SUNFLAG IRON & STEEL COMPANY

LIMITED

CONTINUOUS CASTING

Prepared by : Mr. K. K. Janotra

Approved by : Mr. D. D. Khonde
Released by : E&T Pillar

Release Date :
28/09/2018
Revision -2
CONTINUOUS CASTING PROCESS
Continuous casting of steel is entering a new era of
steel development process invented in the 1950s , with
respect to its increasing application in the production process.
Continuous casting of steel is process in which liquid steel is
continuously solidified in mould into multiple length.
 TYPES OF CASTING

Casting process is classified according to the application of

steel
1. CLOSED CASTING :-
During the closed stream casting, liquid metal is covered with refractory
material to avoid ingress of atmospheric air mainly O2 and N2. Liquid
metal stream to reach stability in tundish and mould especially in case of
aluminum killed steel to prevent formation of inclusion is the most
importance for clean steel making,

2. OPEN CASTING :-
During the open stream casting ,the liquid metal stream falls directly from
the collector nozzle of ladle to the tundish and from tundish to the mould.
The unprotected liquid steel stream picks up o2 and N2 from the
atmosphere which gets entrapped into the steel during casting.
 MAIN PARTS OF CASTING
MACHINE

1. TURRET.
2. LADDLE.
3. TUNDISH.
4. TUNDISH CAR.
5. PRIMARY COOLING .
6. MOULD OSCILLATION UNIT.
7. SECONDARY COOLING,
8. APRON CHAMBER
9. WITHDRAWAL UNIT.
10. GEGA CUTTER.
11. T.O.C.B
12. BILLET/BLOOM MARKING
MACHINE
 DEFECTS IN CASTING
Continuous casting of steel is process in which liquid steel is forced to
solidified in mould and apron chamber with primary and secondary
water as a medium.
Solidification takes place due to conduction, convection and radiation
hence lot of stresses are developed during casting at various
stages. More over during unbending of solidified steel it undergoes
strain at the point of unbending in the withdrawal unit. These factors
leads to casting defects
Defects are mainly classified depending on location, nature and
source of defect.

Based upon nature of defects , these are divided into three main
groups,

 Shape related defects

 Surface related defects

 Internal defects
 DEFECTS IN CASTING
Shape related defects

 Rohmboidity ,
 Bulging,
 Bend
 RHOMBOIDITY
A cast section that becomes a rhombus(An equilateral but not a right angled
parallelogram)is
called rhomboidity.

Sources of Defects Remedies

1. Uneven cooling in mould,
2. Non - uniform primary solidification of
shell, 1. Proper mould tube tapper,
3. Mould foot roller alignment, 2. Spray nozzle alignment,
4. High casting speed, 3. Control superheat,
5. High super heat, 4. Control casting speed,
6. Grossly misaligned spray cooling just 5. Check spray pattern,
below of mould, 6. Check foot roller alignment,
7. Maximum susceptible range is C % 7. Maintain cleaning mould life,
between 0.30 to 0.40% 8. Maintain mould water delta T 5-8 deg.
8. Deposition of water scale on mould cen.
outer wall,
 BULGING
A rounded swelling which distorts & otherwise flat surface,unusal increase/decrease in
size on surface.

Sources of Defects Remedies

1. Insufficient strand support after mould,

1. Change mould tube,
2. Weak & hot shell at mould exit,
2. Maintain primary & secondary cooling
3. Improper mold lubrication,
pattern,
4. Too high straightener pressure,
3. Adjust straightener pressure,
5. Non-uniform primary & secondary
4. Selection right mould powder to
cooling,
minimize friction ,
6. High casting speed,
5. Control casting speed & superheat.
7. High superheat,
6. Appron alingment to be done.
7. Selection of powder as per grade.
 BEND
Billet especially long or thin one from a straight form into a curve or
angular.

Sources of Defects Remedies

1. Too high straightener pressure,

1. Maintain primary & secondary cooling
2. Non-uniform primary & secondary pattern,
cooling,
2. Adjust straightener pressure,
3. High casting speed,
3. Control casting speed,
4. High superheat,
4. Control Superheat.
5. Alingment of roller table, pusher
5. Roller table alingment to be done.
&cooling bed.
 DEFECTS IN CASTING
Surface related defects

 Transverse Cracks
 Longitudinal Cracks
 Oscillation Mark
 Depression
 Slag patch
 Joint
 Blow holes,
 TRANSVERSE CRACKS
Transverse Cracks are defined as transverse or near transverse open crevice, when
concentration of residual stresses exceed.

Sources of Defects Remedies

1.
1. Excess mould cooling water,
2.
2. Too high localized cooling on surface,
3. Sticking of solidified shell on mould 3.
face,
4.
4. Excessive secondary cooling,
5. Large surface temperature gradient in 5.
the spray zone and straightening within
unfavorable range of temperature 6.
between 700*c & 900*c,
6. Positive strip operation of mould,
Reduce S / P& Cu,
Control excess cooling primary &
secondary,
Change mould tube,
Minimize friction in mould with help of
lubrication,
Before casting clean mould,
Maintain cooling cycle give
temperature of billet on surface was
above 900*at withdrawn,
 LONGITUDINAL CRACKS
Longitudinal Cracks-Cracks may be seen on the surface Longitudinal at mid face.

