US1757549A - Method of and apparatus for casting metal - Google Patents

Method of and apparatus for casting metal Download PDF

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US1757549A
US1757549A US306305A US30630528A US1757549A US 1757549 A US1757549 A US 1757549A US 306305 A US306305 A US 306305A US 30630528 A US30630528 A US 30630528A US 1757549 A US1757549 A US 1757549A
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metal
molds
passages
fountain
disposed
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Albert W Smith
James M Nelson
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D35/00Equipment for conveying molten metal into beds or moulds
    • B22D35/04Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
    • B22D35/045Runner base plates for bottom casting ingots

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  • a principal object of the present invention more closely adjacent the pouring fountain is to provide a'method of casting metahmore through whichtlie metal is introduced; particularly steel ingots, as well as an appa- To enable'those skilled in the art to compreratus adapted for the performance thereof, hend andpractice the invention, we shall now by means of which ingots of greater uniformdescribe one manner-of performing our imity d i d lit can h d d proved method by means of an apparatus such than by the methods of casting and appara- 1l111twt8d n the l l r w ngs n in tus which have hitherto been employed.
  • 2 1 is a p P View of the PP F th bj t d advantages f d ratus as assembled preparatory to the castnovel features of operation, design, construc- PQ E Vertlcal f there 03 tion and arrangement of parts' andinstrumenof on hne *T gand a g talities embraced by the invention are hereinl F "ertlcal 866111911 the 1'e0f 3 3 after more particularly pointed out or will i F q f silld sectlons bemg taken be apparentfrom the following description In the directions indicated by the arrowson of one manner of performing our improved the sectlonlmes f t same Symb01S..bemg 55 method by means of the apparatus illustrat used to designate sim lar parts 1n the several ed in the accompanying drawings.
  • each of the several ll'lgO 15 through which the metal passes to the several formed under exactly the same cond tions as molds 3 which, as shown, may take the form 85 all of the other ingot s, Wlth re ultl g q lof hollow cylinders open at their upper and formlty therein.
  • each ofthese main channels 12 are two courses of bricks disposed one above the other, the lower courses of bricks 14 being longitudinally pierced to form the lower metal passages 15 and being'conveniently of substantially rectangular cross sections so as 'to fit more or less snugly in the channels 12.
  • the innermost brick 14' in each of these channels that is, the brick most nearly adjahowever, of somewhat different shape than the other bricks in that its innermost-end is closed and its central opening or passage extended through its upper wall to register with a corresponding opening in the lower wall of superjacent brick 16 in the upper course, the metal passage through this brick 16 being closed at its outer end and communicating at its inner end with a port 17 in the wall of the cup-shaped brick 9 forming the sump 10.
  • the passage through the two complementary bricks 14' and 16 thus forms a vertically disposed slag trap 18 between the sump 10 and the lower metal passage 15 through which the metal must pass after it leaves the sump while the outermost brick 14" in each of the lower courses also differs from the central bricks therein in that it is closed at its outer end save for a small air vent 19 extending therethrough and the purpose of which will hereinafter a pear.
  • a second course of substantially similar bricks with their upper surfaces lying substantially flush with the surface of the stool Disposed a ove the lower course ofbricks in each of the main channels is a second course of substantially similar bricks with their upper surfaces lying substantially flush with the surface of the stool.
  • the central bricks 22 of those forming the upper courses longitudinally pierced from end to end to form the upper metal passages 23 while the inner ends of the innermost bricks 22 are closed and provided with air vents 24 and the outer endsof the outermost bricks 22" similarl closed and provided with air vents 25. If esired, a small clearance may be left between the extremity of each innermost brick 22' and the end of the adjacent brick 16 so as to facilitate escape of air through the vents 24.
  • Ports 26 are provided in the upper walls ')f the end-bricks 22' and 22" through which the the metal can pass from the upper passages 23 to the superjacent molds 3 during the casting operation.
  • auxiliary upper channles 27 respectivcly disposed at right angles to the adjacent main channels and extending in opposite directions therefrom but only cut into the surface of the stool for one-half the depth of the main channels so as tocontain but one course of metal-passage-forming bricks 28 which are disposed therein in a way generally similar to the upper bricks in the main channels and in the same horizontal plane; similarly also the outermost bricks 28' in the auxiliary channels have their ends closed and provided with air vents 29 and are also respectively provided with ports 30 in their upper walls through which the metal can pass from the passages 31 to the superjacent molds 3 respectively adjacent thereto and thus generally corresponding to the ports 26 heretofore described.
  • the brick work is so formed as to provide a central riser, generally designated as 34, disposed in a recess 35 suitablya located in the stool at the intersection of the main and auxiliary channels; through which riser the metal can ascend from the passages'in the lower courses of bricks to pass into the passages in the u per courses dis osed in the channels 12 an 27 and thence through ports 26 and 30 to the superjacent molds.
  • Each of these risers is desirably open at the top and operatively closed by means of a cap 35 which may be hollowed out as shown in Fi s.
  • auxiliar slag trap f br a purpose hereinafter more f ully explained, but as the upward pressure on these caps during the pouring operation is considerable it is requisite to hold them in place by some suitable means, as, for example, by weights '36 which are rested on the caps.
  • a retaining ring 37 of greater diameter than the cap may be disposed about each of the latter and the space between the ring and the cap filled with loam 38, clay or the like, but any other means of holding the caps in position or acking the joints between them and the suhjacent brick work may be utilized if preferred.
