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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.
A hot top, also known as a feeder head, [5] is a specialized riser, used to help counteract the formation of pipes when casting ingots. It is essentially a live open riser, with a hot ceramic liner instead of just the mold materials. It is inserted into the top of the ingot mould near the end of the pour, and the rest of the metal is then ...
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.
The ESR process uses the as-cast alloy as a consumable electrode. Electric current (generally AC) is passed between the electrode and the new ingot, which is formed in the bottom of a water-cooled copper mold. The new ingot is covered in an engineered slag that is superheated by the electric current.
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