US2350899A - Process of producing castings - Google Patents

Description

June 6, 1944. J, E. JOHNSON I 2,350,899

PROCESS OF PRODUCING CA STINC'S Original i iled April 18, 1940 2 Sheets-Sheet 1 lllilllll Jo/m/ xi/M271. w qy- #05699 by WWW June 6, 1944. J, E. JOHNSON v PROCESS OF PRODUCING CASTINGS I Original Filed April 18, 1940 2 Sheets-Sheet 2 W s y m. E. H w. w J

Patented, June 6, 1944 UNlTED STATES PATENT OFFICE Divided and this application December 28, 1942, Serial No. 470,354

Claims.

This invention has for its principal object the production, by an expeditious, facile and novel method or process, of an exact and faithful reproduction or facsimile of an object, such as an insignia, inscription, cameo, intaglio etc. which has been placed in a die or which forms a part thereof. The invention is peculiarly adapted in its application to metals having a high melting point, such as tool steel, because of the results achieved to be referred to in detail hereinafter and for the reason that the work from which the casting is formed is itself directly subjected to intense heat instead of heating the metal in a crucible or other apparatus for bringing it to molten condition. I

Further and other objects and advantages of the invention will be apparent as the description thereof proceeds.

According to the preferred form of the invention, the metal as, for instance, steel or other material from which the casting is to be formed, is employed in the process in shaped or block form, as a rod or bar or a disc or roller and a portion thereof, such as an end or edge, is fused or brought to molten or liquid condition by the direct application of heat, such as for instance, by means of the well-known electric arc method and in which the metal material itself may form one of the electrodes. The end of the rod or bar, or if a disc or roller is employed, its periphery is then fused and forced quickly in molten condition, and while it remains an integral part of the rod or disc, into the die and pressure is then applied to the molten metal within the die, the pressure-applying means preferably being the un-molten or relatively cool portion of the metal work or material itself.

The several figures of the accompanying-drawings show a practical embodiment of an apparatus by means of which the process of the invention may be practiced. In said drawings:

Fig. 1 is a top plan View of one form of such apparatus.

Fig. 2 is a side elevation thereof.

Fig. 3 is a vertical cross-section on the line 3-3 of Fig. 2.

Fig. 4 is a horizontal cross-section on the line 4'4 of Fig. 3.

Fig. 5 is a sectional view of a modified form of apparatus taken on the line 5 -5 of Fig. 6, .and

Fig. 6 is a vertical cross-section of the modification taken on the line GB of Fig. 5.

Referring indetail to the drawings and, for the present, more particularly to Figs. 1 to 4 inclusive:

A walled chamberwithin which the process of the invention may be practiced is indicated at I0. Said chamber is provided with a base II, a front wall I2 detachably secured to the chamber, as by screws I3, whereby access to the interior of the chamber may readily be had, and an inwardly extending annular flange, as shown, forming a bearing member for'a work-holder as will be herein described. A rotatable work-holder is indicated at I5 and carries the work I6 from the lower end of which the casting is to be formed. In the preferred form of the invention the work comprises a rod or suitable fusible and preferably metallic material, such as steel. This steel rod extends downwardly through the work-holder and into the chamber and it is slidably and adjustably held in said work-holder in any desirable manner, as by set-screw l1 passing through the work-holder and into clamping engagement with the rod I6.

The upper end of the work-holder I5 is reduced in character as at I8 and extends through and is journalled within a cross-bar l9. The ends of said cross-bar are provided with guiding pins 20 slidably received within slots 2| of angled vertical supporting arms 22, the angles of which are detachably secured to the upper portion or wall of the chamber by means of adjustable screws 23. Tension springs 24 are connected to said screws and to the cross-bar I9 and constantly urge movement of the cross-bar I 9 downwardly and accordingly movement of the workholder I5 in the same direction with the guiding pins 20 engaging with the slots 2|. A ball-race 25 may be provided and is interposed between the cross-bar I9 and work-holder I5 to decrease the effect of frictionbetween the cross-bar I9 and work-holder I5 when the latter element is rotated. To permit connection between the cross-bar I9 and work-holder I5 while permitting rotation of the latter, ,I have provided a strap 25' fastened to the cross-bar and slidably engaging beneath anannular flange 25" with which the workholder is provided.