  • the channels are somewhat longer than the total of the metal-passageforming bricks disposed therein so as to leave a small space beyond the courses of bricks at the outer end of each channel which may be more or less loosely filled in with old brick work or like material 40 after the bricks are in place so as to hold the latter in longitudinal engagement.
  • a very-small clearance 41 between this filling-in material and the ends of the adjacent bricks so as to allow for the escape of air from the metal passages through the air vents in these bricks; in practice, however,
  • filling-in brick work 40 is not solid but is formed from irregularly shaped pieces there is no necessity for providing this clearance as the air from the metal passages will readily escape through the interstices between the pieces of filling-in material.
  • the ports 26 and 30 through which the metal passes from the metal passages to the mold are symmetrically arranged in groups about the several risers 34; consequently that when the molds 3 are respectively dis osed adjacent these ports substantially coaxially therewith they will be similarly grouped as shown in Fig. 1 and further that, in turn, the risers 34 are all equidistantly spaced from the central sump 10 with which the pouring fountain commuicates and are connected therewith by the inner portions of the lower metal passages 15 and slag traps 18 communicating wth the ports 17 extending into the sump.
  • the lower course of bricks in the main channels is laid on a thin bed of loam or clay 42.
  • the fluid metal is teemed into the funnel at the top of the "pouring fountain and thence passes from the sump 10 through the ports 17 to the slag traps 18 and thence to the lower metal passages 15 through which it flows until the passages are filled.
  • the slag and other lighter impurities are skimmed off of the metal and remain in'the traps so that the metal entering the metal passages 15 is relatively free from impurities.
  • any impurities such as brick scourlngs or the like which may pass through the traps 18 are almost entirely confined to the leading portions of the streams ofmetal with the result that they are carried into the extremities of the metal passages 15 beyond the risers 34 with the first rush of metal andthereafter remain therein and do not pass upwardly through the risers to the upper metal passages; moreover, as the air is fully ventedfrom the passages 15 by the .vents 19 there is no compression thereof in the extremities or dead ends of these passages and thus no tendency for the metal to be driven or splashed back and thrown upwardly into the molds or upper passages before the regular and even flow of metal thereto is established with resultant production of scabby ingots.
  • the metal passes upwardly through the several risers 34 into the upper metal passages and completely fills them before passing therefrom to the superjacent molds through the ports 26 and 30, and since, as in the case of the lower metal passages, the dead ends of the upper passages are filled in advance of the entrance of the metal to the molds and as these dead ends are, likeinated just as in the case of the lower passages. Furthermore, any lighter impurities,
  • the pressure of the refill metal in those molds most nearly adjacent the foun tain is materially greater than in those more remote therefrom due principally to the chilling of the metal in the longer metal passages'to the former during the initial cooling of the ingots with the result that the refill metal frequently breaks through the skin or crust of the ingots subjected to the greatest pressure and exudes therefrom while on the other hand, insufficient metal is supplied to the others to eliminate or minimize the formation of pipes therein.
  • a further advantage of our invention resides in the elimination to a. very large extent of surface cracks in the ingots which under present methods of casting very frequently result-from the swirling motion of the metal in those molds to which the metal can pass most easily from the pouring fountain and which are usually those molds most nearly adjacent thereto.
  • These surface cracks are also sometimes due to the refill metal breaking the thin surface of some of the ingots when the pressure of the said metal is greater in one mold than in another, a condition which for the reasons pointed out cannot occur when the pressure in each of the molds is uniform with that in all of the others.
  • each of the molds is simultaneously filled to the same depth or height as all of the other molds, all of the ingots are of uniform -length with resulting diminution of the amount of metal which must be out off and mote from the pouring fountain, fill more slowly than those adj acent thereto, it is necessary, in order to have the ingots cast in the former of the desired length, to make those cast in the latter of excessive length and to then later cut them off and discard the excess, thus increasing the cost of production because of the undue amount of scrap which must be removed.
  • the molds are very closely grouped together upon the stool and that the metal passages are comparatively short with consequent avoidance of any undue chilling of the metalbefore reaching the molds; additionally. in consequence of the massed-disposition of the molds better cooling effects are obtainable both before and after removal of the molds from the ingots as the cooling of the latter is materially retarded with resultant diminution of surface strains in the ingots to a minimum.
  • ingot molds of different sizes may be utilized as desired without disturbing the other parts of the ap aratus and thus, while it is generally pre erablethat all of the molds employed in one cast should be of the same size. it is immaterial whether they be relatively large or small so long as they are capable of being respectively disposed upon the stool in substantial axial alignment with the several ports 26 and 30. It is therefore possible, without sacrificing any of the advantages of the invention, to employ with the same stool and arrangement of bri k work any of the usual sizes of ingot molds, while because of the compact arrangement of the molds upon the stool, the apparatus when designed to profluid metal and the like.
  • the method of bottom casting a plurality of ingots simultaneously which comprises the steps of teeming molten metal to a d stributing point and then conducting said metal from said point in a plurality of d lf ferent streams of equal length to a plurality of ingot molds arranged at different distances about said point.
  • the method of simultaneously bottom casting a plurality of ingots which comprises the steps of teeming the molten metal in a single stream to a distributing point and then distributing the metal from said point in a plurality of different. streams to a plurality of ingot molds disposed atdifi'erent distances from said point by conducting the metal to each of said molds through paths of equal length.
