Continuous Casting

Introduction

➢ Very notion of continuous casting of steel dates back to Bessemer i.e

1860’s
➢

➢ It however proved to be quite practicable for non metals and alloys by

1937
➢

➢ First pilot plant continuous casting installation in Germany in 1943.

➢

➢ Production of continuous casting from first installation- 1980-30%

1990-65%,present-95%
Diagram of continuous casting system
Principle of continuous casting

➢ Continuous casting defined as teeming of liquid metal in a short mould

with a false bottom through which partially solidified ingot is
continuously withdrawn at the same rate at which metal is poured in
the mould.
➢

Diagram of continuous casting system

Equipments of continuous casting machine
➢ The Equipments for continuous casting of the steel consists of:-
1.Ladle to hold steel for teeming
2.The tundish to closely regulate the flow of steel in the mould
3.The mould to allow adequate solidification of the product.
4.The withdrawal rolls to pull out the ingot continuously from the mould.
5.The cooling sprays to solidify the ingot completely.
6.The bending and cutting devices to obtain hand able length of the
product.

➢
Mould Lubrication

➢ In the early days of continuous casting, moisture free rape seed oil
was almost extensively used as lubricant.

➢ Now mould fluxes have been developed and used to have smooth
casting operation.
➢

➢ It is added as powder in the mould over the liquid steel surface .It
melts in contact with liquid metal surfaces in the mould and provides
a safety cover which prevents atmosphere oxidation.
Mould lubrication
➢ Functions of mould flux are:-
1.Lubrication of strand
2.Transfer of heat from strand to mould wall
3.To minimise heat losses from the top surface.
4.Protect liquid steel from atmospheric oxidation.
5.Absorb non-metallic inclusions rising on the surface.
Casting Powder
Junghan’s Principle

1. Ratio of speeds=Downward Vm/Upward Vm=1:3

2.

3. Downward speed of the mould(Vm)=Withdrawal speed of cast(Vw)

4.

5. Vm<Vw(Tensile stresses will generate in entire mass-transverse cracks)

6.

7. Vm>Vw=Compressive stress(sound casting)=negative strip

Benefits of negative strip

• The crystallised strip of cast is further compacted
• Tensile stresses are prevented
• No transverse cracks
Defect in con-cast products

➢ By far formation of cracks is one of the most common and yet

avoidable defect in con-cast product.
➢

➢ Formation of cracks due to :-

• Pressure of tensile stresses due to reasons of cooling, stripping,

bending, Withdrawal rate, Tension ,Surface finish of the roller apron
withdrawal rolls, mould taper , mould wall surface finish, Mould
lubrication, Reoxidation of steel in open air and so on.

• Rhombodity=shape of cast product like a rhombus(d1-d2=degree of

rhombodity)
 Effect of composition of Casting Powder

V V
is is
c c
o 30 o 200 300
10 20 100
ci ci
t % Al2O3 in Casting Powder t Index for Longitudinal Cracks
y y
Consumption of Casting Powder

P
o
w Casting Speed m/min
d (Productivity)
e
r
Heal Time

Time required to form solid from liquid.

Where, a=Stroke Length

a=12mm

H
a=6mm
e
al
T
i
m Viscocity
e(
S
e
Decrease in Dendrites

Principle-1.Breaking of Dendrite tip occurs due to EMS.

2.Broken tip of dendrite acts as Nucleation site.
So ,dendrites are reduced
Solidification,Segregation
Types of EMS

1.Axial
Eg.Mukund Iron and Steel

2.Rotational
-More Effective
-Current can easily cut tip of dendrite
-Popular
-Good Forgeability

3.Helicoidal
-Normally used in Secondary Cooling Zone
-Not Popular
Nozzle Clogging

• If the liquid steel contains Alumina inclusions(Al-Killed steel).Alumina

Deposition takes place in the SEN(when no Ca treatment).
• So,Tundish cannot feed the mould.

Remedy
• Add Ca-Si lumps

• CaSi Ca + Si Si amount in metal increases,Si+O2=SiO2

CaO.Al2O3(Promotes Inclusions)
Products

Bloom Billet Slab Thin slab Thin strip

W=800-1300mm T≤70mm T≤3mm

≥150mm*150mm ≤150*150mm T=150-300mm

➢ Lowest ➢ Highest
(surface/volume) (surface/volume)

➢ More ➢ Lowest
segregation segregation

➢ Coarse ➢ Fine
dendrites
dendrites
Comparison of Ingot and Continuous Casting

Solidification Time Fast(Non-Equillibium) Slow(Equillibrium)

Dendrite Arm Spacing less More
Segregation(Coring) less More
Inclusion Entrapment More Less
Thermal stresses less More