US2072650A - Method for metalworking - Google Patents

Description

4 Sheets-Sheet 1 Jaw/v 5(l/MEZLE2. 52

J. SCHMELLER, 5R

METHOD FOR METALWORKING Original Filed April 30, 1930 w w na NA March 2, 1937.-

March 2, 1937. J, SCHMELLER. 5 2,072,650

METHOD FOR METALWORK I NG Original Filed April 30, 1953 4Sheets-Sheet 2 I //v VE/V r02 JOHN Sam 154 L 52, 52. 5r

March 2, 1937. J. SCHMELLER. SR

METHOD FOR METALWORKING 4 Sheets-Sheet 3 Jill l Original Filed April 30, 1930 //w//v r02: Joy/v SCH/ 454452, 52.

March 2, 1937. J. S CHMELLER, SR 2,072fi5fi METHOD FOR METALWORKING Original Filed April 50, 1930 4 Sheets-Sheetv 4 ,drraelvsrs Patented Mar. 2, 1937 UNITED STATES 2,072,650 METHOD .Fon ME'raLWonxmG John Schmeller, Sn, Lakewood, Ohio,

Schmeiler Holding Company,

a corporation of Ohio 448,740. Divided ary 12, 1934, Serial No.

5 Claim.

This invention, as indicated, relates to a method for metal working and product resulting therefrom. This application is a division of my application Serial No. 448,740, filed April 30, 1930.

6 More particularly, the invention relates to the method of working metal while in a molten condition in a furnace chamber, in such manner that the same may be deoxidized and mechanically worked upon so as to improve the grain l and fiber of the metal, free the same from impurities and entrapped particles of foreign matter, and improve acterlstics of the final product. The apparatus is especially adapted for the remelting of secondary l material and preparing the same in a single continuous operation for fabrication into articles of high quality. It may be used particularly with such metals as are readily oxidized, such as aluminum, but is also suitable for the treatment a of other .T-Z stals and may be used to advantage in the formation of alloys of various character. It .is readily adaptable for use with aluminum .or alloyed borings, turnings, sawings, filings, skimmings, drosses, or the like,

as material such as this for producing metal suitable for commercial fabrication into castings as a single continuous operation. The material may be cast into ingots, if desired, or may be fed back through the furnace chambers after withdrawinl 30 from the casting side of the furnace with any desired addition of material necessary to form a predetermined alloy. The method includes the reworking of aluminum stock of finely divided character such as is known commercially as "salso vage" or secondary" metal whichstockfrequently is mingled with oils and greases and particles of iron, and often includes material heavily oxidized. The invention is disclosed in connection with a furnace with agitating mechanism. To

40 the accomplishment of the foregoing and related ends, said invention, then, consists of the method and product hereinafter fully described and particularly pointed out in the claims.

The annexed drawings and the following description set forth in detail certain means and one mode of carrying out the invention, and one product resulting therefrom, such disclosed means, mode and product illustrating, however,

but several of various applications of the principle of the invention. i

In said annexed drawings: Figure 1 is a side elevation partially in section of a furnace installation embodying the principle 55 of my invention;

the density and physical charand may be used with PATENT OFFICE assignor to Cleveland, Ohio,

msos

(oi. 'zs-m FigureZisatopplanviewof shown in Figure l;

Figure 3 is a sectional plan view of the furnace the apparatus Figure 4 is a side elevation of thelgrid; Figureb is a top plan view of the grid; Figure 6 is an enlarged sectional detail view showing the grid attaching means; Figure 7 is a side elevation partially in section of a modified type of a furnace somewhat similar to that shown in Figure 1, wherein a communicating chamber is provided on each side of an agitating chamber;

Figure 8 is a plan view, partially in section, of the apparatus shown in Figure 'I;

Figure 9 is a plan view of a modified form of furnace structure; and

Figure 10 is a top plan grid- 1 As isclearly shown in Figures 1 and 8 of-the drawings, the furnace I comprises a brick structure formed of piers and arches and providing for each furnace unit, two closed furnace chambers 2, l, separated by a heavybrick wall and communicating with each other through a small conduit 4 adjacent the floor of said chambers. The reservoir sections of said furnace unit are shown as of substantially equal size although the proportions may be varied in accordance with special requirements or with the character of the stock and the rate of use of the product or other conditions. At a point above the level of the molten metal in said chambers, charging and skimming doors are provided.