  • the step of efpressure, fluidity and fecting equal distribution of the molten metal from a central distributing point to a plurality of ingot molds disposed thereabout and at different distances therefrom by causing the metal to flow from said point substantially the same distance to each of said molds.
  • a plurality of molds arranged at difierent distances about a central distributing point, means for supporting the molds, and means for conducting molten metal from said point to the bottom of each mold and adapted to cause the metal in its passage to each mold to traverse the same distance from said point.
  • a plurality of molds arranged at di%erent distances about a central sump, a stool for supporting the molds, and means for conducting molten metal from said sump to the bottom of each mold comprising a plurality of main channels formed in the supporting means and extending outwardly from the sump, auxiliary channels intersecting the main channels and refractory material lining all of said channels and providing passages for the metal.
  • a pouring fountain means for su e porting the fountain, a plurality of molds disposed on said supporting means about the fountain at different distances therefrom, and means for conducting molten metal from saidfountain to the molds simultaneously and adapted to cause the metal passing into each mold to traverse the same distance from the fountain.
  • a stool having a plurality of channels in its surface, a pouring fountain supported on the stool, a plurality of ingot molds disposed on the stool about the fountain at different distances therefrom, and means disposed in the channels of the stool operative to form passages for conducting molten metal from below the fountain to the several molds and so arranged as to cause the metal in its passage to each mold to traverse the same distance through said passages.
  • An apparatus for bottom casting metal comprising a'mold supporting stoolhaving a plurality of main" channels'radiating outwardly from a single point and an auxiliary channel intersecting each of the main channels, a pouring fountain disposed above said point, a plurality of molds seated on the stool above the channels, refractory lining material disposed in "the channels and provided with passages for conducting the molten metal from the fountain to the several molds through paths of substantially the same length, and means adapted to conduct 'air from said passages in advance of the metal as it flows thereinto.
  • An apparatus for bottom casting metal comprising'a' mold supporting stool and a pouring fountain disposed substantially at the center thereof, the stool being provided with a plurality of main channels formed in its upper surface and extending from the fountain and an auxiliary channel crossing each m'ain'channel adjacent its outer end, a plurality of molds disposed on said stool above saidchannels and symmetrically arranged in groups about the point of intersection of each main and auxiliary channel.
  • refractory lining material disposed in all of said channels and provided with passages for conducting the molten metal from the fountain to the several molds through different paths of substantially the same length, means memes in each passage adjacent the base of the fountain adapted to remove and trap impurities from the metal, and means for venting the air from each passage in advance of the metal as it flows to the molds.
  • An apparatus for bottom casting metal comprising a mold supporting stool and a pouring fountain disposed substantially at the center of thestool,the stoolbeing provided with a plurality of main channels formed in its upper surface and extending from the fountain and an auxiliary channel crossing each main channel adjacent its outer end and of substantially one-half the depth of the main channel, a plurality of molds disposed-on said stool above said channels and symmetrically arranged in groups about the point of intersection of each main and auxiliary channel, refractory lining material disposed in each main channel and provided with superposed passages for conducting molten metal from the fountain to the molds disposed above said main channel, refractory lining material disposed in each of said auxiliary channels and provided with a passage for conducting molten metal from the first mentioned passages to the molds disposed above said auxiliary channels, and means for venting the air from each of said pas sages in advance of the molten metal as it flows thereinto, all of said passages being so arranged as'to conduct the metal through substantially the same linear distance from
  • An apparatus for bottom casting metal comprising a mold supporting stool and a pouring fountain disposed substantially at the center thereof, the stool being provided with a plurality of main channels formed in its upper surface and extending from the fountain in different directions and an auxiliary channel crossing each main channel adjacent its outer end, a plurality of molds disposed on said stool above said channels and symmetrically arranged in groups about the point of intersection of each main and auxiliary channel, refractory lining material disposed in each of said main channels and provided with a lower metal passage extending from beneath the fountain substantially to the outer end of the channel and an upper metal'passage substantially parallel to the lower metal passage and communicating with the superjacent molds, means forming a connection between the upper and lower passages, rcfractory lining material 'in each auxiliary channel provided with passages extending from said connecting means to the superjacent molds, means for venting the air from the ends of all of said passages in advance of the molten metal as it flows thereinto from the fountain, and means disposed adjacent the fountain and forming
  • a plurality of molds arranged at different distances about a central sump, a stool for supporting the molds, and means for conducting molten metal from the sump to the bottom of each mold comprising passages in the stool and extending in a plurality of planes and so arranged that the metal is caused to traverse substantially the same distance to each mold from the sump.
  • a pouring fountain means for supporting the fountain, a plurality of molds disposed on saidsuppor-ting means about the fountain at different distances therefrom, and means for conducting molten metal from the fountain to the molds simultaneously comprising a plurality of passages extending in the supporting means at difierent levels and arranged to cause the metal passing into each mold to traverse the same distance from the fountain.
  • the method of bottom casting a plurality of ingots simultaneously which comprises the steps of teeming molten metal to a distributing point, dividing the metal at said point into a plurality of streams, and then defleeting the course of the streams to cause said streams to traverse equal distances and to flow into a plurality of ingot molds arranged at different distances about said point.

