US3783494A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of repetitively impacting small pieces of metal in order to produce a densified continuous body
Assignee: Republic Steel Corp
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Filing: 1971-07-21
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Granted: 1974-01-08
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Expires: 1991-07-21
Abstract
Abstract A method and apparatus for forming metal products from scrap or other small pieces. Pieces of scrap metal are bonded together by baling into bales of from 20 percent to 50 percent metal by volume. The bales are then heated from 1,200*F. to 2,350*F. and fed through a feed magazine into a harmonic impacting press. Deformation of bales prior to reaching the impacting station in the harmonic press is controlled by control of the press and by peripheral confinement of the bales prior to being fed into the impacting station in the press. There is also a disclosure of a means to fuse bales together through use of a thermal powder.
Inventors
- 👤 M Whalen
- 👤 J Malleck
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 20:11
CPC Classifications
B; B22; B22F; B22F8/00; Y; Y02; Y02P; Y02P10/00; Y02P10/20; Y02W; Y02W30/00; Y02W30/50; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49751; Y10T29/49753
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
108 words
The process of forming a metal body from small pieces of metal which have been secured together to define a workpiece said process comprising: a. feeding said workpiece while heated to from 1,200* F. to 2,350* F. along a feed path of travel to a work station; b. compressing said heated workpiece at the work station by repetitively impacting the workpiece to weld said pieces together thereby forming a product while maintaining the pieces in a solid state condition; and, c. controlling the deformation of said workpiece by forces transmitted from said station along said feed path by perimetrally constraining the workpiece at locations along said feed path.
Claim 2
Dependent Claim
108 words
The process of forming a metal body from small pieces of metal which have been secured together to define a workpiece said process comprising: a. feeding said workpiece while heated to from 1,200* F. to 2,350* F. along a feed path of travel to a work station; b. compressing said heated workpiece at the work station by repetitively impacting the workpiece to weld said pieces together thereby forming a product while maintaining the pieces in a solid state condition; and, c. controlling the deformation of said workpiece by forces transmitted from said station along said feed path by perimetrally constraining the workpiece at locations along said feed path.
Claim 3
Dependent Claim
23 words
The process of claim 1 wherein the perimetral constraint completely surrounds the workpiece in at least one plane transverse to said feed path.
Claim 4
Dependent Claim
17 words
The process of claim 1 wherein the compressing of the workpiece is accomplished with a harmonic press.
Claim 5
Dependent Claim
22 words
The process of claim 3 wherein the compressing is continued until the product is a firmly united, solid, unitary slab of metal.
Claim 6
Dependent Claim
50 words
The process of claim 1 wherein the feed path is defined by a magazine and a plurality of bales of pieces are positioned in the magazine and sequentially fed to said station to provide the workpiece such that the product produced is formed from more than one of the bales.
Claim 7
Dependent Claim
17 words
The process of claim 5 including the step of welding the bales together while in such magazine.
Claim 8
Dependent Claim
38 words
The process of claim 6 including the step of inserting quantities of thermal fusing material between bales in the magazine and thereafter effecting such welding by pressing the bales together in the magazine with said thermal material therebetween.
Claim 9
Independent Claim
129 words
The method of converting random-sized small pieces of steel to a steel body suitable for use in a manufacturing operation while maintaining the steel in a solid state comprising: a. baling the random-sized pieces and compacting the pieces until the bale is at least 20 to 65 percent solid; b. heating said bale to from 1,200*F. to 2,350*F.; c. feeding the bale along a feed path to a compression station; d. thereafter compressing the bale at the station by repetitively impacting the bale while perimetrally confining the bale in planes of impaction until a time when it becomes solid and substantially free of voids and then continuing to compress the solid bale; and, e. perimetrally confining the bale at a location along the feed path and near said station.
