US1568096A - Process and apparatus for casting furnace bosh plates - Google Patents

Description

Jan. 5 1926.

J. SMITH PROCESS AND APPARATUS FOR CASTING FURNACE BOSH PLATES 2 Sheets-Sheet 1 Filed Jan. 29, 192 5 7 IN ENT'OR z c 1,568,096 J. SMITH PROCESS AND APPARATUS FOR CASTING FURNACE BOSH PLATES 2 Sheets-Sheet 2 Filed Jan. 29, 1925 Jan. 5, 1926.

INVENTOR of the casting forms the nose of the plate Patented Jan. 5, 1926.

[UNITED sra'rssv PATENT OFFICE.

JAMES SMITH, DECEASED, LATE OF DORMONT BOROUGH, PENNSYLVANIA; BY ISA- BELLA K. SMITH, ADMINISTRATRIX,

or DORMONT BOROUGH; PENNSYLVANIA,

ASSIGNOB TO ISABELLA K. SMITH, OF DORMONT, PENNSYLVANIA,

PROCESS AND AFPARATUS FOR CASTING FURNACE BOSE PLATES.

Application filed January To all whom it may concern;

Be it known that JAMES SMITH, deceased, late a citizen of the United States of America, and a resident ofthe borough of Dormont, in the county ofAllegheny and State of Pennsylvania, did invent a new and Improved Process andAp aratus for Casting Furnace Bosh Plates, 0 which the following is a specification. I I

The invention consists in a new and improved process and apparatus for casting ofurnace bosh-plates' inan upright posit and without embedded anchors; E

When, as hasheen the common. practice, bosh-platesare cast in a horizontal position,

the horizontally disposed coremustf besupported in place by. means of metal anchors or chaplets which remain embedded, in, the casting and weaken. the same, frequently re-.- snlting in leaks or ruptures.

In Letters Patent of the'Uni'ted States, No. 1,438,271, issued on December 12, 1922, to the said James Smith, nowdeceased, a process and apparatus are disclosed for easting. bosh-plates in a vertical position butwith the nose of the plate at the top and its buttlat the bottom, the core being supported from below'by; a sand base. The result is that the best portion of the castin and the purest metal is in the butt of t e plate, while; its nose, whichis to be exposed to the greatest heat and wear, is formed of the poorest portion of the casting.

In the improved process herein described, the bosh-plates are cast in a *vertical position, but with their noses down, so that the purest metal and therefore the best portion while thepoorer metal goes to form the butt.

Herein is disclosed new and improved apparatus whereby the new and improved process may be successfully and commercially worked.

In the accompanying drawings, which are however merely intended to illustrate the principles of the invention without 1imiting the scope thereof to the structures shown, Fig. 1 is a vertical section taken along the line II in Fig. 2 showing the mold and core assembled in the flask ready for pouring; Fig. 2 isa section along the line II II inFig. 1,-also showing the pouring sprue; Fig. 3 is .an enlarged detail of parts shown also ;in Fig. 1; Fig: 4 is a plan ion 2a,' -;1925. Serial No. 5,658.

view of the core-box used totorm the sand core; Fig. 5 is a vertical section illustrating the operation of forming the cheek-mold inan inverted position, showing the cheek, the

pattern and the sprue pattern assembled on cheek and drag, with their contents, reverted "on...the bottom board and the follow board gremoved; Fig. 8 shows the cope superimposed on the cheek for the step of forming the cope-mold; Fig. 9 shows the cope and cope-mold lifted off the cheek and cheekmold and set aside on trestles; Fig. 10 shows thecheek-mold lifted oil the dragmold and ,set on trestlesand the sand core set down into the cheek-mold; Fig. 11' is a similar view with the cope mold in place .on the cheek mold; Fig. 12 is a top plan view ofthe drag-mold showing-the pouring gates'which connect with the lower end of the sprue; Fig. 13 is a horizontal sec- .tion taken along the line XIIL-XIII in Fig. 11,- and Fig. 14 is a perspective of a conventional type of bosh-plate which is shown for the sake of clearness in description.

The molding flask, which is'shown in Fig. 1 assembled ready for pouring, is comprised ofthe drag-A containingthe drag-mold A thecheek B containing'the cheek-mold B,

and the cope C containing the cope-mold C.

D represents the sand core suspended from above from the cheek-mold. E represents the sprue which connects at its lower end with the horizontal ates F formed in the top of the drag-mol and connected to the as best shown in Fig. 12.

mold cavity at its opposite narrower sides,

The drag, cheek and cope. are detachably i connected together by the pins 1 which engage the. pierced ears 2. When the mold is ready for pouringthe entire flask'is clamped together in the usual manner.