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Description

May 6, 1930. A. w. SMITH ET AL I IETHOD OF AND APPARATUS FOR CASTING UETAL 2 Sheets-Sheet 1 Filed Sept. 1'7. 1928 3 f a max 2 M M m M 16 Vd/TNESS May 6, 1930. A. w. SMITH ET AL METHOD OF AND APPARATUS FOR CASTING METAL Filed Sept. 1'7. 1928 2 Sheets-Sheet 2 MN wm fh, JamaJMA EZZSOIZA WITNESS Patented May 6, 1930 1 "1,757,549
UNITED STATES PATENT OFFICE AtnnnT w. SMITH AND JAMES M. NELSo'N, or YOUNGSTOWN, 01110 METHOD or AND APPARATUS FOR CASTING METAL Application filed September 17, 1928. Serial No. 306,305.
A principal object of the present invention more closely adjacent the pouring fountain is to provide a'method of casting metahmore through whichtlie metal is introduced; particularly steel ingots, as well as an appa- To enable'those skilled in the art to compreratus adapted for the performance thereof, hend andpractice the invention, we shall now by means of which ingots of greater uniformdescribe one manner-of performing our imity d i d lit can h d d proved method by means of an apparatus such than by the methods of casting and appara- 1l111twt8d n the l l r w ngs n in tus which have hitherto been employed. 2 1 is a p P View of the PP F th bj t d advantages f d ratus as assembled preparatory to the castnovel features of operation, design, construc- PQ E Vertlcal f there 03 tion and arrangement of parts' andinstrumenof on hne *T gand a g talities embraced by the invention are hereinl F "ertlcal 866111911 the 1'e0f 3 3 after more particularly pointed out or will i F q f silld sectlons bemg taken be apparentfrom the following description In the directions indicated by the arrowson of one manner of performing our improved the sectlonlmes f t same Symb01S..bemg 55 method by means of the apparatus illustrat used to designate sim lar parts 1n the several ed in the accompanying drawings. figures I As will hereinafter more fully appear our The particular apparatus which wehave chosen to illustrate 1s suitable for the simullnventlon contemplates the simultaneous fillt 1 f g of a plurality of ingot molds y introducr aneous proc uc 10H 0 s1xteen 1ngots but, of
v 't will be understod that the a am the molten metal at the bottoms thereof, (30111.58 1 y P that is, by b0ttom po g as it is termed in iatus may be arranged for the slmultaneous roduction of a r the rt slmulmneously P a i ngots if desired siiiifttiietfifiiiifiiifi tfii responding number of ingots an In Such principles oftheinvention;howevgr, in prac- Z5 manner that the metal fiow1 g to each mold tice good results have been obtained with an from its'point of introduction to the appaapparatus i d as Shown ratus is constrained to traverse exactly the Th appamtus Comprises base or t l 2 same (llstallce Pm 531d P01nt to each of the which may take the form of a rectangular SeWTal molds; m Q fll a the metal relatively thick plate of metal suitably 89 reaches all of the molds m exactly h g grooved or channeled in its upper surface for condition aS o p essu e, mp r flllld1- the reception of bricks of refractory material tXand the hke wlthrthe qng which form, among other things the passages things. that each of the several ll'lgO 15 through which the metal passes to the several formed under exactly the same cond tions as molds 3 which, as shown, may take the form 85 all of the other ingot s, Wlth re ultl g q lof hollow cylinders open at their upper and formlty therein. Additionally, after the 1mlow r ends, which latter simply rest upon tlal pourlng has been completed and the reth u surface f th t l, filloperati on undertaken as hereinafter more Disposed at the center of the stool is the 40 fully e rplained, and the primary function of ouring fountain, generally designated as 4 m hich is toehmmate pipes from the lngo s as into which the metal is poured or teemed dur: tar as possible, the uniformity of pressure exing the casting operation; this fountain may erted by'the refill metal in the several'molds comprise a hollow cylindrical metal casing results in the introduction of exactly the same 5 having a, tubular brick lining 6 and a, funamou t'o refi l etal into each mold and unnel 7 at its upper end also'suitably brick linedder the same conditions as in the case of all as t 7, At it l w d th casing 5 y of the other molds, so that unequal refilling be enlarged to form a base 8 which rests mi of the molds is avoided as well as any burstthe surface of the stool and securely supports ing through of the solidified skin or crust the fountain in upright position; the base at the upper ends of those ingots which are may be provided with a tubular brick lining cent the central fountain 4, is,
'are
8' forming a substantial extension of the lining 6 and seating upon a sin le cup-shaped brick 9, or a plurality of bric segments together forming, a cup-sha ed unit, disposed in a recess at the center 0 the stool and embodying a central cavity 10 forming a sump into which the metal can flow from the fountain. From the recess in which the brick lining is disposed radiate the main channels 12 in which are disposed bricks forming the main metal passages; these main channels are of sufficient depth to receive two courses of bricks one above the other and are preferably disposed at right angles to each other so that the four channels in effect form the arms of a cross. In each ofthese main channels: 12 are two courses of bricks disposed one above the other, the lower courses of bricks 14 being longitudinally pierced to form the lower metal passages 15 and being'conveniently of substantially rectangular cross sections so as 'to fit more or less snugly in the channels 12.