A rotatable sleeve is indicated at 26. Said sleeve is rotatably journalled within an inwardly extending flange or wall 21 which is preferably integral with the side walls of the chamber I0 and the sleeve is provided with an annular flange 28 acting as a stop to limit its upward vertical movement within said .fiange or Wall 21. The sleeve 26 and work-holder I5 are splined together by means of a key 29 on the sleeve which enters a slot 30 in the work-holder. This connection permits vertical movement downwardly .of the end of the rack is adapted to enter a suitable slot 34 in a wall of the chamber and the other nal 69 also mounted in the bore and having wiping electrical contact with the sleeve 26. A conductor 6| is fastened to the binding post 51 and is connected to a source of current supply (not shown) while another conductor 62 is also connected to said source of current supply and to the electrode 45.

The apparatus is shown in inoperative position with the metal die 38 shielded by a baflle plate 63 to prevent the introduction of dirt or other foreign matter into the die and which may be formed as an integral part of a wall of end is provided with a shank 35 journalled in and v extending through an opposite wall and termi-' rotate the sleeve 26 and consequently the workholder |5 which carries the rod f 6 with it.

A slidable die-support comprising a plate, Slide able on the base I, is indicated at 31. Said support detachably carries a metallic die 38 thereon which contains the impression from which the casting is to be made. In its base the die is provided with suitable openings for frictionally receiving pins 39 whereby removal and substitutions of different dies may readily be made with facility after the detachable front wall l2 has first been removed. The die-support extends through an opening in a wall of the chamber with which it slidably interfits and the opposite wall is provided with a screw-threaded opening receiving an adjustable screw 40. Said screw acts as a stop to limit the movement to the left (Fig.3) of the support 31 on the base andby adjusting. said screw, the die may be brought into exact vertical alignment with the work comprising the rod l6.

An actuating rod or bar is indicated at 4| and terminates in a handle "42. Said rod is pivoted at 42', as shown, to a bracket 43 fastened to a wall of the chamber and it is also connected by a pin and slot connection 44 to the die-support 31. A horizontally slidable rod comprising an electrode is indicated at 45. Said rod is slidably received by an insulating bushing 46 munt ed in a wall of the chamber and it is pivotally connected to an end of actuating rod 4| by a pin and slot connection 41. Insulating material surrounds this last-named connection, as illustrated, to prevent short circuiting.

A bracket 46 is mounted on a wall of the housing and has .an arm 49 pivoted thereto as at 49". The lower end of said. arm 49 engages a lug or projection 56 made of an insulating material and carried by the rod 45. The upper end of said arm 49 is connected by a pin and slot connection to a locking arm 52 journalled in a wall of the housing and terminating at its inner end in a lockin member 53 having an opening 54 of a size permitting it to normally loosely receive the work-holding member l5. One side of the opening 54 is bevelled as at 55 and is adapted to be received by an annular notch 56 in' the the chamber. I have also provided means for visual inspection of the end of the rod l6 in a order to inspect its physical condition while being subjected to heat to bring it to molten condition. Said means comprises a tube 64 extending through the wall I2 and in horizontal alignment with the end of the rod l6. Mounted on the outer end of said tube exteriorly of the chamber is a head 65 carrying a transparent plate 66, preferably of glass. This arrangement prevents the entrance of air into the chamber which is desirable in some cases as I have often found it expedient to carry on operations within the chamber in a vacuum or partial vacuum to prevent scaling of the rod H5 or the casting to be formed therefrom and which also enhances the fusing operation by the electric arc method.