While a single furnace unit might be provided, it has beenv found more economical to construct three or more furnace units in series in a single structure, as shown, which may be simultaneously operated by a crew of workmen more economicaliy than a single furnace unit or a series of independent furnaces. Likewise the operating mechanism for a series of furnace units may be more economically installed and the heat losses may be proportionately reduced. In the drawings, therefore, I have illustrated three furnace units in series. The units are each operatively distinct from the others and a diiierent alloymay be run in each chamber.

Each of said units is, divided centrally by a partition wall 5 so as to provide on one side a combined charging and agitating chamber 2 through which the metal stock is fed into the furnace and on the oppositeside with a heating chamber 3 for the reception and temperature control of the casting supply of molten metal.

view of a modified form kischargedthro sintothechar walllpretera bly extends from. Thus when metal stoc of the several ber m u w u w mefi mumm lemm m Mmmm m $13M mmt wmme e mwmmm wmmm wmmmmmmm m me l mm mm memm mmwmew hemmemmmm mmmmm W M MW mmfi m w .w mmmmmmmefidmmmmfimm me emme m mmmmwmm m mm H m m W e wmw mm mwm mmm m mmmmkmmmm M #1: M mmwmmm w mmmwu mum mm g. mm m led socket 80 is 40 wer end of the o d of the stirring rod ember is provided with notches Centrally oi the grid 1; beve provided through which the 10 erating s ll 01' the alitating device received. The lower en operating m to receive projections it upon a series .ll which have beveled sides .2 outwardly extending flanges 48. use the Irids with the o a rtures 01' plates are engaged with said of thearched chambers bed. An of the chamber I to permit at that end of the opening also constitutes event of a leak in the descri a. m i

with a miniting gases therethrouzh. Above inuin loss oi hes. the furnace said rods are each adapted to reciprocate between two maintain said rod in constant alignment e through said fume preterably fla on opposite sides of the square operating rod end'suitable lubricating device for 7 apertur ce root. iers are nged rollers ennsins in pa through the 18 ellarsingaideoci'theturnace beretoion desti' 'ed said rollers may be provided. 'Therod-is set an-'.

- gularly to provide for easy removal of oxide and aperture ii for attaching a lifting cable 52. Ad-

\ jacent the upper end of the rod an extension arm II is provided to which a grid depressing cable M is secured. The respective cables are passed about pulleys it, 56, secured to fixed supports above the rod and adjacent the roof of the furnace respectively and thence passed in opposite directions to a pair of sheave wheels '1, ll, mounted upon a shaft preferably located on a platform II above the level of the furnace roof. The shaft carrying the respective pairs of sheave wheels is oscillated by suitable mechanism shown in this instance as an electric motor '02 coupled with a' suitable reducing gear I! to a crank arm 04 which is joined by a connecting rod OI with a similar crank arm It on the oscillating shaft.