The innermost brick 14' in each of these channels, that is, the brick most nearly adjahowever, of somewhat different shape than the other bricks in that its innermost-end is closed and its central opening or passage extended through its upper wall to register with a corresponding opening in the lower wall of superjacent brick 16 in the upper course, the metal passage through this brick 16 being closed at its outer end and communicating at its inner end with a port 17 in the wall of the cup-shaped brick 9 forming the sump 10. The passage through the two complementary bricks 14' and 16 thus forms a vertically disposed slag trap 18 between the sump 10 and the lower metal passage 15 through which the metal must pass after it leaves the sump while the outermost brick 14" in each of the lower courses also differs from the central bricks therein in that it is closed at its outer end save for a small air vent 19 extending therethrough and the purpose of which will hereinafter a pear. I
Disposed a ove the lower course ofbricks in each of the main channels is a second course of substantially similar bricks with their upper surfaces lying substantially flush with the surface of the stool. As in the case of the bricks in the lower courses, the central bricks 22 of those forming the upper courses longitudinally pierced from end to end to form the upper metal passages 23 while the inner ends of the innermost bricks 22 are closed and provided with air vents 24 and the outer endsof the outermost bricks 22" similarl closed and provided with air vents 25. If esired, a small clearance may be left between the extremity of each innermost brick 22' and the end of the adjacent brick 16 so as to facilitate escape of air through the vents 24. Ports 26 are provided in the upper walls ')f the end-bricks 22' and 22" through which the the metal can pass from the upper passages 23 to the superjacent molds 3 during the casting operation.
Midway between the ports the stool is provided with auxiliary upper channles 27 respectivcly disposed at right angles to the adjacent main channels and extending in opposite directions therefrom but only cut into the surface of the stool for one-half the depth of the main channels so as tocontain but one course of metal-passage-forming bricks 28 which are disposed therein in a way generally similar to the upper bricks in the main channels and in the same horizontal plane; similarly also the outermost bricks 28' in the auxiliary channels have their ends closed and provided with air vents 29 and are also respectively provided with ports 30 in their upper walls through which the metal can pass from the passages 31 to the superjacent molds 3 respectively adjacent thereto and thus generally corresponding to the ports 26 heretofore described. It will thus be apparent that the upper and lower courses of bricks in the main channels and the sin le course of bricks in the upper channels or each group of four molds conver e raidally upon a common center about whic the ports 26 and 30 are equidistantly disposed.
At this central point of convergence of the bricks in the respective groups of channels the brick work is so formed as to provide a central riser, generally designated as 34, disposed in a recess 35 suitablya located in the stool at the intersection of the main and auxiliary channels; through which riser the metal can ascend from the passages'in the lower courses of bricks to pass into the passages in the u per courses dis osed in the channels 12 an 27 and thence through ports 26 and 30 to the superjacent molds. Each of these risers is desirably open at the top and operatively closed by means of a cap 35 which may be hollowed out as shown in Fi s. 2 and 3 to form an auxiliar slag trap f br a purpose hereinafter more f ully explained, but as the upward pressure on these caps during the pouring operation is considerable it is requisite to hold them in place by some suitable means, as, for example, by weights '36 which are rested on the caps. To form a packing for the joints between the margins of the caps and the subjacent bricks a retaining ring 37 of greater diameter than the cap may be disposed about each of the latter and the space between the ring and the cap filled with loam 38, clay or the like, but any other means of holding the caps in position or acking the joints between them and the suhjacent brick work may be utilized if preferred.
As shown, the channels are somewhat longer than the total of the metal-passageforming bricks disposed therein so as to leave a small space beyond the courses of bricks at the outer end of each channel which may be more or less loosely filled in with old brick work or like material 40 after the bricks are in place so as to hold the latter in longitudinal engagement. It will be noted that in the drawings we have shown a very-small clearance 41 between this filling-in material and the ends of the adjacent bricks so as to allow for the escape of air from the metal passages through the air vents in these bricks; in practice, however,
as the filling-in brick work 40 is not solid but is formed from irregularly shaped pieces there is no necessity for providing this clearance as the air from the metal passages will readily escape through the interstices between the pieces of filling-in material.
It will thus be apparent that the ports 26 and 30 through which the metal passes from the metal passages to the mold are symmetrically arranged in groups about the several risers 34; consequently that when the molds 3 are respectively dis osed adjacent these ports substantially coaxially therewith they will be similarly grouped as shown in Fig. 1 and further that, in turn, the risers 34 are all equidistantly spaced from the central sump 10 with which the pouring fountain commuicates and are connected therewith by the inner portions of the lower metal passages 15 and slag traps 18 communicating wth the ports 17 extending into the sump. Preferably, as shown, the lower course of bricks in the main channels is laid on a thin bed of loam or clay 42.
When casting ingots in an apparatus substantially of the character of that to which reference has been made, the fluid metal is teemed into the funnel at the top of the "pouring fountain and thence passes from the sump 10 through the ports 17 to the slag traps 18 and thence to the lower metal passages 15 through which it flows until the passages are filled. In its passage through the traps 18 the slag and other lighter impurities are skimmed off of the metal and remain in'the traps so that the metal entering the metal passages 15 is relatively free from impurities. However, any impurities such as brick scourlngs or the like which may pass through the traps 18 are almost entirely confined to the leading portions of the streams ofmetal with the result that they are carried into the extremities of the metal passages 15 beyond the risers 34 with the first rush of metal andthereafter remain therein and do not pass upwardly through the risers to the upper metal passages; moreover, as the air is fully ventedfrom the passages 15 by the .vents 19 there is no compression thereof in the extremities or dead ends of these passages and thus no tendency for the metal to be driven or splashed back and thrown upwardly into the molds or upper passages before the regular and even flow of metal thereto is established with resultant production of scabby ingots. Hitherto this result has fre- .quently occurred where the metal was allowed to fiow into dead end but unvented passages beneath the molds but as in accordance with our invention the dead ends of all of the metal passages are fully vented this back splashing of the metal and inimical effects resulting therefrom, due principally to the adherence of the splashed metal to the sides of the molds, are substantially eliminated.
