An Overview For The Requirements Of
Continuous Casting Mould Fluxes
Authors: Albert J Moore, R.J.Phillips, T.R. Gibbs - Foseco Inc
Summary
This paper describes the features and
benefits of continuous casting fluxes.
Introduction
A continuous casting mold flux must satisfy
various requirements including thermal
insulation, chemical insulation, inclusion
absorption, lubrication and promotion of
even heat flow through the mold. The
relative importance of these properties
varies according to the type of steel cast,
the prevailing casting conditions and the
end steel requirements.
Figure 1 shows a schematic representation
of a continuous casting mold using flux.
The mold flux consists of an unreacted
powder layer and a melted liquid or slag
layer. Depending on the melting
characteristics of a particular flux, there will
also be a sintered layer or a semi-reacted
layer. Next to the solidified steel shell is the
liquid flux with the solid flux film adjacent
to the water cooled mold.
Fig. 1 Schematic Representation of a Continuous
Casting Mould Flux
Water Cooled
Copper Mould
Semi Reacted
Layer
Flux
Rim
Flux
Film
Liquid Steel
Air Gap
Solidified Steel
Shell Strand Withdrawal
As the steel solidifies, the shell contracts
and an air gap is formed between the mold
and the flux film (1). The flux rim, which is
commonly called the slag rim or rope is
located near the top of the mold. The
depth of liquid flux normally varies
between 8 and 20mm with a minimum
powder thickness of 25mm to ensure a
dark practice.
Mold fluxes can be classified into various
types. The most common types are:
. Fly Ash Powders - Mechanical blends
in which powdered fly ash is a
significant component of the mix. The
availability of consistent fly ash has
limited the production of this type of
powder.
.iSynthetic Powders - Mechanical blends
of fine powdered raw materials made
with high shear mixing.
. Prefused or Fritted Fluxes - These the steel. Figure 2 shows how the basicity
fluxes have a sizeable portion that is pre- (Ca0/Si02) of a flux affects the ability of a
melted and sized. flux to absorb alumina (3). Alumina rods
.Granular Fluxes - Spherical or extruded were immersed into the liquid fluxes with
varying basicity ratios. The difference in the
granules are designed to have less dust
than powdered fluxes. Spherical
rod diameter (Delta R) was plotted against
time for different fluxes. Normal flux
granules are particularly suitable for
basicity ratios range between 0.8 and 1.25
automatic flux applications.
Absorption of non-metallics improves with
increasing basicity and decreasing Al203 in
Mold Fluxes are designed for specific steel
the slag. A lower viscosity increases the
grades and steel plant conditions. Actual
kinetics of inclusion capture and dissolution.
mold flux chemistries vary greatly
It should be noted that this ability of a flux
depending on properties required. Typical
is a compromise between the disire to
ranges are shown in Table 1.
produce clean steel and submerged entry
nozzle life.
Table 1. Typical Chemistry Ranges for
Mold Fluxes Lubrication
Lubrication is probably the most important
Ca0 25-45% Na20 1-20% Ba0 0-10%
function of a mold flux. The flux must act
Si02 20-50% K20 0-5% Li20 0-4% to provide a lubricating film between the
solidifying shell and the water cooled mold.
Al203 0-10% Fe0 0-6% B203 0-10% A lower flux viscosity and/or solidification
point tends to provide better lubrication,
Ti02 0-5% Mg0 0-10% F 4-10%
and this help prevent sticking.
C 1-25% Mn0 0-10%
Fig. 2 Effect of Ca0/Si02 on the rate of Alumina
Dissolution (3)
Major Functions of a Mold Flux
Powder 5
Layer Ca0/Si02
Thermal Insulation 4 2.00
Liquid Flux
1.50
The flux must provide thermal insulation to 3 1.42
R (mm)
1.30
prevent bridging, and steel floaters. 2 1.19
3.00
Improved thermal insulation increases the 1 1.09
0.86
temperature in the meniscus region of the 0 0.60
0 10 20 30 40 50 60
steel which helps to make oscillation marks Time (mins)
less severe and can reduce sub-surface
defects such as pinholes. The main control An increase in basicity (Ca0/Si02) as shown
of insulation is the density of the unreacted in Figure 3, or an increase in the per-
flux, but the type of carbon used and the centage of F or Na20 will result in a greater
physical condition of the flux can also tendency for the flux to recrystallise (4).
affect the insulating properties (2). Too
low a bulk density may cause an
unfavourable dust problem. This problem Fig. 3 Relation Between Basicity of Mould Flux
on Crystallisation Index (4)
is solved by a granulated mould flux. Due
to its particle shape, spherical granular 4
fluxes have improved flowability over other 3
Crystallisation Index
types of fluxes such as powders and 2
extruded granules.
1
Chemical Insulation 0
A continuous slag layer is effective in -1
Low Cao/Si02 High
preventing oxidation of the steel by
insulating the steel from the atmosphere
provided the flux is low in reducible oxides. The crystallisation index shown in Figure 4
was established by obtaining a slag sample
Inclusion Absorption
from the mold and measuring the opaque
fraction of the cross sectional area of the
The liquid slag acts to absorb non-metallic
solidified slag (2).
inclusions such as alumina floating up out
of
 the shell becomes broken as cast Strand B Figure 9 compares the rate of heat removal
Fig. 4 Effect of Crystallisation Index of Mould
Powder on Breakout Frequency (2) is withdrawn. Molten steel enters the for two medium carbon mold fluxes. The
broken gap, Part 2 in the shell, and a new "new" flux has a higher solidification point
0.25
Flux A
shell C is formed along with ripple marks and lower viscosity.
Breakout Frequency (%)