The core D is suspended in place by the cross plates 3 whose ends rest on the top of the cheek-mold and whose centers are provided with circular holes in which are fixedthelengths of. pipes 4 held in place by the upper and lower lock nuts 5. The under surface of the cope mold is provided with suitable recesses 6 to provide clearance for the plates 3 and the upper ends of the'pipes 4:. The lower ends of the pipes 4: extend down into and are embedded in the sand of sand of the core and its exposed portion being wrapped with asbestos tape 7 to prevent the metal adhering thereto. The under surface of the co e-mold is recessed to give clearance for tl ie upper end of the pipe 8. The wrapped portion of the pipe forms the central water port 8 of the finished boshplate, as shown in Fig. 14.

The embedded ends of the pipes 4 and 8 are perforated, as shown in Fig. 3, to provide for the escape of the gases from the sand core, and the cope-mold .is provided with vent passages 9 connecting the upper ends of the pipes 4 and 8 to atmosphere to carry off said gases. 10 represents wires extending down through said pipes and embedded in the sand of the core to reinforce the latter, said wires being bent substantial- -ly as shown. Other wires 11 are also embedded in the core intersecting the cavities in which are formed the cross partitions of the bosh-plate. The intersecting or adjacent portions of said wires may be tied together by light wire which may be easily broken when the wires 10 are withdrawn from the cast plate.

The cope-mold has embedded in its lower surface two hard sand blocks G which are provided with the substantially inverted U- shaped passages 12 whose ends are open to receive the molten metal to form the handles 12 of the bosh-plate, as shown in Fig. 14. The tops of said passages 12 are connected by riser passages 13 with atmosphere, so that metal may compl'etely'fillthe pas.- sages 12 to form the handles 12, and may rise up into view to indicate that the mold has been filled. Also dross and impurities may thus escape through said risers.

14 represents temporary spacers, preferably formed by bending up a strip of sheet metal to substantially M-shape and inserting them at either side of the core between it and the cheek-mold near the lower end of the latter. These spacers serve to properly center the core and hold it in position, thus insuring walls of uniform thickness for the bosh-plate. These spacers are formed of metal which will melt when reached b and immersed in the molten metal, and w iich will become amalgamated with the metal of the plate without impairing-its quality. Thus, said spacers may be made of thin sheet cooper.

The upper end of the sprue E is provided wlth a pouring cup 15. Riser cups 15 are also placed at the upper ends of the riserpassages 13.

The metal is poured down through the sprue E and passes horizontally through the gates F into the mold cavity, first filling the lower portion of. the cavity and thus formmg; the nose of the plate, and then flowing upwardly, melting and amalgamating with it the temporary spacers 14. When the metal comes to the surface through the riser passages 13, it indicates that the mold is full. l/Vhen the metal has set the bosh-plate is removed from the mold and the pipes 4 and 8, and the wires 10 removed, the sand quickly and completely I removed from the interior of the plate, the

metal which has hardened in the gates and risers cut off, and the ports 4 and 8 are threaded for pipe connections.

It is evident that the best portion of the casting forms the nose of the late where the greatest heat is to be resiste This has been impossible of accomplishment by any previous method of casting bosh lates.

There is a decided advantage in introducing the molten metal horizontally at the ends of the core instead of at the sides of the latter. The core is much less likely to be displaced by this method of introducing the metal into the mold cavity. When the incoming metal impinges against the extended sides of the core it is almost impossible to prevent lateral shifting of the latter unless permanent supports, such as anchors or chaplets are used. Again, the introduction of the metal at the ends of the core insures a better distribution and equal flow of the metal.

There is a further advantage in introducing the metal at a level above the bottom or nose of the mold cavity. As the metal first fills up the portion of the mold cavity contained in the drag, it acts as a means for holding the core in its proper alinement, due to the upward rise of the metal, and when the rising level of the metal reaches and engulfs the temporary spacers, the latter have served their purpose and are melted by and amalgamated with the poured metal.

The following is the method of preparing and assembling the mold for casting.

The core D is formed by ramming core sand into the core box D which is integral with the board H. The box is provided with a nose wall 16, side walls 17 and butt wall 18, the side walls preferably diverging t0.

bosh-plate as shown in dotted lines in Fig. 14:. It wlll be understood that the parti- -tions 19 may be of any suitable character and pending upon the particular design of boshplate which is to be cast.