After the lower metal passages 15 are completely filled, the metal passes upwardly through the several risers 34 into the upper metal passages and completely fills them before passing therefrom to the superjacent molds through the ports 26 and 30, and since, as in the case of the lower metal passages, the dead ends of the upper passages are filled in advance of the entrance of the metal to the molds and as these dead ends are, likeinated just as in the case of the lower passages. Furthermore, any lighter impurities,
which may remain in the metal after its pas sage through the risers 34 are collected'in the hollowed out caps 35 above the risers which act as additional slag traps so that by the time the metal emerges from the ports 26 and 30 substantially all such impurities are eliminated therefrom.
- The flow of metal through the molds having been thus established, the teeming thereof into the fountain 4 is continued until the molds are filled to the desired height after which the teeming may be either temporarily or permanently discontinued and the ingots allowed to cool; if desired and in accordance with the usual practice the cooling of the ingots may be hastened by playing a stream of water on their exposed extremities. During this cooling the metal of each ingot shrinks appreciably and a pipe or depression is formed in its upper end upon which, as Well, a relatively hard skin or crust is formed, and for the purpose of eliminating these pipes as far as possible it is customary to fill the fountain with additional metal known as refill metal after the ingots have been cooled for a predetermined period: As the ingots continue to shrink internally this additional metal in the fountain gradually feeds to the ingots and serves to minimize the formation of the pipes and at a suitable IOU several molds varies in accordance with the distance of the latter from the fountain in consequence of which those molds more nearly adjacent the fountain receive the metal at greater pressure and frequently in a state of greater fluidity than those molds more remote therefrom. This results, among other things, in considerable swirling and other disturbances of the metal in thosemolds nearest the fountain with consequent production of scabby ingots and, further, in these'molds generally receiving more metal than the others with resultant production of longer ingots. Moreover,during the refill operation, if employed, the pressure of the refill metal in those molds most nearly adjacent the foun tain is materially greater than in those more remote therefrom due principally to the chilling of the metal in the longer metal passages'to the former during the initial cooling of the ingots with the result that the refill metal frequently breaks through the skin or crust of the ingots subjected to the greatest pressure and exudes therefrom while on the other hand, insufficient metal is supplied to the others to eliminate or minimize the formation of pipes therein.
It will be noted, however, that in accordance with our invention the fluid metal is constrained to travel exactly the same dis-' tance from the fountain to each of the several molds irrespective of the actual distance of the molds from the fountain. In consequence, as the metal is thus fed to all of the molds under exactly the same conditions as to fluidity, temperature and pressure, all of the several ingots are formed under like conditions. And here resides one of the important features of our invention for it enables, among other things, the simultaneous production of a plurality of ingots which are substantially uniform both as regards density and size, while, furthermore, during the refilling operation, if employed, each ingot receives exactly the same amount of metal under the same pressure as every other ingot.
A further advantage of our invention resides in the elimination to a. very large extent of surface cracks in the ingots which under present methods of casting very frequently result-from the swirling motion of the metal in those molds to which the metal can pass most easily from the pouring fountain and which are usually those molds most nearly adjacent thereto. These surface cracks are also sometimes due to the refill metal breaking the thin surface of some of the ingots when the pressure of the said metal is greater in one mold than in another, a condition which for the reasons pointed out cannot occur when the pressure in each of the molds is uniform with that in all of the others.
Moreover, since in accordance with our invention each of the molds is simultaneously filled to the same depth or height as all of the other molds, all of the ingots are of uniform -length with resulting diminution of the amount of metal which must be out off and mote from the pouring fountain, fill more slowly than those adj acent thereto, it is necessary, in order to have the ingots cast in the former of the desired length, to make those cast in the latter of excessive length and to then later cut them off and discard the excess, thus increasing the cost of production because of the undue amount of scrap which must be removed.
We are also enabled in accordance with our invention to effect a much better control of the filling of the molds than has heretofore been possible, for, due to the uniform conditions in all of the molds, any modification of the rate of flow to the pouring fountain or the like is equally effective upon all of the molds simultaneously; in addition, the metal flows smoothly and freely to all of the molds at a uniform rate and without undue pulsating effects in any of them, while due to the interposition of the slag traps in the metal passages through which the metal must pass prior to its entrance to the molds, we are able to free the metal very largely from impurities and thus produce cleaner and more satisfactory ingots.
It will be noted that .in accordance with the preferred practice of our invention the molds are very closely grouped together upon the stool and that the metal passages are comparatively short with consequent avoidance of any undue chilling of the metalbefore reaching the molds; additionally. in consequence of the massed-disposition of the molds better cooling effects are obtainable both before and after removal of the molds from the ingots as the cooling of the latter is materially retarded with resultant diminution of surface strains in the ingots to a minimum.
