 Break out

 Edge cracks
 Longitudinal cracks
 Primary scales
 Random surface defects arising due to fluctuations of
surfaces
 Variations in width
 Non-uniform thickness and flatness
 Non-uniform microstructure in either direction
 Segregation
 Slag particle sticking the surface- entrapment of lubricant
slag particle at the surface.
There are several defects which can be
found on a CC product. The defects in
the CC products arising during the
process of continuous casting of steel
can be classified as:

(i) surface defects, (ii) internal defects,

(iii) shape defects, (iv) mechanical
defects, and (v) deviations from the
prescribed chemical composition of
steel.
Surface defects can be longitudinal mid
face and corner cracks, transverse mid
face and corner cracks, and deep
oscillation marks. Internal defects can be
midway cracks, triple point cracks, centre
line cracks, diagonal cracks, centre
segregation and porosity, casting flux
inclusion, and blow holes. Shape defects
are rhombodity and longitudinal
depression ovality.
Introduction to Ingot Casting:

Molten steel from BOF/EAF is tapped into a teeming ladle.

Deoxidizers, decarburizes and alloying elements if required, are
added for the final finishing with respect to oxygen content and other
elements in steel. The steel may be degassed either before or during
casting.

Ingot casting is done in cast iron moulds having square, round or

polygon cross section.

Ingots with square cross section are used for rolling into billets, rails and
other structural sections.
Whereas, ingots with rectangular cross section
(also known as slab), are used for rolling into flat
products.
Round ingots are used for tube making.

Polygon ingots are used to produce tyres, wheels,

etc.

Typically an ingot weighing 5-20 tons for rolling,

whereas few hundred to 300 tons for forging.
Ingot Mold Type: (Cast Iron)

• Cast iron has good thermal shock

resistance.

• Cast iron has a different coefficient of

expansion from that of steel and hence the
mold shrinks away from the ingot face on
solidification, and thereby separation the two
readily.
• Inner walls of the mould are coated by tar
or fine carbon. The coated material
decomposes during solidification which
prevents sticking of solidified ingots with the
inner walls of the mold.
Molds are essentially of two types:
1. Wide end up or narrow end down as shown in figure 32.1 a)
2. Narrow end up or big end down as shown in figure 32.1 (b)

Figure (a) wide end up moulds (b) Narrow end up moulds

Mechanism of Solidification: (Macrostructure)

The grain macrostructure in ingots and most castings have three distinct
regions or zones:
1. Chill zone,

2. Columnar zone,

3. Equiaxed zone.

The image below depicts these zones of Killed steel.

• The metal next to the mould walls and bottom
is chilled by the cold mould surfaces. This is a thin
layer and is known as chill, shell or skin of an ingot
and has a fine equiaxed grains. Here is the
nucleation phase of the solidification process
takes place.

As more heat is removed the grains grow towards the

center of the casting. These are thin, long columns
that are perpendicular to the casting surface, which
are undesirable because they have anisotropic
properties. OR
• After the formation of initial chill layer further
solidification results in the formation of
dendrities which grow along their principal axis
perpendicular to the mould walls.

• Their lateral growth (on the sides) is restricted

due to the growth of adjoining dendrities giving
rise to elongated crystal. If the length of these is
appreciable is known as columnar structure
• In general columnar structure does not
extend to the centre of the ingot. The
central portion solidifies as equiaxed grains
of bigger sizes than those in the chill due to
slow cooling. These are desirable because
they have isotropic properties.

• One zone blends into the next gradually.

The extent of each zone varies with
composition and temperature of liquid
steel, mould design and its temperature at
the time of teeming.