Assuming the parts are in the positions shown, the operation of the apparatus is as follows:

The rod 4| is thrown to the right on its pivot 42 (Fig. 3) in order to bring the inner end of the electrode into contact with the lower end of the rod Hi to establish the completion of the electrical circuit through the end of the rod and the electrode. The rod 4| is then moved slightly to the left or in a clockwise direction to space the end of the rod I6 and the end of the electrode member 5 to hold and detachably lock 'it in n elevated position against the action of the springs 24. A compression spring 56' is interposed intermediate the arm 49 adjacent its upper end and a wall of the chamber'and urges said arm to swing in a clockwise direction to retain the member l5 in raised and locked position.

A binding post is indicated at 51 and is provided with a shank entering a bore 58 extending through a wallet the chamber. A compres sion spring 59 is mounted in said bore intermediate' the shank of the binding post and a termi- 45 whereby an electric heating are between the members is established. Meanwhile fusing of the end of the rod |6 proceeds and while so proceeding the rack 33 is reciprocated backwardly and forwardly to thereby rotate the rod in an obvious manner and thereby secure a uniform fusion thereof at all places adjacent its lower end. When said end has reached the necessary molten state and before it has had an opportunity to solidify and just before it has fallen by gravity from the unmolten portion of the rod, as determined by visual inspection thereof in the manner previously described, the bar 4| is thrown completely to the left on its pivot in a clockwise direction and as indicated at the left in dotted lines in Fig. 3. ,This movement, obviously, carriesthe die 38 on its support 31 into vertical alignment with the end of the rod I6, retracts the electrode 45 and releases the locking edge 55 from its engagement with the notch 56 whereby the work-holder I5 is moved downwardly instantly within the, sleeve 26 with great speed due to the action of the springs 24, and the molten metal on the end of the rod I6 is brought Within the die 38 and is firmly compressed therein by the unfused or unmolten part of said rod IE to form a splas casting which conforms inconfiguration to the inner configuration of the die 38.

Adhesion or sticking of the molten metal to the die is obviated because of-the relatively large difference in temperature therebetween whereby a very sudden chilling and consequent contraction of the metal is effectively brought about immediately upon its contact with the die. After the casting is so formed, the work-holder l5 car rying the rod IS with the formed casting on the end thereof is manually raised by means of the cross-bar IE to its initial position and locked in that position by swinging the rod or bar to inoperative or vertical position shown in full lines in Fig. 3 to permit the action of the spring 56' to bring the holder l5 and locking member 53 into interlocked engagement. The formed casting may then be cut off from the end of rod 16 at any desired length. As the operating length of the rod l6 becomes shortened because of the successive fusings of its end and the formation of successive castings, its operating length may be lengthened wheneverdesired by loosening the set-screw I! and forcing the rod downwardly within its holder. It will be found that castings produced by the process described herein do not require tempering as by re-heating and plunging in a cold liquid as they are sufiiciently hardened or tempered by the quick cooling effect of the metallic die 38. This sudden chilling of the molten metal on the end of the rod l6, furthermore, prevents it from sticking to the die, as is obvious, and as has previously been explained.

In the modification illustrated in Figs. 5 and 6, the metal or other material from which the casting is formed is preferably in the form of a disc or roller indicated at 6'1 and is detachably mounted in any manner on a separable or two-part shaft 68 the ends of which are journalled in opposite walls of the chamber. The casting in this case becomes a part of the peripheral edge of said disc or'roller. The shaft 68 is prevented from horizontal movement in one direction by a washer and set-screw indicated generally at 69 and the other end of the shaft is provided with a crank 10 for the purpose of rotating it.

An elongateddie is indicated at II and is slidable or movable of its longitudinal axis. It extends within suitable slots '12 formed in the body of the chamber which guide the die in its movement. Said die is grooved as at 13 in its face or side adjacent the disc or roller 81, said groove being formed with or containing the object or inscription etc. which it is desired to reproduce by a casting. A bracket 14 is fastened to a wall of the chamber and a bar or rod 15 is pivoted thereto, as by pivot 16. The upper end of said bar is connected by a pin and slot connection 11 to a detent slide or rod 18 extending through an opening in a wall of the housing which slidably supports it. The inner end of said detent slide normally engages beneath the end of the die H to hold it in the inoperative or retracted position shown in the drawings.

