Continuous Casting Report

Report on
CONTINUOUS CASTING
PREPARED BY :
AKRITI KUMARI
114/16
COURSE: MANUFACTURING ENGINEERING
SUBJECT: TECHNOLOGY OF SPECIAL FOUNDRY
PROCESS.
National Institute Of Foundry And Forge Technology, Hatia ,

Ranchi, Jharkhand-834003
Continuous casting
This process was conceived by BESSEMER in 1858’s & gained popularity during
1960’s.
It is also called strand casting, process &it was first developed for casting non ferrous
metal strips. Now it is used for steel production with major improvement in
efficiency & productivity with significant cost reduction.
• It is process used to produce billets, blooms or slabs much longer in

length than obtained by any other process. In this process molten metal
gets gradually solidified as it is poured. The section obtained is then
subsequently rolled in rolling mills.
• Round ingots, slabs, square billets, hex billets can be produced by

continuous casting process directly from molten metal.
• This process has high efficiency & gives end product in single step.
• It requires more process control & high quality inputs.
• In this process molten metal is transferred from a holding furnace into

a special label called tundish. Molten metal from the tundish is poured
into the top of the bottomless graphite mould of desired shape.
• The mould is open at both ends and is kept filled at all times.
• Metal at the lower end of the mould is cooled so that is solidifies & the
solid product thus formed is extracted in a continuous length from its
lower end.
• There are several variant process like Williams process, hazelett process
& Asarco process.
• The Asarco process is the most popular one.

• In Williams process for producing the continuous steel casting, a water
cooled thin walled brass mould with oval cross section is employed
instead of the graphite mould.
• The more popular variants are the vertical type & the horizontal type
where in the the obtained casting is bent by the rollers. The horizontal
process on the other hand provides greater flexibility & larger length.
• Continuous casting process gives a continued casting output as long as

we keep feeding the defect free pure metal at the inlet.
• The yield of the process is very high.
Types of continuous casting:-

 vertical continuous casting
 horizontal continuous casting
 continuous casting in travelling mould
Vertical continuous casting:
• The mould is made up of copper(water cooled).

• It is commonly used to cast steel.
• The process uses no risers or gating system, hence molten metal should
be slag free & poured with minimum turbulence to reduce mould
friction & to avoid casting to tear.
• The process is started by placing a dummy bar in the mold upon which
the first liquid metal falls.
• The liquid metal gets cooled & is pulled by the pins rollers along with
the dummy bar.
• Molten metal pouring by the basin into the tundish & this molten metal
flow into the mould & it is solidify.
• If it is solidify, it is rolled& continuous goes down.
• If there are inside defect & blow holes. These will be detected. This is
purpose of x- ray transmission & receiver.
• When we are pouring molten metal there is chance of atmospheric
oxygen may react with molten metal & oxide will be form so this has
to be prevented.
• So we are passing argon gas over this.
• It is also used some lubricant oil so that molten metal will not sticky to
the mold so this is system of continuous casting.
Here we can see further process:-
• This is the common schematic of representing the continuous casting process.

• Tundish (which is special type of pouring cup) receives molten metal through
the ladle where molten metal is poured.
• The molten metal is then carried through this where a series of rollers.
• Rollers support the molten metal coming out through this which will be
simultaneously getting solidified upon some special cooling arrangement.
• The metal in the meanwhile will get solidified and there will be an
arrangement for separating the pieces in a required length.
• This device for separating the cast material will be appropriate placed as per
the design requirement of the pieces.
• It is cut to size either by gas cutter or a circular saw, which is movable with
metal.
• There is length restriction for a vertical process as controlling the continuously
incoming metal is difficult & consequently deep underground arrangement
are needed.
• After cutting the material there are sent for further heat treatment operation.
Horizontal continuous casting:
• This process uses a graphite mould

• This is commonly used to cast non ferrous alloys.
• Here is a holding furnace. There is molten metal here. This is mold, this is
water cooled There is another cooling system.
• The bar upon which the molten material are being allowed to get solidifies &
then finally guided towards the cutting zone.
• Shrinkage effect provides a very small gap between the metal & the mold
thereby reducing friction between the two & permitting cast safe to move
continuously through the mold
• Pings & guide rolls regulate the rate of settling cast safe & proper alignment.
• Heat from the molten metal being poured dissipates fast through the mould
walls.
• A skin of solid metal forms quickly at the mould metal interface & shrinks
from the walls.
• The billet can be cut by an argon torch which permits inert atmosphere to
avoid atmosphere contamination.
• X-ray units controls the pouring rate of molten metal from the ladle.
• During cooling, a cone of molten metal must always remain in order to take
care of solidification shrinkage.
Thus, it provides the risering effect.

• Heat extraction is done through water feeding mechanism so that directional
solidification is promote.
• The rate at which the heat from the molten metal is removed must be
synchronized.
• As the molten metal passes through the mold a bar is generated.
• So this bar is fed continuously outward by this roller.
Continuous casting in traveling mould

• In the case of horizontal & vertical continuous casting the mould is stationary.
• Where is the mould we can see belt, these belts are rotating slowly.
• Belts will be rotating like a caterpillar.
• The molten metal trapped between two belts & slowly they will be advancing.
• They will be cooled & after some time it will be solidify.
• We can say cast strip is coming out. Casting rate is 0.5-10 m/min
Maximum Width of cast slab-1.75m
• Slab gauge is within range 10-40mm.
ADVANTAGES -
• 100 percent casting yield
casting yield= (weight weight of poured metal)*100
weight of casting
weight of poured metal is always more than weight of casting in case of many casting
process. In continuous casting there is no getting system, no runner, no raiser no
sprue. So whatever we are pouring is becoming part of casting so we are getting 100
percent casting yield. So decreases cost of production.
• Cheaper to produce ingots(compare to rolling), this process

is highly useful.
• Better surface finish
• Grain structure can be regulated
• Process is automatic so requires less labour.
APPLICATIONS
• long billets of any cross section can be obtained.
• Solid & hollow ingots can be made.
• Production of copper bar (wire).
• Bushing and pump gears
• Materials like copper, aluminium alloys, magnesium,
stainless steel can be easily cast.
REFERENCES
1. https://en.wikipedia.org/wiki/Continuous_casting
2.Foundry Technology by O.P Khanna

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Report on

National Institute Of Foundry And Forge Technology, Hatia ,

• It is process used to produce billets, blooms or slabs much longer in

• Round ingots, slabs, square billets, hex billets can be produced by

• It requires more process control & high quality inputs.

• In this process molten metal is transferred from a holding furnace into

• The Asarco process is the most popular one.

• Continuous casting process gives a continued casting output as long as

• The yield of the process is very high.

Types of continuous casting:-

• The mould is made up of copper(water cooled).

Here we can see further process:-

• This is the common schematic of representing the continuous casting process.

Horizontal continuous casting:

• This process uses a graphite mould

Thus, it provides the risering effect.

Continuous casting in traveling mould

• Cheaper to produce ingots(compare to rolling), this process

2.Foundry Technology by O.P Khanna

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