The proportions of the parts are such the-t the shaft will be rotated through approximately 90' with each complete rotation of the first mentloned crank arm. Each of the pairs of sheave wheels heretofore described is provided witha clutch member 61 on the oscillating shaft. The shifting bars (not shown) for the clutches are extended from the elevated platform to a position convenient to the furnace floor so that the operation of the clutches may be readiiy'controlled adjacent the charging side of the furnace. In addition to the sheave wheels heretofore described and the fixed pulleys, it is desirable to provide counterwcights for the grids and supporting arms and spring take-up means to prevent excessive strains uponthe mechanism. Accordingly, a spring II is inserted in the line. of the grid depressing cable and counterweight If is carried at the end of the grid elevating cable. .Ihe counterweight'is adapted to bear against a stirrup bar I! supported on a pair of springs ll which are secured to ailxed support It above the top range of motion of the counterweight seas to hold said bar in the path of movement of the counterweight vwhen the grid is drawn from the metal bath. The counterweights are guided upon a pair of bars 'I'l supported at each end in the frame of the operating mechanism and springs It on said bars serve as buffers. An adjusting pulley II is provided in the line of grid elevating cable preferably ported on a pair of arms If pivoted to the frame at a point adjacent the sheaves and supporting said pulley rearwardly in alignment therewith.

, Each of said pairs of frames is provided with "a stationary nut as through which the W end of a screw threaded rod 04 is adapted to engage. A handwheei is attached at the lower end of said rod whereby said pulley may be adjusted upwardly or downwardly to the necessary extent to lift the grid to any point desired with m to the liquid mass in the furnace chamber. Thus by turning the screw in one direction the grid may be fully withdrawn from the bath of liquid metal and held at a point above the charging opening of its furnace.

when adjusted in theopposite direction the grid may be forced to a considerable depth within the molten mass of metal as it reaches its lowest limit of motion in the charging side of the furnace. The spring provided in the grid depressing cable is put under tension as the grid is elevated and issrelieved of the larger part of such tension when the grid is lowered to its operative position. It also serves as a resilient safety device when the grid strikes an obstruction in its descent. Thuscomplete control of the agitating mechanism of the furnace is provided both as to the starting and stopping of the agitation and the position of the agitator with respect to the molten mass of metal may be readily adjusted. Through a suitable rheostat the motor speed of the operating device may be controlled and thus the rate of agitation maybe regulated. In the form of construction illustrated in Pigures and}, two pudd'ling or agitating chambers II I, III. are providedat a central position. Melting chambers I" and III are provided respectively on the opposite sides of the agitating chamintroducing metal in the form of large sections,

such as castings or plates or ingots; and having the same flow after melting-into the agitating chamber for the deoxidising and refining action, or such melting chambers, or either of them. selectively, may be used to receive the treated mass of metal from the agitating chamber and temper the same to the proper degreeof heat for fabrieating purposes. The. flow of the metal from either side may be controlled by means of plugs inserted in the communicating openings and by the amount of material introduced into or withdrawn from the respective chambers and the chamber on either side of the puddling chamber may be used for the'melting or casting charge of metal as may be preferred. The construction and action of the agitating mechanism is substantially the same as that previously described in connection with the device illustrated in Figures l, 2 and .3. Each of the chambers adjacent the puddllng chamber is provided withheatins means (not shown) through which oil or other heating medium is introduced in the furnace to maintain the ,metal at the desired degree of temperature. The furnace is shown as having an arch construction similar to tint shown in Figures l to 3. but obviously in either of the constructions the furnace may be built directly on. the ground without heating or safety means beneath the furnace floor.

The agitating chambers III and II! are open at their upper portions} the dividing wall I" extending only to a point a short distance above the metal bath and approximately to a level of the base of" the chargin doors. The charging ,doors IILI", sreofasiae' to permit the with- .drawal of the grid at either side.

Each of the melting charging chambers .is provided with a draw-off hole Iltand a spout] I I.

plugging" by means of a claybalh or the like, of i the opening from said chamber intothe puddling chamber. In the form of construction shown in Figure 9 of the drawings. two puddling chambers,

I I4, I I, are shown centrally of one side of the furnace, and a melting chamber is shown in the space at the'endof the furnace adjacent each of the respective puddling chambers. These melting chambers, Ill, III, communicate by means of an' opening adiacent the bottom thereof with the .puddling chamber, such opening I II being adapted to be plugged from the end of the chamber through'adoorintheendwall of suchmelting chamber These end doors Ill may be used as the charging doors or metal charged into the melting chamber may be placed therein through the ,6 side doors III. In addition to the melting chambers described, the furnace is provided with elongated melting chambers on the opposite side of tbe furnace. These chambers I22, I23, communicate with the agitating chambers through openings I24 adjacent the bottom of said chambers.

