US1454068A - Protective material for molds and method of forming the same - Google Patents

Description

, Patented May 8, 1923'.

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To all whom it may concern: Be it known that we, Hmsnn'r A. MYERS and ARTEEMES D. STRAW, citizens of the United States, andresidents of Toledo, Lucas 5 County, Ohio, and Wauseon, Fulton County, Ohio, have made an Invention Appertaining to Protective Material for Molds and Methods of Forming the Same; and we do hereby declare th following to be a full,-

clear, and exact description of the invention,

such as will enable others skilled in the art to which it appertains tomake and use the same. r i

The purpose of our invention is to provide a protective material for articles of different kinds used in handling or manipulating hot molten material. It particularly has for its object to enable'the rapid production of castings of metals having. relatively high melting points in permanent molds, especially the formation of ferrous metal castings in' iron molds. The protective materials embodying our invention may form alloys or mixtures within the articles with which they are used, and at the same time produce coatings on the articles that will form hard smooth surfaces. The protective 'materials or portions thereof may hav an affinity for and form alloys or mixtures with the material or materials of the articles to which they are applied, which will'produce exceedingly durable surfacing materials that will withstand a large number of applications of-the heated metal without deterio-t ration of the surfacing materials, and without injury to the article. In case of molds 1t will permit the rapid and continuous for nation of smooth, substantially perfect castmgs. 3 .a The composition ofmaterials utilized will fill-the pores of the mold, particularly of iron molds, and will form a coatinghaving a hard, compact, smooth surface that will resist erosion and will prevent pitting and blistering of the casting and pitting .01"

segregation of the materials of which the 'mold is composed.

Th alloying material slightly penetrates the molding surface and the coating pro duced is an exceedingly thin layer, about one-hundredth of an inch thick. The alloy and coatin may be formed or built up in the use of the article by frequent applications of a-suitable material or suitable mate- .parts'of the mold to be protected from the face of the-mold and a hard coating of iron,

mold contains, not considerin Application filed mum 30,1922. Serial no. 532,569.,

rials between the applications of the molten metalto the article, such as, in the case of a mold, between casting operations, utilizing the heat and the pressure of the molten metal that form the castings to heat compress and perfect the mixture and "produce its final protective condition, or the protective material may be applied in any manner and with the use of heat and pressure such as the heat and pressureproduced by the molten metal of one or more castings.

The protective material embodying our invention contains a metal having a low vaporizing or boiling point, thatis, broadly, a low gasifying point, such as zinc, zinc chloride, cadmium, barium, or bismuth,"a carbonaceous material and iron, from which may be formed, "first, alloys of mixtures of the metal with the iron'and' the-carbon within the surface of the article, and, secondly, coatings that contain mixtures of the oxide of the metal selected, carbon and iron, and a small amount of the metal thatmay alloy with th iron. The proportions of the ingredients of the materials; may be varied according to the'comp'osition of the mold, the metal or alloy'that is tob cast therein, and the physical and chemical characteristics to be produced in the casting. Particularly advantageous re'sultsare obtained when the protective material contains 'zinc'a'nd is deposited on iron articles,since zinc is {readily formed from its compounds and will adhere to or alloy with the ironand in the presence of air readily forms a coating containing zinc oxide on the surface ofthe articles. To cast ferrous metals in ferrous molds we find i't-preferable to place a layer containing zinc oxide and carbon over the molten metal and to utilize the iron of the 95 mold or of the casting, or both, to produce. an alloy or mixture containing iron, zinc and carbon that'is formed within the sur-- zinc oxide and carbon on the surface of the mold. The alloy or mixture that penetrates or is formed Within the surface of the mold and the coating on the mold maycontain these ingredients in various proportions. The alloy or mixture within" the surface of the impurities, about 3% to 5% of carbon, a out 50% to 60% of iron, and about 30% to 40% of zinc,

as f

and a small amount of zinc oxide. A sample mixture runs'about 4% of carbon, 50% of iron, 44% of zinc and a small amount of zinc oxide. The coating mixture contains about 5% to. 15% of carbon, 8% to 14% of iron, and the balance of zinc oxide, with a small amount of'zinc, ordinarily about 8% of carbon, 12% of iron, of zinc oxide, and the balance of zinc. The amount of the zinc varies, it being probably located at the point of union between the coating and the.

