Jul 15 , 2025
In the continuous casting of aluminum, molten metal flows continuously from a holding furnace, through various channels, and into a mold to form a solidified strand. This process demands extremely reliable, precise, and non-contaminating materials to ensure consistent product quality, minimize defects, and enable long casting campaigns. Non-wetting, high-density calcium silicate boards are indispensable in this application due to their unique combination of properties.
1. Caster Tips / Hot Top Boards: These are critical components that form the upper part of the continuous casting mold, defining the top surface of the solidifying ingot or billet.
o Why used: Non-wetting properties prevent molten aluminum from sticking and building up, ensuring a smooth, consistent casting surface and reducing secondary machining needs. Their thermal stability and dimensional precision are crucial for controlled solidification and defect prevention.
o Benefit: Improves surface quality of the cast product and extends the lifespan of the tips.
2. Transition Plates / Distribution Boxes: Used in the systems that guide and distribute molten aluminum from the launder or tundish into the casting mold.
o Why used: Their excellent machinability allows for precise geometries to control metal flow and turbulence. Non-wetting nature prevents metal adhesion and dross formation within critical flow paths.
o Benefit: Ensures uniform metal delivery, reducing inclusions and defects in the final product.
3. Launder Linings / Flow Control Systems: For channels transferring molten aluminum from the furnace to the casting unit.
o Why used: Provides superior insulation to maintain consistent metal temperature throughout the flow path, vital for stable casting. Their non-wetting surface minimizes aluminum buildup and simplifies cleaning, reducing dross and metal loss.
o Benefit: Maintains thermal stability of the melt, reduces heat loss, and prevents metal contamination.
4. Floats and Dams: Used for level control, flow regulation, or dross skimming within tundishes or distribution boxes.
o Why used: Their non-wetting property and buoyancy allow them to effectively control molten metal flow without significant metal adhesion. Their thermal shock resistance ensures stability in varying conditions.
o Benefit: Precise flow control and effective dross separation, contributing to cleaner metal.
The use of non-wetting high-density calcium silicate boards in continuous casting equipment directly translates to:
Enhanced Product Quality: Fewer inclusions, reduced porosity, improved surface finish, and consistent metallurgical properties in the cast products.
Increased Production Efficiency: Longer casting campaigns due to extended component lifespan and less downtime for cleaning and maintenance.
Reduced Metal Loss: Minimized dross formation and metal adhesion to components.
Precise Control: Excellent machinability allows for complex, dimensionally stable components crucial for controlled metal flow.
These properties make non-wetting high-density calcium silicate boards an indispensable material for achieving high-quality and efficient continuous aluminum casting operations.
