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The Casting Powders Book pp 177–222Cite as

Different Types of Mould Powders

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Abstract

The mould powder must carry out a series of tasks. Arguably, the most important of these tasks is the formation of a slag film which provides the optimum level of lubrication and heat extraction from the shell. These properties are determined by the (i) mould dimensions (ii) the casting conditions and (iii) the steel grade being cast. Empirical rules have been developed to express the properties providing good casting performance; these include the required values for the powder consumption, slag viscosity and the break temperature but the fraction of crystal phase in the slag film (fcrys) should also be cited. The various types of mould powders are described, e.g. starter, exothermic and prefused powders. Most mould powders in use are denoted as Conventional; the properties of these powders would be expected to be (i) consistent with those derived from empirical rules and (ii) to contain fluorides to form cuspidine in the slag film. However, there are a number of specialist powders which have been developed to carry out specific tasks or to cover special steel grades or casting conditions. The specialist mould powders include the following: F-free powders; C-free powders, Non-Newtonian powders, and fluxes used to cast high–speed, thin slabs and round billets and powders used to cast steels with high Al and rare earth contents and stainless steels. Although the properties of all these fluxes are consistent with those predicted by the empirical rules, developments have been made to deal with special features for each type of powder.

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Abbreviations

D :

Diameter (m)

d :

Thickness (m)

k :

Thermal conductivity (Wm−1K−1)

Q MR :

Melting rate (kg s−1 or kg min−1)

Q s :

Powder consumption (kg m2(mould))

q :

Heat flux density (Wm−2)

t :

Thickness of mould (m)

w :

Width of mould (m)

γ :

Surface tension (mNm−1)

η :

Viscosity (dPas)

T :

Temperature (°C)

T br :

Break temperature (°C)

T liq :

Liquidus temperature (°C)

T sol :

Solidification temperature (°C)

V c :

Casting speed (m min−1)

C/S :

%CaO/%SiO2 = basicity

EMBR:

Electromagnetic Braking

HC:

High carbon (steel)

IR:

Infrared

LC:

Low carbon (steel)

MC:

Medium carbon (steel)

SEN:

Submerged entry nozzle

ULC:

Ultra-low carbon (steel)

A:

Al2O3

B:

B2O3

C:

CaO

F:

FeO

Fl:

CaF2

K:

K2O

L:

Li2O

M:

MgO

Mn:

MnO

N:

Na2O

S:

SiO2

T:

TiO2

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  1. Royal School of Mines, Imperial College London, London, UK

    Kenneth C. Mills

  2. Swerea KIMAB AB, Kista, Sweden

    Carl-Åke Däcker

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Mills, K.C., Däcker, CÅ. (2017). Different Types of Mould Powders. In: The Casting Powders Book. Springer, Cham. https://doi.org/10.1007/978-3-319-53616-3_6

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