mold and indistinguishabl between the coating and the alloy in the mold. It possibly forms a sub-layer between the two and concoated, as just described, or it maybe my other suitable metal havmg vaporizing and boiling'points lower than that of the metal to be cast in the mold, and preferably one having an oxidizing oint in -atmospheric oxygen below the melting point of the metal to be cast. A layer of carbonaceous material, such as the products of an incomplete combustion flame produced from a hydrocarbon fluid fuel, such as acetylene or ordi- 118.13 fuel gas or carbureted gasolene or oil,; is e posited over the oxide. The mold is then filled with the molten metal from which the castings are to be formed. After the removal of the casting a succeeding layer of the metal oxide and carbon is again formed over the matrix and another casting is made. Upon removal of the casting another layer of the metallic oxide and a'layer of carbon is formed, and so on repeatedly until the protective material is suiiiciently built up on and formed in the mold. This is accomplished ordinarily after ten or twelve castings have been made in the mold.

In forming the protective material, deposits of carbonaceous materials may be omitted. If desired, layers of any wellknown heat insulating material, such as magnesia, may be deposited over the layers of metallic oxide, between each of thecastings in the preparation of the mold. Also the preparatory dipping or impregnation may be omitted, since the oxide may be reduced by the iron. or carbon or a reducing flame, and the metal thus released from its oxy en will alloy with or penetrate the mold.

T e deposition of the protective material on the mold may be accomplished in various ways, such as spraying the metal or one of marinas its oxides or saltson the mold. Also the material may be deposited by painting and, if need. be, mixtures with vehicles may be used. If desired, the mold'may be heated during the application of the metal. Also the metal or its, oxide or its salt may be deposited in a mixture of carbonaceous material on the mold in any suitable way, such as painting or spraying or dipping. The

.oxide, if used, may be subsequently reduced by heating the mold either by a suitable heater or by casting molten metal in the mold and the desired alloy or mixtures formed at or within the surface of the mold.

Also the preparatory impregnation of the mold may be accomplished by inserting the mold in a container of metal gas or directin as of the metal against the mold. If this is done in the presence of oxygen, oxide of the metal will be deposited. The amount of the oxide thus produced will vary according to the amount of concentration of the oxygen.

Inasmuch as the protective substances prevent adherence of metal to metal and to aluminous and cementitious materials, the protective composition may be formed on or incorporated in ladles, pots, troughs, or other articles formed of metal or of the said materials, orboth, and used in handling or manipulating molten iron.

The term mixture as used in the claims, covers broadly both alloys and mixtures.

We claim:

1. A container having metalincorporated therein and for containing molten metals,

and having a protective coating comprising carbon, iron, and an oxide of a metal gasifiable below the melting point of iron.

2. A container having metal incorporated therein and for containing molten metals, and havinga protective coating comprising carbon, iron, and zinc oxide.

3. A container having metal incorporated therein and for containing molten metals, and having a protective coating comprising from about 5% to 15% of carbon, 8% to 14% of iron, and zinc oxide.

4. A container having metal incorporated I therein and for containing molten metals, and having a protective coating comprising about 8% of carbon, 12% of iron, and 75% of zinc oxide. 7

5. A container having metal incorporated therein and for containing molten metals, and having a protective coating comprising from about 5% to 15% of carbon, 8% to 14% of iron, and an oxide of a metal, the

. gasifying point of the metal being below that of the melting point of iron.

6. container having metal incorporated therein and for containing molten metals,

and having a protective coating comprising about 8% of carbon, 12% of iron, and 75% of the oxide of a metal, the gasifying point I castings,

and 75% prising about 8 and 75% metal gasifiable below the melting point of iron.

