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Continuous 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. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary molds to form ingots.
Continuous casting is used due to the lower costs associated with continuous production of a standard product, and also increased quality of the final product. Metals such as steel, copper, aluminum and lead are continuously cast, with steel being the metal with the greatest tonnages cast using this method.
Continuous casting directly shapes the aluminium into rolling slabs without an intermediate ingot casting step. Twin-belt or twin-roll strip casting produces alloy strips 6-7mm thick directly from the melt for subsequent rolling. The casting method depends on the subsequent processing and use of the recycled aluminium alloy. [15]
In aluminium castings, hydrogen is the only gas that dissolves in significant quantity, which can result in hydrogen gas porosity. [9] For casting that are a few kilograms in weight the pores are usually 0.01 to 0.5 mm (0.00039 to 0.01969 in) in size. In larger casting, they can be up to a millimetre (0.040 in) in diameter. [8]
Direct chill casting. Direct Chill casting is a method for the fabrication of cylindrical or rectangular solid ingots from non-ferrous metals, especially Aluminum, Copper, Magnesium and their alloys. The original ingots are usually further processed by other methods (rolling, forging, etc.). More than half of global aluminum production uses the ...
Centrifugal casting or rotocasting is a casting technique that is typically used to cast thin-walled cylinders. It is typically used to cast materials such as metals, glass, and concrete. A high quality is attainable by control of metallurgy and crystal structure. Unlike most other casting techniques, centrifugal casting is chiefly used to ...
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