A rod 19 is secured to the upper end of the die H or it may be integral therewith. Secured to the said rod 19 is a cross-arm 80 and tension springs 8| are fastened to said cross-arm adjacent its ends and to an upper wall of the cham her. The action of said springs Bl tend by their action to forcibly and expeditiously move the die ll downwardly within the slots 12 as is obvious.

The bar or rod 15 terminates at its lower end in a handle 82 and said bar or rod is connected by a pin and slot connection 83 to an angle bar, the horizontal leg of which is indicated at 84 while its vertical leg is indicated at 85. The vertical leg 85 may be supported by a pin or bolt 86 extending loosely therethrough and into the body of the housing and a compression spring 81 encircles said pin or bolt and bears against said leg and housing and tends by its action to retain said leg a spaced distance from said housing.

A pin and slot connection 88 connects the upper end of the leg to an electrode 89 slidably mounted in anzinsulated bushing 90 in a wall of thechamber, said pin and slot connection being surrounded by insulating material as in the previousrcase. A conductor 9| is connected to a source of. current supply (not shown) and to the outer. end of .electrode 89 while conductor 92 is connected to the same source of current supply and to a wall of the chamber.

. As in the previous case, the handle 82 is manipulated in the proper direction to bring the inner end of the electrode 89 into contact. with the periphery of the disc or roller 61 to establish an electrical circuit. It is then again manipulated slightly to space the roller from the end of the electrode whereby a heating electric arc is established to fuse the peripheral edge of the disc or roller. When the fusing of such edge has been completed and just before the fused metal falls of its own weight by gravity, the handle is swung in such manner as to release the detent 18 from engagement with the die or mold H which travels downwardly under the influence of springs 8| and the fused metal on the peripheral edges of the disc or roller 61 enters the groove (3 in the die to form the desired casting. The unfused and comparatively coolportion of the disc provides sufiicient pressure and resistance for the formation of the casting on the edge of the disc. Said disc, with the finished casting thereon, is then removed and a new one substituted for repetition of. the same operation. As in the previous case, the cool die prevents the fused metal on the edge of the disc from sticking thereto.

I have shown in this modification a device for feeding a powdered carbonized material to the fusing metal for hardening the metal and casting which obviously could be employed in the preferred form of apparatus, if so desired, and in fact it is preferred to so employ it. A hopper 93 for holding the powdered carbonized material 94 is fastened to a wall of the chamber by brackets 9'5. Thishopper interconnects with a feed tube 96 directed toward the peripheral edge of the disc or roller 61. The passageway between the hopper and tube may be open or closed by a handled spindle or plunger 97. Just as about the edge of the disc or roller 61 has reached fused. condition the carbonized material is permitted to fall thereon by opening the connection between the hopper and feed tube 96, while the disc or roller 61 is continuously rotated by the crank Ill.

This application is a division of my prior application for patent for Apparatus for producing castings, filed April 18, 1940, ser. 'No. 330,237, allowed June 3, 1942.

The invention claimed is:

1. The process 'of producing a metallic casting consisting in providing a solid mass of metal having substantially the same physical properties therethroughout and provided with a free and unsupported portion from which the casting is to be made, heating said unsupported portion of said metal to reduce the same to a molten state, bringing such molten portion of the metal into contact with a cooling die while it remains integral with the unmolten portion of the metal to suddenly chill it and simultaneously compressing the molten portion of the metal against the die by pressure applied by the unmolten portion of the metal to form a splash" casting integral with said unmolten portion conforming in configuration with the inner configuration of said cooling die.. V

-2. The process of producing a metallic casting consisting in providing a mass of. metal from which the casting is to be made and having substantially the same physical properties therethroughout, rotating said mass of metal, subjecting an edge portion of said metal to heat to reduce the same 'to a molten state, bringing the molten portion of the metal while integral with the unmolten portion thereof into contact with a cooling die to'suddenly chill it and simultaneously compressing the molten portion of the.

metal against the die by pressure applied by the unmolten portion of the metal to form a splas casting integral with said unmolten portion conforming in configuration with the inner confi uration of said cooling die.

