Continuous Casting Skin Slab Defect
Continuous casting is an industrial process used to produce a wide range of materials from steel to aluminum and other metals. Continuous casting involves pouring molten metal into a heated mold, which then crystallizes the heated metal into a solid form. As the metal cools, it is continuously drawn out of the mold and transferred to a continuous casting machine. This machine then cuts the metal into slabs of desired shape and size. One of the common defects in the continuous casting process is skin slab defect.
Skin slab defect occurs when a portion of the slab is not completely filled with molten metal due to a problem in the continuous casting process. This problem can be caused by misaligned or improper mold temperature, low molten metal levels, uneven flow of molten metal, and different levels of cooling. A skin slab defect may appear on one or both sides of the slab and is often accompanied by excess slag or oxidation along the edges. This defect severely reduces the yield and quality of the final product.
When skin slab defect occurs, the material must be properly inspected and evaluated prior to cutting and finishing work. The defect area should be identified and analyzed as quickly as possible to determine the source of the defect. The source of the defect may be at the source of the molten metal, the mold itself, or the cooling process. Once the source of the problem is identified, corrective measures can be taken to ensure the defect does not reoccur and cause further quality losses.
In situations where the skin slab defect is detected at the finished product stage, the material may need to be scrapped. If scrap is not possible, a rework or repair process may be necessary to salvage the material. Depending on the size and scope of the defect, some of these repairs may be simple or others may be extremely complex and costly.
In order to avoid skin slab defect and the resulting costs of repair or scrap, care must be taken throughout the continuous casting process. Proper alignment and control of the mold temperatures, molten metal levels, and cooling aspect are essential for the successful creation of quality parts. Following these best practices will help to eliminate skin slab defects, extending the yield and the lifetime of finished products.