The butt wall 18 of the core box is pro aided with end channels 20 and an intermediate channel 20* to receive thecore pipes 4 and 8. The channels 20 are shallower at their outer extremity, as indicated by the shoulder 20"., and, after a bottom layer of sand is placed in the box, the wrapped pipes t are laid therein with their lower lock nuts 5 bearingoutwardly against said shoulders the inner and deeper portions of the channels; p

the=drag "and. all clampedithereto, and: the

providing room for the lower lock nuts and the asbestos wrapping 7, thus providing:- convenient means for properly positioning the pipes 4 in the core box.i The wrapped pipe 8 is also positioned in the intermediate The wires '10 are placed in po-- channel sition with their outer ends extending through the pipes 4 and 8. The interior wires 11 are also placed in position. The partitions 19 are apertured as shown to ac-' r-ommodate the-wires.

The core box is now filled with sand and rammed. The sand is then struck off flush with the iopofthe core box anda core plate put in place and'clamped tothe box, and the whole inverted. The clamps are then removed and the box rapped to free thecore and the box lifted off. The; core is then sprayed'and baked. v

The cheek B is inverted and placed on the' follow board I and the pattern J mounted thereon. The sprue form E is then stepped into a socket in the follow board; The sand is now filled in and rammed, thus forming the cheek-mold B.- This step is illustrated in Fig. 5. Referring now to Fig. 6, the drag A is now inverted and placed on the cheek B and the sand filled in and rammed,

parting sand being used to separate the molds. The bottom board K is now placed on the drag A, and the parts are clamped together and the whole reverted into the position shown in Fig. 7 and the follow board removed.

The cope C is placed on the cheek B, as

shown in Fig. 8. The sprue pattern E is drawn upward until its top is level with the top of the cope. The previously prepared sand blocks G are placed inposition on the top of the pattern J. The print-forms '3 and 8 are positioned on the pattern J to form the recesses to receive the plates 3 and the upper ends of the pipes 4: and 8. A parting is made and the, sand is now filled in and rammed to form the cope-mold C.

The cope and its mold is then removed.

ositioned in any desired manner de and the pattern J is'withdrawn, and the cheek and its mpld lifted from the drag and set on trestles, as shown in- Fig. '10. The plates 3 are. now placed in position on the pipes 4 and the upper lock nuts 5 are put in place. The core D is then placed down in thecheek' mold, as shown in Fig. 10, being supported from above by means of the crossplates 3 'which span the cheek mold as shown. The temporary spacers 14 are then inserted up between the core I) and the cheek mold B. The gates Fare cut in the top surface of the drag mold A, as shown in Fig. 12. The'cope G and its mold C are replaced on thezcheek' Band its mold B, as shown in Fig .--1'1-. szTherventpassages 9 and the .rise'r. passages '13 have. been: previously formed theacope-mold Q".' 1 I Y 'mold': is ready for pou'ring.

molten metal first flows downwardly from 3 the admission level to form the nose of the plate which metal 'in' setting anchors the core in position, and the subsequently admitted metal flows upwardly within the cavity to form the remainder of the plate.

2. The process of casting furnace b'oshplates, nose downwardly and in a vertically disposed position in a moldwherein-the core issuspended from above, which consistsin admitting the metal into; the mold cavity surrounding the core at theoppositenarrower sidesof the core and at a levelabove but near the lower endof the core, so that the metal first flows downwardly from the admission level to form the nose of the plate which metal in setting anchors the core in position, and the subsequently admitted metal flows "upwardly within the cavity toform the remainder of the plate.

3. The process of casting furnace boshplates,-nose downwardly and in a vertically disposed position in 'a mold wherein the core is suspended from above, which consists in interposin between the broader sides ofthe core and tie adjacent mold walls temporary spacers, and admitting the metal atthe narrower sides of the core at'a level near but above the lower end of th core so thatthe molten metal first admitted flows downwardly in the cavity surrounding the core plate, nose downwardly, in a vertically disposed position, in a mold containing acoreinterposing between the broader sides of the core and the adjacent mold walls temporary spacers, and admitting the meta'lat the narrower sides of the core at a level near but above th lower end of the core sothat'the molten metal first admitted flows down wardly in the cavity surrounding the core to form the nose of the plate and said metal in setting anchors the core in position and the subsequently admitted metal flows upwardly within the mold cavity and forms ,4

the remainder of the late, the spacers being of suitable material so that they are melted by the rising metal and become amalgamated in the plate.