8. container having iron incorporated therein and for containing molten ferrous metals, and .having a protective coating com prising carbon, iron, and zinc oxide.

9. container having iron incorporated therein and for containing molten ferrous 'metals, and having a protective coating com- 5% to 15% of carbon, 14% of iron, and zinc oxide.

iron incorporated prising from about 8% to 10. A containrhaving therein and for containing molten ferrous metals,

and having a protective coatin comprising. about 8% of carbon, 12% 0 iron,

of zinc oxide. 11. A container having iron incorporated therein and for containing molten ferrous metals, and having a protective coating comprising from about5% to 15% of carbon, 8% to 14% of'iron, and an-oxide of a metal,

" the gasifying point of the metal being below that of themeltin point of iron.

12. A container haying therein and for containing molten ferrous metals, and having a protective coating com.- of carbon, 12% of iron, of the oxide of a metal, the gasifying point of the metal being below that .of the melting point of iron. 13. A metal-containing mold for metal castings, and having a protective coating comprising. carbon,-.iron, and an oxide of a metal gasifiable below the melting point of iron.

14. A metal-containing and having a protective coating comprising carbon, iron, and zinc oxide.

15. A metal-containing mold for metal castings, and having a' protective coating comprising from about 5% to 15% of carbon, 8%"to 14% of iron, and zinc oxide.

16. A metal-containing mold for metal.

castings, and having a protective coating comprising about 8% of carbon, 12% ofiron,

and 75% of zinc oxide.

17. A metal-containing mold for metal castings, and having a protective coating comprising from about 5% to 15% of carbon, 8% to 14% of iron, and anfoxideof a castings,

metal, the gasifying point of themetal being below that of the melting point of iron.

18. A metal-containing mold for metal and having a protective coating of carbon, 12% of iron, and 7 5% of the oxide of a metal, the. asifying point of the metal being below t at of the melting point of iron.

19. A' mold containing iron for metal castcomprising about 8% point of iron.

iron incorporated mold for metal metals, and having'a protective coatiu prism carbon, iron, and an oxide of a metal gasifia 1e below the melting oint of iron.

20. A mold containing iron or metal castings, and having a protective coating comprising carbon, 113011, and zinc oxide. '2

' 21. A'mold containing iron for metal castcoating comings, and having a protective prising from about 5% to 15% of carbon, 8% to 14% of iron, and zinc oxide.

22. A mold o ntaimng iron about 8% of carbon, 12% of zinc oxide. f T

23. A mold containing ironfor castings, and having a protective coating comprising from about 5% to 15% of carbon, 8%- to 14% of iron, and an oxide of a nietal, the

asifying'point of the metal being below t at of the melting point of iron.

24. A -mold containing iron and having a protective coating comprising about 8% of carbon, 12% of iron, and 7 5% of the oxide of a metal, the gasif ing oint of the metal being below that oft e me ting 25. An iron mold metals, and having a prising carbon, iron, and an oxide of a metal gasifiable below the melting point of iron.

, 26. An iron mold for casting ferrous metals, prising carbon,

foi-

casting ferrous iron, and zinc oxide.

' 27. An iron mold for casting ferrousv and having a protective coating com- 5% to 15% of carbon, and zinc oxide.

metals, prising from about 8% to 14% of iron,

'ings, and having a protective coating comfor castings, and'having a protective coating comprisin of iron, and o for castings,

protective coating comand having a protective coating com-.

28. An iron mold for casting ferrous i metals, and having a protective coating com prising about,8%-of carbon, 12% of iron, and 75% ofzinc oxide.

29. An iron mold for' castingferrous metals, and having a protective coating comprising from about 5% to 15% of -carbon, 8% to 14% of iron, and an oxide of a metal,

the gasifying point-of the metal being below that of the melting point of iron. v

' 30. An iron mold for casting ferrous com- 8% of carbon,'12% 0 iron,

prising about the oxide of a metal, the gasifyand 75% of ing point of the the melting point of iron.

