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March 22, 1932-
D.’ s. CONNEILLY ET AL '
1,850,743
METHOD OF CASTING PRODUCTS EMBODYING- MATERIAL OF LOW SPECIFIC GRAVITY
Filed March 25. 1931
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' p. a comgzgy
, Z’ J Hal/212
1,850,743
Patented Mar. 22, 1932
UNITED STATES PATENT OFFICE
DONALD S. GONNELLY, OF WOOSTEB, AND THEODORE I’. HATER, OF CARTON, OHIO, .AS- ‘
SIGNOBS ‘1'0 WOOB'I'ER PRODUCTS INC, 01' WOOSTEB, OHIO, A CORPORATION OF OHIO
‘METHOD OF CASTING .ZPBODUCTS monme
0! LOW SPECIFIC GRAVITY
Application mm ma a5, 1931. semi 110. 525,128.
The invention relates to a method of pro
ducing' cast bodies bodily incorporating
zones of relatively low speci?c gravity ma
terial.
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lsr’lplstantially distributed throughout the cast
y.
These and other objects are attained by the
improved method comprisin the present in
More particularly, the invention relates to vention, as will be hereina er pointed out
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a method of producing cast metal stair treads, in detail.
embodying segregations of comminuted abra
sive or wear-resistant material. ‘ '
In general terms, the invention consists in
sp '
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abrasive or wear-resistant mate
Stair treads which are in common use are rial over the bottom surface of‘ the mold
10 usually provided with a coating or wearing cavity in which the product is to be cast,
surface of abrasive or wear-resistant mate spraying said abrasive material with a suit
rial. A common method of producing such able binder, suspending a preferably per
stair treads is to sprinkle the surface of the forated plate adhesively coated with abrasive
mold in which the tread is to be cast with or wear-resistant material in the mold cavity
15 comminuted resistant material, spray the re
in spaced preferably parallel relation to said
sistant material with a suitable binder, and bottom surface‘ thereof, anchoring said plate
then pour the casting.
.
Stair treads produced by this method how
ever, present a wear-resistant coating, the
20 particles of which are rapidly dislodged or
=worn 0E in use, and the more or less pure
cast metal next encountered does not possess
the necessary frictional and wear-resistant
qualities.
against displacement, and pouring molten
metal into the mold cavity.
A. preferred embodiment of the present
invention is illustrated in the accompanying 70
drawings, in which
Figure 1, is a fragmentary cross sectional
view of a mold prior to the casting of the
product therein, showing a plate coated with
Itis therefore desirable to provide a cast abrasiveior wear-resistant material suspend
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stair tread containing comminuted wear-re ed in the mold cavity;
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Fig. 2 is a detached fragmentary
sistant material distributed throughout the
same, but a satisfactory method of making tive view of the plate partially coated with
the same has not, to our knowledge. been abrasive on wear-resistant material; and
known in the past. The di?iculty arises in' Fig. 3 is a. fragmentary cross sectional view
i
that when the molten metal is poured into of the ?nished product.
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Similar numerals refer to similar parts
the mold, wear-resistant material which is
throughout
the drawings.
free to move, will rise to the top of the mold
The invention may be carried out by em
because of its relatively low speci?c gravity.
Accordingly, it is an object of the present ploying an ordinary mold as shown in Fig.
invention to provide a method of producing 1, having the cope 10 and the drag 11. The '
a casting having -, comminuted abrasive or mold cavity 12 is preferably located in the
as shown, and has inlet and outlet gates
wear-resistant material substantially segre drag
13
and
14 respectively, communicating with
gated at desired zones in the casting.
the ends of the mold cavity.
Another object is to provide for substan
The cope may be provided with a pouring
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40
tially restricting the ?ow of and segregating sprue 15, communicating with the gate 13,
the comminuted material during the casting and with a riser 16 communicating with the
operation, by employing a medium of such gate 14. .
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character that the same will become substan
One or more plates, which may be approxi
tially fused and merged with the cast metal mately 28 gauge, low carbon steel, are pro
when the latter has become chilled.
vided for accomplishing segregation of the
,
A- still further object is to provide a meth
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abrasive or wear-resistant, material within
od of producing a casting having commi the cast product. For convenience, one plate
50 nuted abrasive or wear-resistant material 17 is shown in the drawings.
