Introduction
Continuous casting is the process in which molten metal is continuously poured into a mould where it is either solidified or left to semi-solidify for subsequent hot or cold working. Continuous casting has many advantages compared to traditional methods of casting metal, including increased casting speed, improved product quality, reduced labor costs and reduced manufacturing time. There are different types of continuous casting processes, but the clean steel continuous casting process is one of the most widely used and efficient.
Process
Clean steel continuous casting starts with the preparation of the liquid steel in a furnace. The steel is then continuously poured into an open-bottomed chilled mould and allowed to solidify as it moves along a swinging launder and/or casting rolls. The process uses a number of different techniques to ensure that the casting is as uniform and defect-free as possible. The first of these techniques is accurate levelling and mould maintenance.
The level of the molten metal must be consistent and the mould must be adequately cooled, bled of any voids, and free of any defects or inclusions. Once the mould is prepared, the next step is to reduce the level of oxygen and non-metallic inclusions present in the steel. To do this, degassing and/or desulphurisation agents are added to the steel. This helps create a cleaner and more uniform product, reducing the risk of ruptures, cracks, and other problems during the metal casting process.
The molten steel is then poured into the mould and allowed to solidify as it moves along a path controlled by the speed and direction of the casting rolls. The speed and direction of the casting rolls is then altered to produce the desired product shape, such as rounds, squares, slabs, or bars. During the solidification process, oxygen and other gases trapped within the steel are released which results in small voids being formed within the casting. These voids are then filled with a remelting agent, usually a flux-additive suchas aluminium, to minimise the impact on the product’s strength, integrity and overall appearance.
Finally, the cast product is cooled and allowed to solidify. The solidified metal is then cut into the desired sizes and shapes and sent to the finishing line.
Benefits
The clean steel continuous casting process offers many advantages over other metalcasting processes. Firstly, it is much faster than other methods as there is no interruption in the casting process, resulting in a faster and more efficient production rate. Secondly, it produces a higher quality product with fewer defects and a tighter tolerance. This ensures that products made with this method are of consistently high quality. Lastly, the process also reduces energy consumption as the steel is preheated before it is loaded into the mould and cooled immediately after casting.
Conclusion
The clean steel continuous casting process is a much faster and more efficient method of casting metal. It ensures that products made with the method are of consistently high quality and produce fewer defects. Additionally, it also reduces energy consumption and labour costs, making it a more economical choice of production. This is why the clean steel continuous casting process has become so popular in a variety of industries.