Claim 10
Independent Claim
129 words
The method of converting random-sized small pieces of steel to a steel body suitable for use in a manufacturing operation while maintaining the steel in a solid state comprising: a. baling the random-sized pieces and compacting the pieces until the bale is at least 20 to 65 percent solid; b. heating said bale to from 1,200*F. to 2,350*F.; c. feeding the bale along a feed path to a compression station; d. thereafter compressing the bale at the station by repetitively impacting the bale while perimetrally confining the bale in planes of impaction until a time when it becomes solid and substantially free of voids and then continuing to compress the solid bale; and, e. perimetrally confining the bale at a location along the feed path and near said station.
Claim 11
Dependent Claim
20 words
The method of claim 8 wherein the impaction is performed with a harmonic press having opposed platens and side restraints.
Claim 12
Dependent Claim
42 words
The method of claim 8 wherein the impaction is performed with a pair of opposed, oppositely-acting platens impacting opposed outer surfaces of the bale while other outer surfaces of the bale are confined against lateral outward movement as the bale is impacted.
Claim 13
Dependent Claim
48 words
The method of claim 8 wherein said bale is impacted with a platen achieving a rate of strain of at least 4 whereby the sharpness of the impaction blow permits inertia of rest of the bale to contribute to the minimization of longitudinal dissipation of its impact forces.
Claim 14
Dependent Claim
21 words
The method of claim 8 wherein the impaction is at rates of strain in accordance with the table of FIG. 12.
Claim 15
Dependent Claim
27 words
The method of claim 8 wherein the peripheral confinement is achieved with members that surround the bale in at least one plane transverse to said feed path.
Claim 16
Dependent Claim
38 words
The method of claim 13 wherein the members are tapered at angles of 5* tO 15* with said feed path and wherein said taper is inward in the direction of workpiece travel whereby the members act as funnels.
Claim 17
Dependent Claim
27 words
The method of claim 13 wherein the members are reciprocated in paths transverse to said feed path whereby to facilitate a feed portion of an impaction cycle.
Claim 18
Independent Claim
137 words
A method of forming a continuous body of solid metal from particulate metal, comprising: a. densifying particulate metal to form a porous body; b. progressively densifying said body by repetitively impacting said porous body in a press at a zone of impaction while said particles are confined against movement in at least one direction whereby said particles are welded together by molecular migration while kept in solid state condition, said forces being applied such that a pool of controlled size of substantially densified metal is formed closely adjacent to and in advance of said zone of impaction, said pool providing a supply of more thoroughly homogeneous, non-porous metal for the impaction zone to insure complete densification of the total body, said body being in the heated condition in the range of 1,200*F. to 2,350*F. during said impaction.
Claim 19
Independent Claim
137 words
A method of forming a continuous body of solid metal from particulate metal, comprising: a. densifying particulate metal to form a porous body; b. progressively densifying said body by repetitively impacting said porous body in a press at a zone of impaction while said particles are confined against movement in at least one direction whereby said particles are welded together by molecular migration while kept in solid state condition, said forces being applied such that a pool of controlled size of substantially densified metal is formed closely adjacent to and in advance of said zone of impaction, said pool providing a supply of more thoroughly homogeneous, non-porous metal for the impaction zone to insure complete densification of the total body, said body being in the heated condition in the range of 1,200*F. to 2,350*F. during said impaction.
Claim 20
Dependent Claim
25 words
The process of claim 16 wherein the size of said pool is controlled by adjusting the volume of particulate metal flowing through said impaction zone.
Claim 21
Dependent Claim
88 words
The process of claim 17 wherein said press includes at least one compressive member and the size of said pool is also controlled with said compressive member achieving a rate of strain from 4 to 12 calculated by the formula RS (V/BT) wherein: RS is rate of strain; V is the vector of member along a path normal to the feed path; T is the time the member is in engagement with the workpiece per cycle; and, B is the thickness of the workpiece compressed by the member.
Claim 22
Dependent Claim
87 words
The process of claim 16 wherein said press includes at least one compressive member and the size of said pool is controlled with said compressive member achieving a rate of strain from 4 to 12 calculated by one formual RS (V/BT) wherein: RS is rate of strain; V is the vector of member along a path normal to the feed path; T is the time the member is in engagement with the workpiece per cycle; and, B is the thickness of the workpiece compressed by the member.
