The Casting Powders Book

1. Front Matter

   Pages i-xix

   PDF

2. Introduction and Overview

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 1-17

3. Slag Infiltration, Lubrication and Frictional Forces

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 19-58

4. Heat Transfer in the Mould and Shell Solidification

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 59-108

5. How to Manipulate Slag Behaviour in the Mould

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 109-146

6. Effect of Casting Variables on Mould Flux Performance

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 147-175

7. Different Types of Mould Powders

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 177-222

8. Fluxes for Ingot Casting

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 223-270

9. Manufacture of Mould Fluxes

   • Kenneth C. Mills, Carl-Åke Däcker

   Pages 271-283

10. Properties of Mould Fluxes and Slag Films

    • Kenneth C. Mills, Carl-Åke Däcker

    Pages 285-392

11. Selection of Mould Fluxes and Special Mould Fluxes for Continuous Casting

    • Kenneth C. Mills, Carl-Åke Däcker

    Pages 393-416

12. Using Mould Fluxes to Minimise Defects and Process Problems

    • Kenneth C. Mills, Carl-Åke Däcker

    Pages 417-535

13. Correction to: The Casting Powders Book

    • Kenneth C. Mills, Carl-Åke Däcker

    Pages E1-E1

This book deals with casting powders and explains how they work and how they are best used to minimise defects in the ninety per cent of world steel production that is continuously cast. It also includes a chapter on mould powders for ingot-casting. The factors affecting various aspects of powder performance are described and different defects, their causes, and means of avoiding them are considered.

Providing the first comprehensive coverage of mould powder properties and uses, the text treats theoretical and practical matters and gives direct advice on problem-solving. Drawing on a wealth of scientific and technological research, represented by its extensive references, The Casting Powders Book shows readers how they can design and create mould powders optimised to fulfil the necessary functions of:

• lubrication of steel shells and reduction of shell–mould friction;
• absorption of inclusions floating up from the steel;
• chemical insulation of steel from carbon-rich mould powder; and
• protection of the steel meniscus from oxidation and thermal insulation to                  prevent surface-freezing.

Thermophysical properties and heat-transfer processes are also given detailed attention and case studies illustrate the methods and materials described.

The Casting Powders Book is designed to be a periodic reference that can be dipped into as the need arises. Readers from different backgrounds are well-served by the depth and variety of content:

• engineers trouble-shooting a continuous-casting process interested in how mould fluxes can minimise defects and process problems and how their performance is in turn affected by casting parameters;
• academic scientists interested in the theoretical aspects and properties of mould fluxes and slag films;
• engineers working with ingot-casting processes;and many others will find this book an invaluable resource.

• Continuous Casting
• Heat Transfer in Casting
• Ingot Casting
• Mould Powder
• Mould Slag Infiltration and Lubrication

• Royal School of Mines, Imperial College London, London, UK

  Kenneth C. Mills

• Swerea KIMAB AB, Kista, Sweden

  Carl-Åke Däcker

Ken Mills worked at the National Physical Laboratory, Teddington from 1963-1999 and has been in the Department of Materials, Imperial College from 1995-present.  His primary interest at NPL was in the measurement of the physical properties of materials involved in high temperature processes (metals, slags and refractories). He has been working on mould powders for continuous casting for more than 35 years and formed the UK Working Group on Casting Powders and was a member of the Europ. Coal & Steel Committee on Theoretical Steelmaking for  more than 10years. During his time at NPL he became interested in the factors affecting the continuous casting process and the mechanisms responsible for process problems and defects. His interest in this area has led to the awards of the Bessemer Gold Medal (2013) and Honorary Membership of the Iron and Steel Institute of Japan (2003). At Imperial College he lectured in Process Metallurgy and in Heat and Fluid flow.  His research at ImperialCollege has been largely focused on continuous casting with research on i. the properties and performance of continuous casting slags  ii.  mathematical modelling of the process. However, other steelmaking –related projects were also carried out. In recent years he has revived his interest in the estimation of physical models of slags and metals (for use in the macro model) from their chemical composition. He has published three books, more than 200 journal papers and has contributed in chapters to several books. He is the most cited author in this field of mould powders.
Carl-Åke Däcker, now working as Senior Scientific Advisor previously being Manager of the Materials& Process Development Department at Swerea KIMAB. In his work at the Institute he has dedicated most of his own research on mould powder development in close co-operation with the Swedish steelmakers and published around 10 conference papers in this field. In 2012 he was awarded Professor Hasse Fredriksson award for “many years’ research of mould powder properties and its effect on continuous cast blanks surface quality”. Before joining the Institute he worked 24 years with research, in the Swedish industry. 12 years at the Metallurgical Department at SSAB in Oxelösund where casting was an important issue, 7 years at Rockwool AB where he worked with raw-materials and melting of Rockwool glass.

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