suitable electrical generator)-directly to the portion of metal or alloy to which
it is intended to unite or weld the other portion, and after bringing the two portions
which are to be united, into close proximity we proceed to form a voltaic are at the
junction of the two portions as follows:-
To the end of the cable or other suitable conductor—leading from the positive pole
of the dynamo to the resistance coils, resistance frames or resistance blocks (F) and
from thence to the portions of metal or alloy to be united, we attach a carbon
or other suitable body (G) provided with an insulated handle (H) and by which it can
be moved about without danger to the operator.
When the dynamo (or other suitable electrical generator) is developing sufficient
current we bring the end of the carbon (G) into contact with the portions of metal or
alloy which are to be united, and thus form a voltaic are at their junction with each
other. When sufficient heat has thus been developed at the junction of the two
portions of metal or alloy so as to bring them into a molten state, they are firmly
pressed together and the current switched off, or, if desired, when the voltaic are has
been formed as above described, pieces of metal or alloy either cold or in a highly
heated or molten state may be introduced into the region of the are, so as to be further
heated, and form one with the article operated upon when the carbon is withdrawn
and the voltaic arc broken.
Secondly-In carrying out that part of our invention which relates to the super-
heating of molten metals or alloys either before or during the operation of casting, we
arrange the ladle or other vessel containing the molten metal or alloy as in Fig. 4, so
as to form part of the electrical circuit, and form one or more voltaic arcs in the
manner described either on the upper surface of the molten metal or alloy as at (I), or
at the point where the molten metal or alloy is being discharged as at (K) (Fig. 5).
In cases where the operation of casting has been performed, and the metal or alloy
in the "git" or runner of the casting is not sufficiently fluid to "feed" the casting,
the voltaic are may be formed as already explained and as indicated in Figs. 4 & 5
but in such a position that the voltaic arc impinges directly upon the metal or alloy
in the "git" so as to render it more fluid.
Figs. 6 & 7 show in plan and elevation the dynamo (A) and the engine (B) for
driving it together with the resistance coils, resistance frames or resistance
blocks F F F F, and the switches M. N. O. all arranged upon a carriage capable of
being moved about from place to place as required, and further indicate more
particularly the manner in which the resistance coils, resistance frames or resistance
blocks are introduced into the circuit, so as to render the voltaic arc formed
sufficiently steady and continuous to enable the processes herein before described
capable of being successfully carried out, and also to enable two or more similar
operations to be performed at the same time.
From the negative pole (Q) of the dynamo, or other suitable electrical generator a
cable or other conductor (C) is led direct to the article (D) to be operated upon in
the manner already described, and in cases where more than one operation is required
to be carried on at the same time the cable or other conductor (C) is divided into two
or more branches as at C. C.
From the positive pole (P) a similar conductor is led as shown, and made to
branch off in the directions É and K; one portion of the current passing first
through E E, then through the resistance coils, resistance frames or resistance
blocks F. F. (arranged either in parallel or in series, or in both series and parallel)

page_text: .
+
and from thence through I. I. to the switch M; while the other portion of the
current traverses a similar path through K K. F. F. to L L, and from thence to the
switch N.
From the switches M or N the current passes along a cable or other suitable
conductor through the insulated handle (H) held by the operator, and to the carbon
or other suitable body (G), where the operation being carried on.
When it is found desirable to augment the heating power of the current we arrange
an intermediate main switch (0) between the two systems of resistance coils,
resistance frames or resistance blocks F F and F F; then by means of suitable
conductors from (I) and (L) to the main switch (0) the two systems F F and F F
can be joined into one, when desired and the heating power of the current thereby
augmented.
Figs. > and show in detail the portable holder, having an insulated handle (H),
and by which the carbon or other body (G) is held in position while the operation is
being carried on.
Figs. 10, 11, 12 & 13 show respectively a double and single switch in detail.
The hooked portion (R) being made of brass or other conducting material and
provided with an insulated handle (II) by means of which it can be slid along the
bar S. T; the portions (S) and (S) in each case are made of brass, and con-
nected to the cables or other suitable conductors leading from the dynamo, while
the portions T, T, T are made of any suitable non-conducting material.
From the lower portion of the hook (R) the cable or other conductor is led to
the operator's handle, and the current is switched off or on as the case may be,
by simply sliding the hook (R) from one end of the bar S. T. to the other.
In cases where the article to be operated upon constitutes part of the cargo of a
ship or itself constitutes part of a ship or other vessel floating on water, we arrange
the apparatus as herein described upon a steam launch or other vessel capable
of propelling itself or being propelled to the place required, and perform the
various operations herein before set forth while the steam launch is lying
alongside the ship or other vessel on which the work is required to be done.
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 use of resistance coils, resistance frames, or resistance blocks, arranged
as herein before described, either in parallel or in series, or in both parallel and
series combined, for the purpose of steadying and increasing the intensity of the
voltaic arc, while the operations herein before set forth are being performed.
2. The superheating of molten metals or alloys by the formation of voltaic arcs
as herein before set forth, either during, or immediately before, or after the
operation of casting.
3. The method herein described of arranging the engine and dynamo together
with all the necessary resistance coils, resistance frames or resistance blocks and
switches upon a portable carriage, or upon a steam launch, capable of propelling
itself or being propelled to the place where the operations herein set forth are
required to be performed.
4. The use of portable carbon holders and switches, preferably of the form
shown by Figs. 8 to 13 of the accompanying drawings, in combination with the
resistance coils, resistance frames, or resistance blocks as herein before described,
for the purpose of controlling the various operations herein before set forth.
Dated this 28th day of August 1890.
JOHN CHRISTIAN WERNDLEY.
HENRY FOSTER.