31. A container having metal incorporated therein and for containing molten metals,

metal being below that of and having a subsidiary protective material comprising carbon, iron, and zinc.

32. A container having metal incorporated therein and for'containingmolten metalsl,

and having a subsidiary protective materia comprising from about 3% to 5% of carbon 50% to 60% ,of iron, and 30% to 40% o zinc.

33." A container having metal incorporated therein and for containing molten metals,

and a subsidiary protective material comprising about 4% of carbon, 50% of iron, and44% ofzinc.

34. A container-having metal incorporated therein and for containing molten metals, and having a subsidiary protective material comprising from about 3%'to5% of carbon, 50% to 60% of'iron, and a metal having a gasifying point below that of the melting point of iron.

35. A container having metal incorporated therein and for-containing molten metals, and having a subsidiary protective material comprising 4% of carbon, 50% of iron, and 44% of a metal having a gasifying pointbelow that of the melting point of iron.

36. A metal containing mold for metal castings, and having a subsidiary protective material comprising from about 3% to 5% of carbon, 50% to 60% of iron, and 30% to 40% of zinc.

37. A metal containing mold for metal castings, and having a subsidiary protective material comprising about 4% of carbon,

50% of iron, and 44% of zinc.

38. A metal containing mold for metal castings, and having a subsidiary protective material comprising from about 3% to 5% of carbon, 50% to 60% of iron, and a metal having a gasifying point below that of the melting point. of iron.

A metal containing mold for metal castings, and having a subsidiary protective material comprising about 4% of carbon,

" 50% of iron, and 44% of a metal having a gasifying point below that of the melting point of iron.

40. A mold containing iron for metal castings, and having a subsidiary protective material comprising carbon, iron, and a metal gasifiable below the melting pointv of iron.

41. A mold containing iron for metal castings, and having a subsidiary protective material comprising carbon, iron, and zinc.

42. A mold containing iron for metal castings, and having a subsidiary protective material comprising from about 3% to 5% of carbon, 50% to 60% of iron, and 30% to 40% of zinc.

43.-A mold containing iron for castings, and having a subsidiary protective material comprising about 4% of carbon, 50% of iron, and 44% of zinc.

44. A mold containing iron for castings, and having a subsidiary protective material comprising from about 3% to 5% of carbon, 50% to 60% of iron, and a metal having a gasiiying point below that of the melt ing point of iron. i

45. A mold containing iron for castings, and having a subsidiary protective material comprising about 4% of carbon, 50% of iron, and 44% of a metal having a gasifying point below that of the melting point of iron. Q

a gasitying inaaoee 46. A container having metal incorporated therein and forcontaining molten metals, and having a protective mixture incorporated within the surface of the container comprising carbon, and a metal gasifiable below the melting point of iron.

47. A container having metal incorporated therein and for containing molten metals, and having a protective mixture incorporated within the surface of the container comprising carbon and zinc.

48. A container having metal incorporated therein and for containing molten metals, and havinga protective mixture incorporated Within the surface of the container comprising from about 3% to 5% of carbon, 50% to 60% of iron, and 30% to 40% of zinc.

49. A container having metal incorporated therein and for containing molten metals, and having a protective mixture incorporated within the surface of the container comprising about 4% of carbon, 50% of iron, and 44% of zinc 50. A container having metal incorporated therein and for containing molten metals, and having a protective mixture incorporated within the surface of the containercomprising from about 3% to 5% of carbon, 50% to 60% of iron, and a metal having a gasiitying point below that of the melting point of iron.

51. A container having metal incorporated therein and for containing molten metals, and having a protective mixture incorporated ivithin the surface of the container comprising 4% of carbon, 50% of iron, and 44% of a metal having a gasifying point below that of the melting point of iron.

52. A container having iron incorporated therein and for containing molten ferrous metals, and having a subsidiary protective mixture incorporated within the surface of the container comprising about 4% of carbon, 50% of iron, and 44% of a metal having point below that of the melting point of iron.

