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R G ,2 Rhymu/Vu RR/DEWHY Patented Dec Dec. 27, 1938. _ R. R. RIDG‘WAY 2,141,617 > BORON CARBIDE ALLOY AND METHOD OF MAKING THE SAME Filed June 10, 1936 /r G_ ,2 RHYMu/vu RR/DEWHY Patented Dec. 27, 1938 2,141,617 UNITE :IJ- STATES TENT .FFI 2,141,617 BORON CARBIDE ALLOY AND METHOD OF MAKING THE SAME Raymond R. Ridgway, Niagara Falls, N. Y., as signor to Norton Company, Worcester, Mass., in. corporation of Massachusetts Application June 10, 1936, Serial No. 84,474 7 Claims. (Cl. 75-136) This invention relates to a boron carbide alloy In accordance with this invention, I propose and to a method of making the same, and par to make the desired alloy by the electrical heating ticularly a boron rich boron carbide of controlled of reagent materials in a. resistance furnace and composition which is adapted for various indus by so controlling the composition of the charge trial uses. and the power input as to produce the desired In accordance with my prior Patent 1,897,214, product. This invention is based on the dis boron carbide having a continuous crystalline covery that if the boron oxide content of the structure free from parting planes of graphite furnace charge is increased over the stoichio and conforming substantially to the formula B40 metric requirements for making a composition - ' has been made in an electric resistance furnace corresponding with the formula 34C as set forth 10 by heating a properly proportioned mixture of in my prior patent, and if the power input is held boron trioxide and carbon to a temperature in the below a de?nite rate, then the product will con vicinity of 2400" C. at which the materials of the tain an excess of boron which. may be as high as . charge react to form boron carbide and carbon 85 or 90% of boron with the remainder carbon. monoxide. The pure material has approximately Since the optimum power input varies with the 15 the composition of 78.3% of boron and 21.7% of furnace construction and size, de?nite ?gures carbon. A product called boron carbide has also for the power input are necessarily specified with been marketed which has a carbon content great relation to the surface area of the resistor, as ly in excess of the theoretical requirements for noted below.' However, it may be generally stated B40 and which is considered to consist of a mix that the higher the power input, the richer will ture of boron carbide of unknown formula con be the carbon content and conversely, the lower taining a large excess of free graphite intimately the rate of energy input, the richer the boron con associated with the crystals of boron carbide. An tent of the boron carbide composition. analysis of one composition thus made heretofore The alloy may be made in a furnace of the type has approximated 50% of boron and 40% of car covered by my previous patent and which may bon as well as small amounts of impurities. be structurally arranged as shown in my prior Owing, however, to the presence of the free application Serial No. 50,932, filed November 1, graphite, this material has been wholly unsatis 1935. This preferred type of furnace is shown in factory far various industrial uses. For ex the accompanying drawing, wherein: ample, the presence of the ?akes of graphite Fig. l is a vertical central section of the fur 80 interspersed with the crystals of boron carbide nace; and has prevented the mixture from being molded Fig. 2 is a vertical section on the line 2-2 of into a shape of any utility such as is feasible with Fig. 1. the boron carbide made in accordance with my As illustrated, the furnace comprises a metal prior patent. ‘ casing having a cylindrical or peripheral wall ill In the metallurgical field, there is a demand of iron, aluminum or other suitable metal and for a material comprising boron which may be the two end walls 12 of similar material, which suitably employed in the deoxidation of molten are shaped and arranged to form a cylindrical metals, such as copper, and in the manufacture reaction chamber within which an electrical re of boron alloys; but the high content of free sistor is mounted substantially centrally or axial 40 graphite in the boron carbide and carbon mixture ly of the peripheral wall. For the purpose of heretofore made or the low content of boron in fastening the peripheral wall to the end walls, the the boron carbide of commerce formerly sold for former is provided with outstanding annular metallurgical purposes has made it diflicult to ?anges M at its two ends, thus forming a spool use such materials metallurgically. It is, there shaped structure. The end walls l2 are each fore, highly desirable to provide a boron carbide annular in shape and coextensive with the ?anges, alloy which is richer in boron than the products so that they may be readily fastened together. heretofore obtained. In order that the end walls l2 may be electri It is, accordingly, the primary object of this cally insulated from the peripheral portion 10 of invention to make a boron carbide alloy of a the casing, a gas tight insulation iii of asbestos or 50 high boron content and which has a controlled other suitable material is placed between the composition and to provide an economical and ?anges and the end walls. This insulation is efficient method of making the same. Further made annular in shape and located only adjacent objects will be apparent in the following disclo to the ?anges l4, since it is not needed at the sure. central portion of the furnace and particularly 55 2 2,141,617 because it is fusible at the high temperature of resistor rod 22 and be clamped tightly there the resistor. To facilitate assembly and loading against by means of suitable bolts and nuts. of the furnace charge, the end walls are made The electrode terminals are suitably fastened readily removable. They are fastened to the to these clamping members as by welding metal ?anges by the bolts i8 passing through aligned strips 46 thereon, so that the electric current openings in the metal parts and the asbestos may be readily transmitted from an outside ring therebetween and secured in place by the source of power to the resistor rod. It will be nuts IS. The various parts of the clamping bolts understood that various electrical apparatus well and nuts are also insulated from the metal parts known to those skilled in the art is to be em 10 by means of the insulating washers as well as ployed in connection with this furnace structure sleeves surrounding the bolts which may be made for transmitting the required electrical power to of any suitable material, such as asbestos. the furnace and regulating the same. Also, the The resistor 22 is mounted axially of the pe dimensions of the furnace chamber and the ripheral wall In and arranged to extend through length and cross sectional area of the resistor 15 the charge and project outwardly from each end rod will be so proportioned as to obtain the de of the casing. In order to support the resistor, sired electrical results. It is desirable in this each of the annular end walls i2 is provided with type of furnace that the graphite resistor be a cylindrical extension or hub 24 which has an su?lciently large relative to the size of the ingot outwardly extending ?ange 26. These parts form to be made that it will not be wholly consumed an annular trough within which cooling water or broken until the reaction has gone on for 20 may ?ow. Mounted within these cylindrical hubs a su?icient time. It may be observed that in 24 are graphite sleeves 30 which have been shaped making boron carbide the rod is protected to to ?t snugly therein and prevent the passage of a large extent by the moron carbide formed gases as well as to conduct heat to the water around it so that the boron oxide cannot con cooled trough wall 24. The graphite sleeves 30 in tact and react therewith. turn support the resistor rod 22 which is adapted The exposed ends of the resistor rod and the to carry the electrical current for heating the end walls l2 are kept cool by circulating water charge of material within the casing. This re through the hollow clamps and in the trough 24 sistor is preferably made of graphite, although it surrounding the sleeve 30. This may be readily 30 may be made of other suitable electrically con accomplished by means of the valved water pipes 30 ductive material depending upon the nature of 50 which communicate from a suitable source of the charge being treated. This graphite rod 22 water supply to the lower members of the clamps. is also shaped for accurate sliding ?t within the A pipe 5| connects the upper clamp with the sleeves 30 so as to' provide a gas tight joint and lower member, and from each of the upper clamps a heat conducting path. Thus the sleeve 30 a further pipe 52 carries water to the branch arm 35 serves as an enlargement on the end of the high 53 where the water escapes through perforations temperature rod 22 which may be water cooled into the upper portion of the trough 24. Like su?iciently at its outer surface so that it may wis'e an extension of the pipe 52 communicates be supported on the metal wall of the hub 24 with the pipes 55 which extend longitudinally of and in turn cool the exposed end of the resistor the cylindrical wall ill and near the top thereof.
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