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2
‘1,850,743
This plate is preferably perforated as
shown, and adapted to be anchored against
displacement in the mold cavity during cast
ing. Before insertion into the mold cavity,
i the pouring sprue 15 into the mold cavity 12 i
and allowed to chill.
When the molten metal enters-the molten
cavity through the’ gate 13, it ?rst ?ows under
plate '17 and over the bottom of the mold
however, the plate 17 is thoroughly coated on the
cavity.
As the binder holding the abrasive
all surfaces with comminuted abrasive or
18’ to the bottom 12’ becomes gasi
wear-resistant material as- indicated at 18, material
?ed,
some
of the particles of the abrasive will
such as carborundum, which may be applied befreed and
begin to rise, due to their rela
by using a- suitable adhesive, such as as
phaltum adhesive material.
The fusing point of the plate 17 is prefer
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tively low speci?c gravity.
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,
As the molten metal rises to the region or
zone of the adhcsively coated plate 17, its
ably'lower than that of the metal constituting heat
will also act upon the adhesive mate
casting,
which
metal
may
be
‘the body of the
rial
holding
the comminuted abrasive mate
cast iron, so that during the casting operation,
said plate will become substantially entirely rial 18 to the plate, to liberate some of the
80
particles of the abrasive material 18.
Since the plate 17 is secured to the cope
If desired, a fusible adhesive material, such
against bodily displacement, the pressure of
fused and merged with the molten metal.
as sodium silicate, may be used for coating
the plate 17 with carborundum, so that when
the casting is poured the adhesive will fuse
with the molten metal.
The plate 17 may be ‘anchored in the mold
the molten metal upon the underside of the
plate 17 would ordinarily tend to warp the
plate, but theperforations permit some of
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‘the molten metal to be forced up through- the
cavity immediately adjacent the bottom sur plate, with the result that any substantial
face thereof, or suspended and anchored in warping of the plate is obviated. ‘
It will be “understood that since the metal
the cavity in spaced relation to said bottom
surface, as shown in Fig. 1. This may be plate 17 is relatively cold‘, its effect will be
accomplished by any convenient means, as to chillthe molten metal in its immediate
by punching tangs 20 out of the plate for con zone more quickly than the surrounding
tacting with the cope of the moldto properly metal, with the result that the molten metal
space the plate therefrom; and by providing becomes pasty and more or less quiescent in
holes 21 in the plate 17, ‘through which the zone of the plate, in a relatively short
foundry nails 22 may be driven into the cope time. Consequently, the upward flow of a
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for securing the plate thereto against dis substantial part of the particles ofabrasive
material 18 is restricted, since these particles
placement during the casting operation.
Preferably-r, the plate 17 is of such dimen
are caught in the zone of pasty metal.
However, a certain proportion of the par
sions as to have its ends spaced from the ends
of the mold cavity, as shown at 23 and 24, ticles of abrasive material 18 will rise up
when the plate is positioned in the. mold wardly a substantial distance before the
molten metal in the zone of the plate 17 be
cavity.
I
.
If a plurality of plates 17 are used they comes suf?ciently pasty to restrict the up
may be suspended and anchored in a similar _ ward ?ow of those particles.
.
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Likewise, a certain proportion of the par-v
ticles
of abrasive material 18’ will rise to
cavity.
,
_ Tn carrying out the invention, the mold ward the plate 17 , but a'substantial portion
cavity 12 is formed in the drag 11 in the usual thereof will be retained at the bottom of the
manner. The bottom surface 12-’ of the cav mold cavity until the iron becomes su?icient
_ manner at vertically spaced lntervals in the
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* ity 12 is then sprayed with a suitable binder ly pasty to restrict their upward ?ow. Thus
such as asphaltum binder and the like, and the molten metal becomes intermingled with
comminuted abrasive material, which may be the abrasive or low speci?c gravity material. 11
As aforesaid, the character and thicknes
carborundum, is sprinkled over the sprayed
of
the plate 17 is such that it becomes sub
bottom surface as indicated at 18’. The bot
tom of the mold cavity covered withthe com stantially entirely fused and merged with
minuted carborundum is again sprayed with the body of the casting by the time the same
has become chilled.
the asphaltum binder.
i
The plate 17 adhesively coated with abra
The casting 25, shown in cross section
sive or wear-resistant material is then se Fig. 3, is produced by the improved method
cured to the underside of the cope, in a man' using a. single plate 17. The segregated zone
ner previously described. The cope is placed 26 of abrasive material at the outer surface
in position on the drag, andthe plate 17 is of the casting corresponds in location to the
thus suspended in spaced preferably parallel bottom surface of the mold cavity, and the
_ relation to the bottom surface 12’ of the‘ segregated zone 27 of abrasive material cor
mold cavity, and has its ends spaced from the responds to the relative location of the
plate 17.
