2. What is Casting
• A manufacturing process
• Types of casting
• Sand casting
• Die casting
• Permanent casting
• Centrifugal casting
• Permanent mold casting
3. CONTINUES CASTING
• Continuous casting, also called strand casting, is the process
whereby molten metal is solidified into a semifinished billet,
bloom, or slab for subsequent rolling in the finishing mills.
4. • Most basic metals are mass-produced using a continuous casting
process, including over 500 million tons of steel, 20 million tons
of aluminum, and 1 million tons of copper, nickel, and other
metals in the world each year
5. • The continuous casting has several configurations to produce
the steel as vertical, vertical with curved type, horizontal and
strip casting.
6. • Curved machines are used for the majority of steel casting and
require bending and / or unbending of the solidifying strand.
7.
8. EQUIPMENTS
• Ladle
• Tundish
• Mold
• Dummy bar
• Roller apron
• Withdrawal rolls
• Bending and straightening rolls
• Cooling sprays
• Cutting devices
• Auxiliary electrical and/or mechanical gears to help run the machine
smoothly.
10. The tundish holds enough metal to provide a continuous flow to
the mold, even during an exchange of ladles, which are
supplied periodically from the steelmaking process
11. THE IMPORTANCE OFTUNDISH
• The metal remains in the tundish for a relatively short time, reflecting the
continuous nature of tundish operation
• Thus, the major refining reactions such as deoxidation and desulfurization are
carried out in the ladle.
• Enhances oxide inclusion separation
• Provides a continuous flow of liquid steel to the mold during ladle exchanges
• Maintains a steady metal height above the nozzles to the molds, thereby
keeping steel flow constant
• Provides more stable stream patterns to the mold
• The goals of a tundish are to minimize heat loss, deliver the melt evenly into
molds, minimize the formation of macro inclusions, and maximize their
removal.
12. THE PROCESS OF CONTINUOUS CASTING OF
BILLETS
• Continuous casting transforms molten metal into solid on a continuous
basis and includes a variety of important commercial process.
• These processes are the most efficient way to solidify large volumes of
metal into simple shapes for subsequent processing.
• To preheat the tundish before starting the process is that will contribute
about reducing of the cracks over the working living in the tundish.
14. Procedure of continuous casting
of billets.
• 1)The liquid steel comes
from the steel plant in a ladle
• 2) From ladle it is tapped
in a tundish
15. 3) Liquid Steel is flowed through the nozzle to mould from
tundish.The flow rate through the nozzle into the mold can be
controlled by a stopper in the tundish
4) HeatTransfer in continuous casting by mist spray
5)The outer shell is being ’grabbed’ by a driven roll just beneath
the mold, pulling a strand of steel out of the mold.
6)The core of the strand, as it exits, is still liquid; because of that,
the strand proceeds through a secondary cooling section
7)The strand is bent from the vertical plane to horizontal plane
using rolls
18. THE BENEFITS OF CONTINOUS CASTING
• Considerable energy savings
• less scrap produced, i.e. improved yield
• Improved labor productivity
• Improved quality of steel
• Reduced pollution
• Reduced capital costs
• increased use of purchased scrap when output is maximized
19. DISADVANTAGES
• Not suitable for small quantity production.
• Continuous and efficient cooling of mold is required, else, center line
shrinkage develops.
• Requires large floor space.
20. Conclusion
• Continuous casting has evolved from a batch process into a
sophisticated continuous process.This transformation has occurred
through understanding principle of mechanical design , heat
transfer , steel metallurgical properties and stress strain
relationships, to produce a product with excellent shape and
quality.
• In recent year the process has been optimized through careful
integration of electro-mechanical sensors, computer-controls, &
planning to provide a highly automated system designed for new
millennia.