Sources of Defects Remedies

1. Types of lubrication used in mould, 1. Lower P ,S and increase MnS

2. Susceptibility increase with P & S , 2. Reduce super heat,
3. High corner radius, 3. Reduce casting speed,
4. Alignment of top zone and foot rolls 4. Change mould powder,
with respect to mould, 5. Maintain mold life.
5. High casting speed, 6. Proper alignment of foot roller and
6. High super heat, spray zone to be done.
 DEEP OSCILLATION MARK
Oscillation Mark -Its Appears like a Grooves perpendicular to the casting
direction.
Sources of Defects
1. High negative strip time,
2. Stroke length is too high,
3. Low viscosity powder,
4. Wrong frequency and casting speed
ratio,
5. Low casting speed,
6. Steel chemistry C around 0.10% more
prone, also in stainless steel,
Remedies
1. Maintain optimum stroke length And
required frequency,
2. Proper powder selection its used to
help minimize to friction,
3. Proper selection of powder.
4. Maintain negative strip time 0.14-0.22
sec.
5. Porper casting speed.
 DEPRESSION
Depression Marks-These are local deformations in the cast surface. If the thickness of
the mould flux film is small or non-existent, the solidifying shell may stick to the mould
& cause a tear in it. It may cause depression mark on billet.

Sources of Defects Remedies

1. Mould taper & life.
1. Control high super heat,
2. Secondary cooling not covering billet
properly, 2. Control high casting speed,
3. High super heat, 3. Check secondary cooling nozzle
alignment,
4. High casting speed,
4. Change mould tube,
5. Alignment of foot roller.
5. Foot roller alignment to be done.
 SLAG PATCHES
Slag Patch-The slag particles(non-metalic inclusion) visible on billet surface.

Sources of Defects Remedies

1. Errosion of SEN (slag entrapment)

1. Better Deoxidation practice,
2. Re-oxidation of steel,
2. Shrouding of ladle stream,
3. High Viscosity of casting powder.
3. Use better quality refractories,
4. High alumina contain in covering
4. Use flow modifiers in tundish,
powder,
5. Use of good quality casting powder.
5. Low steel level in tundish,
6. Quality of SEN.
6. Low quality refractories
 JOINTS
Joint- The partially discontinue of cast billet,become a joint at the surface on
billet.

Sources of Defects Remedies

1. Castability problem, flushing done in 1. Heat making at LHF/VD with proper care
running casting for inclusion floating.
2. AMLC fluctuation 2. Calibration & maintenance of AMLC.
3. Jerking in strand due to withdrawal. 3. Maintenance of withdrawal roller bearing.
 BLOWHOLES
Blow Holes-Evolution of gas during solidification of steel. Entrapment of gas
produces blow holes in the billet.

Sources of Defects Remedies

1.Excess mould lubrication,

1. Better deoxidation,
2.Mould powder entrapment,
2. Proper AL addition,
3.Residual slag,
3. Proper Ca-Si injection,
4.Control refractories erosion,
4. Avoid moisturizer fluxes,
5.Moisture in casting powder,
5. Preheating refractories,
6.Moisture in refractories,
 DEFECTS IN CASTING
Internal defects

 Off Corner Cracks

 Halfway Cracks
 Center Crack
 Star Crack
 Diagonal Cracks
 Piping ,
 Pinholes,
 Macro Inclusions
 Porosity/Center Looseness
 Flakes
 Inclusions.
 OFF-CORNER CRACKS
Off Corner Crack-In the transverse section of billets this type of cracks can be
observed around 15mm from corner and 4-6mm from the surface. This type of
cracks has a tendency to occur with deep depression marks and also with
oscillation marks.

Sources of Defects Remedies

1. Dependent on grade,(medium carbon
steel & sulphur steel) selection of
powder.
2. More friction between mould to shell,
3. Sulphur produce hot shortness during
billet straightening in withdrawal ,stress
developed on corner, sulphur deposit on
grain boundaries this grain boundaries
break or rupture,
4. Non - uniform cooling just below mould
1. Control S in liquid metal,
2. Proper selection of powder,
3. Mould taper and its life
4. Increasing the water of upper sprays
which will cool the strand and increase
the solid shell thickness.
 (Halfway) MID FACE CRACKS
Midway(Halfway) Cracks-They appear as dark lines running normal
to a given face in a region between the surface and the centerline.

Sources of Defects Remedies

1. Adjusting spray to minimize reheating,

1. High cooling temperature,
2. Maintain optimum casting speed,
2. Improper SEN centering,
3. Check for missing nozzles in spray
3. More casting speed,
cooling,
4. High super heat,
4. Low pouring temperature,
5. Improper mould powder,
5. Check mould lubrication,
6. Warm mould condition,
6. Control superheat.
 CENTRE CRACKS
Centre Crack-They are visible on billet centre like a line.