_
ends of the mold cavity.
“5.
The molten'metal is then poured through
The density of the zone 27 shades off or
ll
1,850,74é
3
,
diminishes toward the upper surface of the ci?c gravity material, anchoring a. fusible
casting as viewed in Fig. 3, and the density medium adhesively coated with comminuted
of the 'zone 26 shades o? toward the zone 27, low speci?c gravity material in the mold
so that a substantial distribution of abrasive cavity in spaced relation to the bottom there
5 material is attained between the segregations of, and introducing molten metal into the 70
mold cavity.
.
.
thereof.
4.The
method
of
casting
products
bodily
In use, the zone 26 forms the surface to be
presented to wear, and when this surface be incorporating wear-resistant material, which
comes worn off, the metal next encountered includes forming a mold for the product to
o oifers substantial resistance to wear due to be cast,.adhesively coating thebottom of the 75
the bodily incorporated distributed particles mold cavity with comminuted wear-resistant
.
15
of abrasive material, although somewhat less material, suspending a fusible plate adhesive
wearing resistance than is possessed by the ly coated with comminuted wear-resistant
material in the mold cavity, anchoring said
outer skin 26.
lVhen the casting has become further worn plate against displacement, and introducing 80
off, the zone 27 is encountered which offers rel molten metal into, the mold cavity.
5. The method of casting products bodily
atively high resistance to wear, and the metal
incorporating
different materials, which in
beyond that zone still contains su?icient dis
tributed abrasive to o?er substantial and sat cludes coating a fusible medium with com 85
minuted material of relatively low speci?c
0 isfactory resistance to Wear.
Thus a casting is produced which possesses gravity, positioning the coated fusible medi~
wearing and frictional resistance substan— um in a mold cavity and spaced from the walls
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tially throughout, prolonging the life. of the thereof, and introducing molten metal into
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casting, and giving a more satisfactory per the mold cavity.
6. The method of casting products bodily
formance at every stage of its life.
It is apparent that by employing ‘a plu incorporating different materials, which in
cludes coating a fusible medium with com
rality of spaced plates adhesively coated with minuted
material of relatively low speci?c
wear-resistant material, wear-resistant ma
terial may be distributed substantially even gravity, positioning the coated fusible medi
ly throughout the casting to produce a cast um in a mold cavity'and spaced from the
product offering increased resistance to wear walls thereof, and introducing molten metal
under the coated fusible medium in the mold
throughout the body of the casting.
.
Obviously, a cast product having a highly cavity.
7. The method of casting products bodily
segregated outer skin of wear-resistant ma
terial may be produced by anchoring an im incorporating di?erent materials, which in
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cludes coating a fusible medium with com
?<"‘/ 'JVGCl plate coated with wear-resistant ma
tcrial immediately adjacent the bottom sur vminuted material of relatively low speci?c
face of the mold cavity before introducing the gravity, placing the coated medium in a mold
cavity, and intermingling molten metal with
molten metal.
It is to be understood that various modi?ca the low speci?c gravity material in the mold 105
tions may be made in carrying out the inven cavity.
In testimony that we claim the above, we
tion, without departing from the scope of
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have hereunto subscribed our names.
the appended claims.
We claim:
£5 .
.
l. The method of casting products bodily
incorporating wear-resistant material, which
DONALD S. CONNELLY.
THEODORE J. HAHN.
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includes forming a mold for the product to
be cast, suspending a fusible medium adhe
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sively coated with comminuted wear-resistant
material in the mold, anchoring said adhesive
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ly coated medium against displacement, and
introducing molten metal into the mold.
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2. The method of casting products bodily
incorporating wear-resistant material, which
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includes forming a mold for the product to be
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cast, suspending a perforated metallic plate
adhesively coated with comminuted wear-re
sistant material in the mold, anchoring said
adhesively coated plate against displacement,
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and introducing molten metal into the mold.
3. The method of casting products bodily
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incorporating low speci?c gravity material,
which includes forming a mold for the prod
not to be cast, adhesively coating the bottom
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of the mold cavity, with comminuted low spe~
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