It will be apparent that ingot molds of different sizes may be utilized as desired without disturbing the other parts of the ap aratus and thus, while it is generally pre erablethat all of the molds employed in one cast should be of the same size. it is immaterial whether they be relatively large or small so long as they are capable of being respectively disposed upon the stool in substantial axial alignment with the several ports 26 and 30. It is therefore possible, without sacrificing any of the advantages of the invention, to employ with the same stool and arrangement of bri k work any of the usual sizes of ingot molds, while because of the compact arrangement of the molds upon the stool, the apparatus when designed to profluid metal and the like. Moreover, as with a given stool the same brick work and sizes of bricks may be utilized irrespective of the dimensions of the molds which are to be employed, We are able by our invention to effect material economy in plant operation by eliminating the necessity for keeping on hand a plurality of bricks of difierent sizes, thus cutting down the space requisite for the storage of bricks as well as the capital invested in the amount of bricks which must be kept on hand, the reduction in brick inventory which we are thus able to effect amounting in some cases to as much as 60%..
' While we have herein described one form of apparatus adapted for the performance of our invention with considerable particularity, we do not thereby desire or intend to specifically limit ourselves thereto nor to confine the use of our improved method solely to the casting of steel ingots as the same may be employed for the casting of other metals if desired while various changes and modifications may be made in the details of construction and arrangement of the apparatus itself without departing from the spirit and scope of the invention as defined in the appended claims.
Having thus described our invention, we claim and desire to protect by Letters Patent of the United States:
1. The method of bottom casting a plurality of ingots simultaneously which comprises the steps of teeming molten metal to a d stributing point and then conducting said metal from said point in a plurality of d lf ferent streams of equal length to a plurality of ingot molds arranged at different distances about said point.
2. The method of simultaneously bottom casting a plurality of ingots which comprises the steps of teeming the molten metal in a single stream to a distributing point and then distributing the metal from said point in a plurality of different. streams to a plurality of ingot molds disposed atdifi'erent distances from said point by conducting the metal to each of said molds through paths of equal length.
3. In a method of bottom casting a plurality of ingots simultaneously, the steps of conducting the molten metal from a central distributing point throughsubstantially equal distances to each of a plurality of molds disposed about said point at different distances therefrom to thereby cause the metal to reach each of said molds under substantially the same conditions as to temperature.
4. In a method of simultaneously bottom casting a plurality of ingots, the step of efpressure, fluidity and fecting equal distribution of the molten metal from a central distributing point to a plurality of ingot molds disposed thereabout and at different distances therefrom by causing the metal to flow from said point substantially the same distance to each of said molds.
5. In a method for simultaneously bottom casting a plurality of ingots, the step of efi'ecting equal distribution of the molten metal from a central distributing oint to a plurality of ingot molds disposed thereabout and at different distances therefrom by causing the metal to flow to each of said molds from said distributing point through passages of equal length to thereb cause the metal to enter each of said mol s under substantially the same conditions as to pressure, temperature and fluidity.
6. In an apparatus for castin metal a plurality of molds arranged at difierent distances about a central distributing point, means for supporting the molds, and means for conducting molten metal from said point to the bottom of each mold and adapted to cause the metal in its passage to each mold to traverse the same distance from said point.
7. In an apparatus for castin metal, a plurality of molds arranged at di%erent distances about a central sump, a stool for supporting the molds, and means for conducting molten metal from said sump to the bottom of each mold comprising a plurality of main channels formed in the supporting means and extending outwardly from the sump, auxiliary channels intersecting the main channels and refractory material lining all of said channels and providing passages for the metal.
8. In an apparatus for bottom casting metal, a pouring fountain, means for su e porting the fountain, a plurality of molds disposed on said supporting means about the fountain at different distances therefrom, and means for conducting molten metal from saidfountain to the molds simultaneously and adapted to cause the metal passing into each mold to traverse the same distance from the fountain.
9. In an apparatus for bottom casting metal, a stool having a plurality of channels in its surface, a pouring fountain supported on the stool, a plurality of ingot molds disposed on the stool about the fountain at different distances therefrom, and means disposed in the channels of the stool operative to form passages for conducting molten metal from below the fountain to the several molds and so arranged as to cause the metal in its passage to each mold to traverse the same distance through said passages.
10. 'An apparatus for casting metal comprising a channeled stool, a pouring fountain supported on the stool, aplurality of ingot molds disposed on the stool about the fountain at unequal distances therefrom and means disposed in the channels'of the stool forming conduits for conducting the metal vrespect to' each other andconverging to a central sump and a plurality of other channels respectively intersecting said first mentionedi cliannels-and of one-half the depth thereof, a p'ouriiig"fountain disposed above said snmpmfpMrant of ingot molds disposed about "'said"*fountain atditferent distances therefrom, and refractory material disposed in said channels and forming superimposed passages adapted" to conduct molten metal from t'he's'ump through said first mentioned channels' to certain of said molds and other passages'operative'to conduct metal through said second mentioned channels from the first mentioned passages to others of said molds, the passages being so arranged as to cause the metal flowing to each of the molds to traverse the same distance from the sump.
12. An apparatus for bottom casting metal comprising a'mold supporting stoolhaving a plurality of main" channels'radiating outwardly from a single point and an auxiliary channel intersecting each of the main channels, a pouring fountain disposed above said point, a plurality of molds seated on the stool above the channels, refractory lining material disposed in "the channels and provided with passages for conducting the molten metal from the fountain to the several molds through paths of substantially the same length, and means adapted to conduct 'air from said passages in advance of the metal as it flows thereinto.
