Continuous casting is a process in which molten metal is poured or extruded through a water-cooled die into a long, solid strand of metal. The strand is then cooled, cut and reheated in a reheat furnace to prepare it for further processing, such as rolling or forging. Continuous casting is used to reduce the amount of energy and resources used in the manufacturing of metal products and to increase productivity.
Continuous casting is one of the most efficient and cost-effective ways to produce high quality, large volume metal products such as steel and iron bar, plate, strip and pipe. The process eliminates the need for much of the labor and energy required for more traditional processes such as ingot casting and forging. In continuous casting, molten steel is poured into a mold and then cooled by a slow-moving spray of water. The resulting solid strand is pulled, sometimes with help of induction or other heat sources, through the die to form the desired shape. The strand is then cut into lengths and reheated to increase ductility before it is rolled or forged.
Continuous casting has many advantages compared to other existing methods of manufacturing. The process is able to produce superior quality castings with greater strength, consistency and purity in less time and with fewer manpower requirements. This greatly reduces manufacturing costs, making continuous casting a more efficient and cost-effective alternative than traditional methods.
Continuous casting also has reduced scrap rates, as well as improved product quality, consistency and purity. The process uses significantly less energy and materials than other methods, resulting in lower overall production costs. The process is also much faster than traditional methods, reducing lead times for products and allowing for quicker delivery of finished parts.
Continuous casting is a versatile process that can be used for a variety of metal alloys. It is particularly popular for producing thin-gauge strip and wire, making it ideal for producing small parts for electronics, medical parts, automotive components and more. Continuous casting can also be used for larger components, such as construction beams, rebar and railroad tracks.
The process is also often used to produce small to medium-sized parts, such as gears, radius components and structural parts. Due to its superior temperature uniformity and control, many manufacturers use the process to produce intricate and highly detailed small parts that require precision.
