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    7continuous Casting

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    rushabhkhot

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    © All Rights Reserved
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    7continuous Casting

    Uploaded by

    rushabhkhot
    5 views10 pages

    Original Title

    7Continuous Casting

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    Copyright:

    © All Rights Reserved
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    5 views10 pages

    7continuous Casting

    Uploaded by

    rushabhkhot

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 10

    Continuous casting

    Continuous casting is a casting method, in which


    the steps of pouring, solidification and withdrawal
    (extraction) of the casting from an open end mold
    are carried out continuously.

    Cross-sectional dimensions of a continuous


    casting are constant along the casting length and
    they are determined only by the dimensions of the
    mold cavity.

    The length of a continuous casting is limited by 1


    the life time of the mold
    Continuous casting technology is used for both ferrous and non-
    ferrous alloys.

    Traditional continuous casting processes use stationary (or


    oscillating) molds, in which the solidified bar moves relative to the
    mold surface.

    Friction caused by the movement results in formation of micro-


    cracks and other defects in the surface regions of the casting.

    Lubricating oil supplied to the mold surface and self-lubricating


    graphite molds decrease the friction/sticking and reduce the
    defective surface zone.

    This defective zone is commonly machined (milled) prior to Rolling.


    2
    Depending on the mold position (vertical or horizontal) continuous
    casting machines may be vertical or horizontal
    3
    Steels are commonly cast in vertical continuous casting machines.

    Molten metal is continuously supplied from the ladle to the


    intermediate ladle (tundish) from which it is continuously poured
    into the mold at a controllable rate keeping the melt level at a
    constant position.

    The water-cooled copper mold (primary cooling zone) extracts the


    heat of the metal causing its solidification. The mold oscillates in
    order to prevent sticking with the casting.

    When the casting goes out from the mold it is cooled in the
    secondary cooling zone by water (or water with air) sprayed on the
    casting surface.

    Most of vertical continuous casting machines are equipped with


    4
    strand guide units bending the casting and changing its
    configuration from vertical to horizontal.
    The casting is continuously extracted from the mold by the
    withdrawal unit followed by a cut-off unit.

    The casting process begins from inserting a dummy (primary)


    bar into the mold.

    Then a molten metal is poured into the mold where it solidifies


    and grips the end of the dummy bar.

    The dummy bar is disconnected from the casting after passing


    the withdrawal unit.

    Direct Chill (DC) casting method is used for vertical semi-


    continuous casting of non-ferrous metals (Aluminum alloys,
    Copper alloys, Magnesium alloys).
    5
    6
    Horizontal continuous casting machine is generally
    used for casting non-ferrous alloys.

    Horizontal continuous casting in stationary mold with


    graphite water-cooled molds.

    Due to the water cooling (primary and secondary)


    solidification rate provided by continuous casting is
    higher than in other casting methods.

    Therefore continuous castings have more uniform


    and finer grain structure and enhanced mechanical
    7
    properties.
    Advantages of Continuous Casting

    (i) The process is economical than rolling

    (ii) up to 97-98 % casting yield.

    (iii) The process can be easily mechanized


    and thus unit labor cost is less.

    (iv) Casting surfaces are better.

    (v) Grain size and structure of the casting can8


    be easily controlled.
    Applications of Continuous Casting

    (i) It is used for casting materials such as brass,


    bronzes, zinc, copper, aluminium and its alloys,
    magnesium, carbon and alloys etc.

    (ii) Production of blooms, billets, slabs, sheets,


    copper bar etc.

    (iii) It can produce any shape of uniform cross-section


    such as round, rectangular, square, hexagonal, fluted
    9

    or gear toothed etc.


    10

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