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Continuous casting methods for ingot processing also exist, whereby a stationary front of solidification is formed by the continual take-off of cooled solid material, and the addition of a molten liquid to the casting process. [9]
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. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary molds to form ingots .
A slab is a length of metal that is rectangular in cross-section. The slab is created directly by continuous casting or indirectly by rolling an ingot on a slabbing mill. [1] Slabs are usually further processed via flat rolling, skelping, and pipe rolling. Common final products include sheet metal, plates, strip metal, pipes, and tubes. [3]
The original ingots are usually further processed by other methods (rolling, forging, etc.). More than half of global aluminum production uses the Direct Chill casting process. [1] Direct Chill casting operates by pouring liquid metal continuously into a short mold (7.5–15 cm deep) that is open at the bottom.
Degassing [4] is a process that may be required to reduce the amount of hydrogen present in a batch of molten metal. Gases can form in metal castings in one of two ways: by physical entrapment during the casting process or; by chemical reaction in the cast material. Hydrogen is a common contaminant for most cast metals.
Permanent mold casting is a metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold. However, gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces hollow castings.
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A bronze casting showing the sprue and risers. A riser, also known as a feeder, [1] is a reservoir built into a metal casting mold to prevent cavities due to shrinkage.Most metals are less dense as a liquid than as a solid so castings shrink upon cooling, which can leave a void at the last point to solidify.