and also communicate with the end melting chambers H0, H1, through suitable openings in the bottom thereof. The walls III, lit, between the end and rearward melting chambers may extend only to a slight distance above the metal bath, so

that the heat within the several melting chambers-may extend continuously around the furnace'. Suitable'oil or gas burners may be employed to maintain the heat in the melting and casting chambers at any desired temperature.

Suitable tapping holes and spouts may be provided adjacent the several chambers.

Tbeapparatusdisclosedinl'igures'landiiis particularly suited for carrying on a continuous 26 process oi production of material suitable for commercial fabrication fromreadily oxidisable metalssuchasaluminumwithahighdegreeof speed and great economy of manufacture, and permits of the addition of finely divided material 30 directlyintothepuddlingchamberandtheadditionofheavyscrapthroughoneoftheauxiliary chambers in connection with such puddling chamber. Thus all classes of commercial secondary sources of raw material for aluminum manufacturemaybedrawnuponandthesupplyofmetal forthepuddlingandcastingchambersmaybe kept up to requirement by drawing upon any stock which may be available at the particular time of use.

4 In each of the instances illustrated substantially the entire quantity of metal in the puddling chamberisacteduponbythegridwhlchstrikes the metal with a heavy impact and forces subdivided pcrtions thereof through the apertures in the grid and carries loose particles through the interacting streams of molten metal and into the portions of the molten bath below the upper surface thereof so that the collected metal in the bottom of the puddling chamber may be brought into direct contact to freshly exposed particles of aluminmn and envelope and incorporate the same directly into such body through coalescence.

Theworkingofthemetalinthiswayhasa readily recognisable effect in improving the tenacity and strength of the fabricated material and the recovery of metal has been carried out commercially withashighorahigherdegreeof recoverythanordinaryfireassayofsampleswill showbecauseofthe greaterlosses caused in course of such assay through oxidation.

It will be noted that oxidation is prevented through the fact that the grease and oil and other combustible material carried with the charge of fine particles placed within the agitating chamber are gasified under conditions wherein .complete combustion is not effected and therefore reducing gases such as carbon-dioxide. carbon monoxide. hydrogen, and other gases are held as a blanket at slightly greater than atmospheric pressure above the surface of the bath of molten metal undergoing treatment. The agitating member rises above the surface of the bath for periods of time adequate for the cooling of the grid to such degree that its working emciency is not 7 impaired through substantially continuous use.

with the use of materials such as cast iron for the puddling apparatus, it is necessary to have a period of cooling substantially equal to the period of contact with the hot metal in order to prevent the undue heating of the puddling apparatus and the alloying of the same with the bath of molten aluminum, or other metal.

In the form of construction illustrated in Figure 10, a grid III of somewhat modified form is shown wherein the arms I82 are provided at their ends with sections iii of an outer flange which is thus not continuous, in order that fracture of the grid will not occur through undue expansion of the narrow marginal members.

It has heretofore'been proposed to puddle type metal and like low melting point metals by means of mechanism constantly immersed within the molten bath and this is commercially practicable because of the low temperatures involved. Where, however, high temperatures from l200 to 1600' l". are present in the furnace it will be readily understood that the ordinary mechanism for agitating the molten bath could not be employed as I it would not remain in operative condition for an adequate period to warrant its installation. Furthermore, the constant contact of an iron vessel with a bath of molten aluminum or of iron stirring devices with such, bath tends to alloy said iron with the aluminum introducing a factor which interferes with the quality of the finished product, as iron in excess is very harmful to the physical characteristics of the aluminum for fabricating purposes.