13. An apparatus for bottom casting metal comprising'a' mold supporting stool and a pouring fountain disposed substantially at the center thereof, the stool being provided with a plurality of main channels formed in its upper surface and extending from the fountain and an auxiliary channel crossing each m'ain'channel adjacent its outer end, a plurality of molds disposed on said stool above saidchannels and symmetrically arranged in groups about the point of intersection of each main and auxiliary channel. refractory lining material disposed in all of said channels and provided with passages for conducting the molten metal from the fountain to the several molds through different paths of substantially the same length, means memes in each passage adjacent the base of the fountain adapted to remove and trap impurities from the metal, and means for venting the air from each passage in advance of the metal as it flows to the molds.
14. An apparatus for bottom casting metal comprising a mold supporting stool and a pouring fountain disposed substantially at the center of thestool,the stoolbeing provided with a plurality of main channels formed in its upper surface and extending from the fountain and an auxiliary channel crossing each main channel adjacent its outer end and of substantially one-half the depth of the main channel, a plurality of molds disposed-on said stool above said channels and symmetrically arranged in groups about the point of intersection of each main and auxiliary channel, refractory lining material disposed in each main channel and provided with superposed passages for conducting molten metal from the fountain to the molds disposed above said main channel, refractory lining material disposed in each of said auxiliary channels and provided with a passage for conducting molten metal from the first mentioned passages to the molds disposed above said auxiliary channels, and means for venting the air from each of said pas sages in advance of the molten metal as it flows thereinto, all of said passages being so arranged as'to conduct the metal through substantially the same linear distance from the fountain to each mold.
15. An apparatus for bottom casting metal comprising a mold supporting stool and a pouring fountain disposed substantially at the center thereof, the stool being provided with a plurality of main channels formed in its upper surface and extending from the fountain in different directions and an auxiliary channel crossing each main channel adjacent its outer end, a plurality of molds disposed on said stool above said channels and symmetrically arranged in groups about the point of intersection of each main and auxiliary channel, refractory lining material disposed in each of said main channels and provided with a lower metal passage extending from beneath the fountain substantially to the outer end of the channel and an upper metal'passage substantially parallel to the lower metal passage and communicating with the superjacent molds, means forming a connection between the upper and lower passages, rcfractory lining material 'in each auxiliary channel provided with passages extending from said connecting means to the superjacent molds, means for venting the air from the ends of all of said passages in advance of the molten metal as it flows thereinto from the fountain, and means disposed adjacent the fountain and forming a connection with each of the lower metal passages adapted to intersect and trap impurities from one of said streams to flow into each of said the metal as it flows into said lower passages. molds.
16. In an apparatus for casting metal, a In witness whereof, we have hereunto set plurality of molds arranged at difi'erent disour hands this 13th day of Sept, 1928. tances about a central sump, a stool for sup ALBERT W. SMITH, porting the molds, and means for conducting JAMES M. NELSON. molten metal from the sump to the bottom of each mold comprising a plurality of'intercommunicating passages arranged in the stool at difl'erent levels and connecting each mold with the sump.
17. In an apparatus for casting metal, a plurality of molds arranged at different distances about a central sump, a stool for supporting the molds, and means for conducting molten metal from the sump to the bottom of each mold comprising passages in the stool and extending in a plurality of planes and so arranged that the metal is caused to traverse substantially the same distance to each mold from the sump.
18. In an apparatus for bottom casting metal, a pouring fountain, means for supporting the fountain, a plurality of molds disposed on saidsuppor-ting means about the fountain at different distances therefrom, and means for conducting molten metal from the fountain to the molds simultaneously comprising a plurality of passages extending in the supporting means at difierent levels and arranged to cause the metal passing into each mold to traverse the same distance from the fountain.
19. In a method for simultaneously bottom casting a plurality of ingots, the steps of effecting equal distribution of the molten metal from a central distributing point to a plurality of ingot molds disposed thereabout and at different distances therefrom by-causing the metal to flow to each of said molds from said distributing points through passages of equal length extending in a plurality of different planes whereby the metal is caused toenter each of said molds under substantially the same conditions as to pressure, temperature and fluidity. I
20. The method of bottom casting a plurality of ingots simultaneously which comprises the steps of teeming molten metal to a distributing point, dividing the metal at said point into a plurality of streams, and then defleeting the course of the streams to cause said streams to traverse equal distances and to flow into a plurality of ingot molds arranged at different distances about said point.
21. In a method of simultaneously bottom casting a plurality of ingots, the steps of effooting equal distribution of the molten metal from a central distributing point to a plurality of ingot molds disposed thereabout and at difli'erent distances therefrom by divid ing a stream of the metal into a plurality of lesser streams, conducting said lesser streams along paths of equal length, and then causing
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4456417A (en) * 1980-07-07 1984-06-26 Jones & Laughlin Steel Corporation Method and apparatus for aligning, supporting, and transporting hollow cylinders
US4614217A (en) * 1984-09-14 1986-09-30 The Garrett Corporation Method of assembling a horizontal shell mold casting system and the resulting system
EP2965838A1 (en) * 2014-06-09 2016-01-13 Refractaria, S.A. Distributor for steel casting

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4456417A (en) * 1980-07-07 1984-06-26 Jones & Laughlin Steel Corporation Method and apparatus for aligning, supporting, and transporting hollow cylinders
US4614217A (en) * 1984-09-14 1986-09-30 The Garrett Corporation Method of assembling a horizontal shell mold casting system and the resulting system
EP2965838A1 (en) * 2014-06-09 2016-01-13 Refractaria, S.A. Distributor for steel casting

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