Sources of Defects Remedies

1. High casting speed,

1. Control Casting speed ,
2. High super heat,
2. Control super heat,
3. Too high straightener pressure,
3. Control straightener pressure,
4. High intensity of spray cooling,
4. Check spray intensity,
 STAR CRACKS
Star Crack-They are visible only on billet centre like star.

Sources of Defects Remedies

1. Irregular fracturing due to coarase

Austenite grain size near strand 1. Control straightning pressure,
surface, 2. Control super heat & casting speed.
2. Irregular secoundary cooling, 3. Control intensity of cooling,
3. High superheat & casting speed.
 DIAGONAL CRACKS
Diagonal Crack-Diagonal cracks run between the obtuse corners of a rhomboid
section. Sometimes these cracks may grow outwards towards the corners of the
billet to form longitudinal crack depending upon the magnitude of the strain and
the solid shell thickness.

Sources of Defects Remedies

1. Control super heat & casting speed.

1. Asymmetrical cooling in mold or spray,
2. Install foot rolls at bottom of mould and
2. Caused by high rhomboidity,
roller apron,
3. Misalignment between mould and roller,
3. Clean all chocked nozzle,
4. Uneven spraycooling.
4. Check mold life,
5. Apron alignment.
5. Check secondary flow,
6. High superheat & casting speed.
6. Check alignment of apron,
 PIPING
Piping-Piping is mainly a big cavity in the centre of the surface of the billet.

Sources of Defects Remedies

1. Fast solidification of steel, 1. Proper solidification of steel.

2. High casting speed, 2. Control Casting speed .
3. High intensity /non uniform of cooling, 3. Control superheat.
4. Hight temperature of liquid steel, 4. Uniform spray cooling.
 PIN HOLES
Pin Holes-Its a porosity occurs due to the dissolution of gases on billet surface.
Sources of Defects
1. Unsatisfactory deoxidation,
2. High O2 actvity in steel.
3. Gas evolution during melting or
solidification,
4. Moisture in casting powder and fluxes.,
Remedies
1. Gas level control O2,N2,H2,during
melting or proper cover of tundish,
2. Complete shrouding of steel stream to
avoid reoxidation
3. Use of dry casting powder and fluxes.
4. Proper deoxidation of steel during
melting,
 MACRO INCLUSION
Macro Inclusion-Inclusions are non metallic particles embedded in the steel
matrix.

Sources of Defects Remedies

1. Ensure ladle stream was proper

1. Powder entrapment, shrouding,
2. Re-oxidation of steel, 2. Control AMLC variation in mould,
3. Erosion of refractories material, 3. Use flow modifier in tundish, Reduce
4. Steel flow disturbance in tundish, casting speed at the end of cast,
5. Feo/Mno more than 1.2%, 4. LRF - final slag FeO-MnO less than
6. Too much fluctuation in mould, 1.2%,
5. Proper tundish sealing.
6. Use of low SiO2 refractory.
 POROSITY/CENTER LOOSENESS
Porosity/Centre Looseness-Mainly a cavity observed at the centre.

Sources of Defects Remedies

1. High superheat
1. Control Superheat below 50 deg cen.
2. High casting speed.
2. Control casting speed as per norms.
3. Uneven secondary cooling.
3. Uniform cooling.
4. No EMS.
4. Run EMS in all the heats.
 FLAKES
Flakes- are short, discontinuous internal fissures caused by stresses produced
by decreased solubility of hydrogen during cooling, also referred to as internal
hairline cracking or snow flakes.

Sources of Defects Remedies

1. High hydrogen in steel. 1. Hydrogen to be remove in VD.
2. Improper preheating of tundish. 2. Tundish preheating as per norms to
3. Use of Moist powder and fluxes. remove moisture.
3. Use of dry powder and fluxes.
 INCLUSION
Inclusion-This defects is when the molten metal containing non-metal poured in
mould.
Sources of Inclusion
Based on the source of Inclusions are classified
into i) Endogenous inclusions & ii) Exogenous
inclusions.
i) Endogenous inclusion like oxides (FeO,
Al2O3, SiO2, MnO, Al2O3.SiO2,FeO.Al2O3,
MgO.Al2O3), Sulphides(FeS, CaS, MnS, MgS,
Ce2S3), Oxysulphides(MnS.MnO,Al2O3.CaS,
etc), Nitirides(TiN, AlN, VN, BN etc.) etc, which
are already present in the liquid steel.
ii) Exogenous inclusions like slag, refractory
fragments, casting and covering powder, etc.
Remedies
1.Dam or turbo pad used in
tundish.
2. Mould level controled by AMLC.
3. Tundish level controled by operator.
4. Proper tundish drying and pre-heating
have to be done.
5. Proper SEN heating have to be done.
6. During casting, MEMS have to be in
working condition.
Thank you