The present furnace, therefore, presents a structure wherein a non-metallic chamber is provided for the heating of readily oxidirable metals. and metals which readily form ferrous alloys, and at the same time is of adequate strength and equipped with safety chambers beneath the same so that no harmful or dangerous elements are involved in the commercial utilization of the same.

While the ducts connecting the chambers at either side of the puddling chamber with the puddling chamber have been shown adjacent the base of each of the chambers, and the floors of said chambers have been substantially on an equal level, it is to be understood that under certain circumstances it may be found desirable to have a supply chamber for the molten mass, at a higher level than that of the puddling chamber and the casting chamber for the device at a lower level. Such variations are to be understood as coming within the scope of any claims of suflicient breadth not to specifically exclude the same.

The product resulting from the working and sub-dividing of the molten metal mass, particularly of aluminum and its alloys has been found to be of a tenacity superior to that of any product which might be formed by other methods from the same identical class of material. Thus, if secondary material such as borlngs, ,turnings, filings, skimmings, and the like, are melted in an ordinary melting pot under the prwent practice, a large portion of such product will escape in the form of oxides and gases and the actual aluminum recovered will be but a small percentage of that found to be present in the raw material. with the applicantsapparatus and method of treatment, however, it has been found that the recovery of aluminum in the final product can be made equal to that shown to be in the raw material even when secondary material, carrying as low as fifteen (15) per cent of aluminum'ls employed Furthermore, through the use of this apparatus and method, metal in fabricated form can be produced in a single operation, from very low grade raw material. The 'metal, whether cast into finished articles or into ingots, after the drawing molten metal from the mass undergoing agitation into a separate chamber, controlling the temperature thereof to a degree requisite for fabricating purposes, and withdrawing molten thorough puddling it received in the apparatus metal from time to time for fabricating pur- 5 described, shows a great tenacity and. a fine poses, quality of grain such as can be produced only 3. In a method of reworking aluminum, the under most perfect conditions with substantial steps which consist of maintaining three separate laboratory facilities as compared with high speed masses of molten aluminum in communication commercial production. with one another in a. non-oxidizing atmosphere, it)

Other modes of applying the principle of my agitating one of said masses, adding finely divided invention may be employed instead of the one aluminum to the mass undergoing agitation, addexplained. c a being e a e a t e ing stock substantially free of oxides to one of the me n a d s p h r in i clos d, provi ed h other masses of metal, and withdrawing molten m an n steps stated y ny f h following metal from the third mass of metal for fabricat- 15 claims or the equivalent of such stated means ing purposes. and steps be employed. 4. In a method of reworking aluminum, the t I h f r p arly point out and dissteps which consist of maintaining three separate tinctly claim astray-invention: masses of molten aluminum in communication In a m t o o t t aluminum, t e steps with one another in a non-oxidizing atmosphere, 0 which consist of maintaining two separate masses agitating one of said masses, adding finely divided of molten aluminum in communication with one l mi t the mass undergoing agitation, add a oth r n a non-oxidizing mo p e, agitating ing heavy aluminum stock substantially free of One of Sa d ma Supplying material thereto oxides to the second of said other masses of 2 from the other 01 Said m ss W d fl metal, and withdrawing molten metal from the molten metal from the mass underg agitation third of said masses of metal for fabricating purinto a separate chamber, controlling the temp r thereof to a degree requisite f fabri- 5. In a method of treating aluminum, the steps cating Pu p and Withdrawing molten metal which consist of maintaining an intermediate from ime to t for fabricating p p mass of molten aluminum in communication with 30 2. In a method of treating aluminum, t ep an adjacent mass oi molten aluminum at each which consist of maintaining two separate masses id thereof thrgugh narrow k portigns of molten aluminum in c mm ni a i n wi h n jacent their base, agitating said intermediate another in a non-oxidizing atmosphere. agitating mass, supplying material through one of the other one of said mas s ppl n r m l d m t ria masses, and withdrawing material for fabricating 35 directly to said mass undergoing agitation and supplying molten aluminum to the mass undergoing agitation from the other of said masses, withpurposes from the other of said adjacent masses.