3. The process of producing a casting consisting in providing a rod of metal from which the casting is to be made and having substantially the same physical properties therethroughout, subjecting an end of said metal rod to heat and reducing the same to molten condition, bringing the molten end of the rod downwardly into contact with a cooling die by mechanical means assisted by gravity while said molten end is integral with said rod simultaneously applying pressure to the unmolten body of the rod to compress the molten end against the die to form a splash casting conforming in configuration to the configuration of said cooling die and removing the casting so formed to retain the untreated portion of said rod for the production of successive castings by a like process.

1 4. The process of producing a casting consisting in providing a metallic rod having substantially the same physical properties therethroughout, subjecting an end of said rod to heat to fuse the same, forcing the fused end of said rod down wardly into contact with a cooling die while it remains integral with said rod, applying pressure tothe unfused body of the rod to force the fused end against said die to effect a sudden chillingof said iused end and form a splash casting on the end of the rod and-then removing the casting so formed from therhody of the rod to retain the untreated portion of said rod ,for the production of successive castings by a like process.

5. The process of producing a casting consisting in providing a metallic rod having substantially the same physical properties therethroughout, subjecting an end of said rod to fusing tem perature by the electric arc process while rotating said rod, discontinuing the heating and rotation of the rod when the end of the rod is reduced to a molten state and then subjecting the molten portion of the rod to the action of a forming and cooling die for suddenly-chilling it and shaping it into the desired form by pressure applied by the unfused portion of said rod while it remains integral with the body of the rod.

6. The process of producing a. casting consisting in providing a mass of metal having substantially the same physical properties therethroughout, subjecting an edge of said mass to fusing temperature while simultaneously applying powdered carbonized material to said fusing edge, forcing the fused metal so treated to enter a. cooling die and subjecting the fused metal within the die to pressure applied by the unfused portion of said mass.

7. The process of producing a casting consisting in providing a solid mass of metal having substantially the same physical properties therethroughout, subjecting a portion of said mass to fusing temperature within a partial vacuum and reducing such portion of the mass to a molten state, disposing the molten portion of the mass in a cooling die and simultaneously applying pressure to the unmolten portion of said mass to compress the molten portion within the die to form a splash casting integral with said unmolten portion.

8. The process of producing a casting consisting in providing a disc of metal, subjecting the periphery of said disc to fusing temperature while rotating said disc and moving a die into contact with the fused peripheral edge of said disc.

9. The process of producing a casting consisting in providing a mass of metal having substantially the same physical properties therethroughout and from a portion of which the casting is to be produced, rotating said mass, subjecting an edge portion thereof to heat, discontinuing said rotation and heating when said edge portion has been reduced to a molten condition, forcing said molten portion while it remains integral with the unmolten portion into contact with a cooling die and compressing said molten portion within the die by pressure applied thereagainst by said unmolten portion to suddenly chill said molten portion and to form a splash casting integral with said unmolten portion.

10. The process of producing a casting consist! ing in providing a metallic rod having substantially the same physical characteristics therethroughout and from an end of which the casting is to be produced, rotating said rod, subjecting an end of said rod to heat within a partial vacuum to reduce said end to molten condition while retaining the body of the rod in unmolten condition, discontinuing said rotation and heating and moving the rod to force the molten end thereof into contact with a cooling die to compress said molten end within said die by pres- 7 sure applied vthereagainst by said unmolten body to suddenly chill said unmolten portion and thereby form a splash casting on the end of said rod.

I JOSEPH E. JOHNSON.

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