5. The process of casting a furnace boshsuspended from above, which consists in interposing between the sides of the core and the mold walls temporary spacers meltable by the molten metal, and introducing the molten metal at both narrower sides of the core.

6. The process of casting'a furnace boshplate, nose downwardly, in a vertically disposed position, in a mold containing acore suspended from above, which consists in inter-posing between the sides of the core and the mold walls temporary spacers meltable by the molten metal, introducing the molten metal at both narrower sides of the core, and a level slightly above the lower extremity of the core whereby the nose of the plate is first cast and the metal in setting forms a centering support for the core.

7. The process of casting a furnace boshplate, nose downwardly, in a vertically disposed position, in a mold containing a core suspended from above, which consists in introducing the molten metal into the mold at the narrower sides of the core and slightly above the lower extremity of the latter, whereby the nose of the bosh-plate is first formed and the metal in setting forms a centering support for the core.

In means for casting furnace-bosh plates, nose downwardly and in a vertically disposed position, th combination of a mold, a core suspended from above in the mold cavity, and pouring gates leading into the mold cavity opposite to both the narrower sides of the core. I i

9. In means for casting furnace-bosh plates, nose downwardly and in a vertically disposed position, the combination of a mold, a core suspended from above in the mold cavity, and pouring gates leading into the mold cavity opposite to both the narsides of the core, and temporary spacers interposed between the broader sides of the core and the walls of the mold cavity.

11. In means for casting furnace-bosh plates, nose downwardly and in a vertically dis osed position, the combination of a mo (1, a core suspended from above in the mold cavity, pouring gates leading into the mold cavity opposite to both the narrower H sides of the core, and temporary spacers in terposed between the broader sides of the core and the walls of the mold cavity, said spacers being of suitable material so as to be melted by and amalgamated with the molten metal.

12. In means for casting anchorless boshplates in a vertical-position comprising a mold, a core suspended from above in said mold, and means for introducing the molten metal into the lower portion of the mold at a level slightly above the lower extremity of the core and at both narrower sides thereof.

13. In means for casting anchorless boshplates in a vertical position comprising a mold, a core suspended from above in-said 'mold, means for introducing the molten metal into the lower portion of the mold at a level slightly above the lower extremity of the core and at both narrower sides thereof, and temporary spacers interposed be tween the sides of the core and the walls of the mold above the level of the entrance of the molten metal.

14. In means for casting anchorless boshplates in a vertical position comprising a mold, a core suspended from above in said mold, means for introducing. the molten metal into the lower portion of the mold at a level slightly above the lower extremity of the core and at both narrower sides thereof, and-temporary spacers interposed between the sides of the core and the walls of the mold above the level of the entrance of the molten metal, said spacers being of material adapted to be melted by the metal and to be amalgamated therewith.

15. In means for casting furnace boshplates in a vertically disposed position and nose-downwardly comprising a mold having a cavity corresponding to the outer conformation of the bosh-plate to be formed, a core suspended from above within said cavity, and gates for the admission of metal opening into the lower portion of said cavity gates.

and above the lower extremity of said core, said gate-s being formed in the two narrower vertical walls of said cavity adjacent to the narrower sides of said core.

y 16. In means for casting furnace bosh plates in a vertically disposed position and nose-downwardly comprising a mold having a cavity corresponding to the outer eonformation of the bosh-plateto be formed, a core suspended from above within said cavity, gates for the admission of metal OPGIllIlglIltO the lower portion of said cavity and above the lower extremity of said core, said gates being formed in the two narrower 15 vertical walls of said cavity adjacentto the narrower sides of said core, and temporary spacers lnterposed between the core and the walls of the cavity above the level of the 17. In means for casting furnace boshplates in a vertically disposed position and nose-downwardly comprising a mold having a cavity corresponding to the outer conformation of the bosl1plate to be formed, a core suspended from above within said cavity, gates for the admission of metal open ng into the lower portion of said cavity and above the lower extremity of said core, said gates being formed in the two narrower vertical walls of said cavity adjacent to the narrower sides of said core, and temporary spacers interposed between t'liecore and the *walls of the cavity above the level of the gates, said spacers being composed of material which is melted and incorporated in the molten metal as the latter engulfs said spacers.

Signed at of January, 1925.

' ISABELLA K. SMITH, Arlmimlstrat'r im of the Estate of Jams Smith, deceased.

Pittsburgh, Pa., this 17th day i

Images