JOHN SCHMELILER, st.

CERTIFICATE OF CORRECTION.

Patent No. 2 072,650.

of the above numbered patent requiring correction as follows: first column, line 35, claim 2, 'for "remelted" March 2 1% JOHN SCHMELLER, SR.

It is hereby certified that error appears in the printed specification Page 5, read unmelted; and that the said Letters Patent should be read with this correction therein that the same may conform toithe record of the case in the Patent Office.

Signed and sealed this 20th day of April, A. D. 1937.

Henry Van lirsdale (Seal) Acting Commissioner of Patentsm ratus and method, metal in fabricated form can be produced in a single operation, from very low grade raw material. The 'metal, whether cast into finished articles or into ingots, after the drawing molten metal from the mass undergoing agitation into a separate chamber, controlling the temperature thereof to a degree requisite for fabricating purposes, and withdrawing molten thorough puddling it received in the apparatus metal from time to time for fabricating pur- 5 described, shows a great tenacity and. a fine poses, quality of grain such as can be produced only 3. In a method of reworking aluminum, the under most perfect conditions with substantial steps which consist of maintaining three separate laboratory facilities as compared with high speed masses of molten aluminum in communication commercial production. with one another in a. non-oxidizing atmosphere, it)

Other modes of applying the principle of my agitating one of said masses, adding finely divided invention may be employed instead of the one aluminum to the mass undergoing agitation, addexplained. c a being e a e a t e ing stock substantially free of oxides to one of the me n a d s p h r in i clos d, provi ed h other masses of metal, and withdrawing molten m an n steps stated y ny f h following metal from the third mass of metal for fabricat- 15 claims or the equivalent of such stated means ing purposes. and steps be employed. 4. In a method of reworking aluminum, the t I h f r p arly point out and dissteps which consist of maintaining three separate tinctly claim astray-invention: masses of molten aluminum in communication In a m t o o t t aluminum, t e steps with one another in a non-oxidizing atmosphere, 0 which consist of maintaining two separate masses agitating one of said masses, adding finely divided of molten aluminum in communication with one l mi t the mass undergoing agitation, add a oth r n a non-oxidizing mo p e, agitating ing heavy aluminum stock substantially free of One of Sa d ma Supplying material thereto oxides to the second of said other masses of 2 from the other 01 Said m ss W d fl metal, and withdrawing molten metal from the molten metal from the mass underg agitation third of said masses of metal for fabricating purinto a separate chamber, controlling the temp r thereof to a degree requisite f fabri- 5. In a method of treating aluminum, the steps cating Pu p and Withdrawing molten metal which consist of maintaining an intermediate from ime to t for fabricating p p mass of molten aluminum in communication with 30 2. In a method of treating aluminum, t ep an adjacent mass oi molten aluminum at each which consist of maintaining two separate masses id thereof thrgugh narrow k portigns of molten aluminum in c mm ni a i n wi h n jacent their base, agitating said intermediate another in a non-oxidizing atmosphere. agitating mass, supplying material through one of the other one of said mas s ppl n r m l d m t ria masses, and withdrawing material for fabricating 35 directly to said mass undergoing agitation and supplying molten aluminum to the mass undergoing agitation from the other of said masses, withpurposes from the other of said adjacent masses.

JOHN SCHMELILER, st.

CERTIFICATE OF CORRECTION.

Patent No. 2 072,650.

of the above numbered patent requiring correction as follows: first column, line 35, claim 2, 'for "remelted" March 2 1% JOHN SCHMELLER, SR.

It is hereby certified that error appears in the printed specification Page 5, read unmelted; and that the said Letters Patent should be read with this correction therein that the same may conform toithe record of the case in the Patent Office.

Signed and sealed this 20th day of April, A. D. 1937.

Henry Van lirsdale (Seal) Acting Commissioner of Patentsm

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