Claim 23
Dependent Claim
40 words
The process of claim 19 wherein said press includes two compressive members and B equals one-half the workpiece thickness as measured in a plane intersecting a location in a moving workpiece wherein the workpiece has just reached substantially solid condition.
Claim 24
Dependent Claim
19 words
The process of claim 20 wherein compression is performed by compressive members which are anvils of a harmonic press.
Claim 25
Dependent Claim
43 words
A method as in claim 21 in which said anvils are carried by said press so as to have at least 60 percent of the working surface thereof offset to one side of a vertical line passing through the eccentric of said press.
Claim 26
Dependent Claim
144 words
A process of forming a metal body from small pieces of metal which have been secured together to define a workpiece, said process comprising the steps of: A. feeding said workpiece while heated to from 1,200*F. to 2, 350* along a feed path of travel to and through a work station in a substantially continuous manner; b. applying compressive welding forces to said heated workpiece at said work station by repetitively impacting the workpiece, said forces being applied in directions transverse to said feed path, c. perimetrically confining portions of said workpiece in and near said work station during the application of said forces to control the deformation of the workpiece and to establish a controlled pool of substantially densified metal disposed closely adjacent and in advance of said work station; and, d. said workpiece being maintained in solid state condition during said proceSs.
Claim 27
Dependent Claim
144 words
A process of forming a metal body from small pieces of metal which have been secured together to define a workpiece, said process comprising the steps of: A. feeding said workpiece while heated to from 1,200*F. to 2, 350* along a feed path of travel to and through a work station in a substantially continuous manner; b. applying compressive welding forces to said heated workpiece at said work station by repetitively impacting the workpiece, said forces being applied in directions transverse to said feed path, c. perimetrically confining portions of said workpiece in and near said work station during the application of said forces to control the deformation of the workpiece and to establish a controlled pool of substantially densified metal disposed closely adjacent and in advance of said work station; and, d. said workpiece being maintained in solid state condition during said proceSs.
Claim 28
Independent Claim
140 words
A method of forming a continuous body of solid metal from pieces of particulate metal which have been secured together as a workpiece and heated to a temperature at which the pieces are still in solid state condition, comprising the steps of: a. feeding the heated workpiece along a path of travel to and through a work station in a substantially continuous manner; b. perimetrically confining portions of the heated workpiece in and near said work station to restrain expansion of the workpiece in directions transverse to said feed path and repetitively impacting portions of the workpiece in said work station in order to apply compressive welding forces in directions transverse to said feed path to weld the pieces into a solid homogeneous mass and to establish a pool of substantially densified metal is in advance of said work station.
Claim 29
Independent Claim
140 words
A method of forming a continuous body of solid metal from pieces of particulate metal which have been secured together as a workpiece and heated to a temperature at which the pieces are still in solid state condition, comprising the steps of: a. feeding the heated workpiece along a path of travel to and through a work station in a substantially continuous manner; b. perimetrically confining portions of the heated workpiece in and near said work station to restrain expansion of the workpiece in directions transverse to said feed path and repetitively impacting portions of the workpiece in said work station in order to apply compressive welding forces in directions transverse to said feed path to weld the pieces into a solid homogeneous mass and to establish a pool of substantially densified metal is in advance of said work station.
Claim 30
Dependent Claim
40 words
The method of claim 24 wherein said compressive welding forces are applied by oppositely acting relatively moveable platens which engage opposite sides of the workpiece to compress the workpiece and to effect feeding of the workpiece through the work station.
Claim 31
Dependent Claim
24 words
The method of claim 25 wherein the size of said pool is controlled, at least in part, by controlling the movement of said platens.
Claim 32
Dependent Claim
31 words
The method of claim 25 wherein said platens are constrained to move along substantially elliptical paths having major axes which extend longitudinally relative to the path of travel of the workpiece.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1977-01-07 | 1977-07-09 | 1978-01-08 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1981-01-07 | 1981-07-09 | 1982-01-08 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1985-01-07 | 1985-07-09 | 1986-01-08 | $7700.00 | Window Closed / Lapsed |