53. A metal-containing mold for metal castings, and having a protective mixture incorporated within the surface of the mold comprising from about 3% to 5% of carbon, 50% to 60% of iron, and 30% to 40% of zinc.

54. A metal-containing mold for metal castings, and having a protective mixture incorporated Within the surface of the mold comprising about 4% of carbon, 50% of iron, and 44% of zinc.

55. A metal-containing mold for metal castings, and having a protective mixture incorpora-ted Within the surface of the mold comprising from about 3% to 5% of carbon, 50% to 60% of iron,-and a metal having a gasifying point below that of the melting castings, and having a protective mixture incorporated within the surface of the mold comprising about 4% of carbon, 50% of iron, and 44% of a metal having a gasifying point below that of the melting oint of 1-ron.

57 An iron mold for casting ferrous metals, and having a protective mlxture incorporated within the surface of the mold comprising carbon, iron, and a metal gasifiable below the melting point of iron, and a protective coating comprising carbon, iron and an oxide of a metal gasifiable below the meltin point of iron. 58. 11 iron mold for castin ferrous metals, and having a protective mlxture incorporated within the surface of the mold comprising carbon, iron, and zinc, and a protective coating comprising carbon, iron and 'zinc oxide.

59. An iron mold for casting ferrous metals and having a protective coating comprising from about 5% to 15% of carbon, 8% to 14% of iron and zinc oxide and a protective mixture incorporated within the surface .of the mold comprising from' about 3% tov 5% of carbon, 50% to 60% of iron and to 40% of zinc.

60. The process of forming a protective material for molds for casting metals, which comprises depositing on the mold layers of the oxide'of a metal that has a gasifying point below-the melting point of the metal of the casting, and of a carbonaceous material, and heating and compressing the coating materials. 7

61. The process of forming a protective material for molds for casting metals, which comprises depositing onthe mold layers of the oxide of a metal that has a gasifyin point below the melting point of the meta of the casting, and the products of an incomplete combustion flame produced from a hydrocarbon fuel, and heating and compressin the coating materials.

62. e process of forming a protective material for molds for casting metals, which comprises depositing on the mold lafyers'of' the oxide of zinc and. the products .0 an incomplete combustion flame produced from a hydrocarbon fuel.

q 63. The process of forming aprotective materialfor molds for casting metals, which consists in depositing on the mold a metal gasifiable at a temperature below the melting point of the metal of the casting, and depositing on the reviously deposited metal a layer of the oxi e of a metal that has a gasifyin point below the melting point of the meta of the'casting.

64. The process of forming a protective material foriron molds for, casting ferrous metals, which consists in depositing zinc on the mold, anddepositing on the mold layers of the oxide of zinc and of a carbonaceous material, and heating and compressin the coating materials.

65. he process of forming a protective material for iron molds for casting ferrous metals, which consists in depositin zinc on the mold, and depositing on the mo (1 layers of zinc oxide, and the products of an incomplete combustion flame produced from a hydrocarbon fuel, and heating and compressing the coating materials.

66. The process of forming a protective material for iron molds for casting ferrous metals, which consists in depositing zinc on the mold, and also depositing on the mold layers of zinc oxide, and the products of an incomplete combustion flame produced from a hydrocarbon fuel, and casting ferrous metals in the molds.

67. In the process of forming a protective material for iron molds for casting ferrous metals, which consists in depositing layers of theoxides of a metal and of a carbonaceous material on the molds. r

68. The process of forming a protective material for iron molds for casting ferrous metals, which consists in depositing layers of the oxides of a metal and of a carbonaceous material on the molds and heating and compressing the coating materials.

69. The process of forming a' protective material for iron molds for casting ferrous metals, which consists in depositing layers ceous material on the'molds and heating and compressing the coating materials by casting metal in the mold.

In testimony whereof, we have hereunto signed our names to this s ecification. I-IUBERT MYERS. .Allt'llill']MES D. STRA'W.

of the oxides of a metal and of a carbona-