0.2 D. The new thin shell is broken as the cast

0.15
Flux B
moves in the downward direction, Part 3, Table II shows the improvement in the
0.1 and another thin shell is formed in Part 4. longitudinal surface cracking rate using the
0.05
Flux C
The processes are repeated as the cast "New" high solidification point flux (8).
Flux D
0
moves down in the mold until position C in
0 0.5 1 1.5 2 2.5 3 3.5 Table II. Longitudinal Cracking Rate for
Crystallisation Index of Mould Powder
Medium Carbon Mold Powders (8).
Fig. 7 Effect of Carbon Content on Shrinkage
After Solidification
Index 0 indicates the slag was completely Solidus - 40°C Range
No. Slabs No. Slabs Persentage
Cracked
glassy while index 3 indicates the slag was 5

Av Shrinkage Coefficient
100% opaque. X-ray defraction of the 4 Old Powder 1.485 75 5,05

opaque area proved it to be crystalline. As

(x10 / C)
3
New Powder 894 8 0,89
the flux tends toward being more 2

crystalline, the incidence of sticking can 1

increase dramatically. Flux Properties to Consider
0
0 0.1 0.2 0.3 0.4 0.5 0.6

A typical schematic view of shells C (%)

The viscosity, solidification point, melting
remaining in the mold after a sticking point, and slagging speed are typically
breakout is shown in Figure 5 (5). Part 5 reaches the bottom edge of the considered the most important properties
mold and a breakout occurs. of a flux. For some steel grades or
conditions, it is sometimes necessary to
Fig. 5 Appearance of Shell Remaining in the
Mould After Sticking Breakout With the high cost of a breakout, the need give special considerations to the flux
to prevent sticking is clear. Correct mold density and/or chemistry.
fluxes are integral in preventing casting
disruptions. Viscosity is the major control of flux con-
b c
sumption with lower viscosities tending to
c
Promotion of an Even Heat Flow cause an increase as shown in Figure 10 (9).
d
a d
a
The effect of an increase in Al203 on the
Type I Type II
Fig. 8 Influence of Heat Flux on Longitudinal
flux viscosity and solidification temperature
(a) Oscillation Marks (c) Constricted Line of Shell
(b) Ripple Marks (d) Breakout Position Cracking (7) are shown in Figures 11 and 12.

5
Index of Longitudinal Cracking

The breakouts caused by sticking are of Fig. 11 Effect of Increase in Alumina on Flux
4
Viscosity
two types: those occurring near the centre 3

of the wide face of the slab (Type I) and 2 12

those occurring near the corner (Type II).
Viscosity (Poise at 1300 C)

1
The breakout always occurs at the 0 8
Flux A

Flux B
intersection (d) between the constricted 85 90 95 100 105 110 115
Flux C
Heat Flux (kcal/m2hr
line (c) and the bottom of the mold. The 4
Flux D

angle of the constricted line is typically 30

to 45 degrees against the horizontal along The final requirement is to provide an even 0
0 5 10 15

heat flow. This is necessary to prevent Al203 (wt%)

uneven solidification of the steel shell

Fig. 6 Process of Breakout Caused by Sticking
which can lead to cracking of the cast
(5) Fluxes C & D show a much lower increase
product. Medium carbon steel grades have
in viscosity and consequently, are more
1. 2. 3. 4. 5.
a larger shrinkage after solidification which
Meniscus stable during usage. Mg0 additions to the
makes these grades especially prone to
(a)
flux are useful to stabilise viscosity as Al203
(d) cracking, Figure 7 (6).
Breakout is absorbed.

(b)
Fig. 9 Heat Removal Comparison, 'Old and New'
The increase in Al203 in the molten flux
Medium Carbon Mould Powder chemistry is often below 3% with clean
(a) Stuck Shell
(b) Withdrawn Shell
(c) New Solidified Shell
(d) Ripple Mark steel practices, such as slag deoxidation
1.5
34
32
and good shrouding techniques (8, 10).
Heat Removal (gal/gm)
Casting Speed (m/min)

30
Speed 28
which the shell is extremely thin or even 1 From Old Powder
to New Powder
Switch Back to
Old Powder
26
24
broken. Usually this constricted line HT Removal
22
20
Fig. 12 Effect of Increase in Alumina on Flux
0.5 Solidification Temperature
circumscribes the entire shell without any 18
16

breaks. There are ordinary oscillation 0

14
12

marks in area (a). In area (b), both above 0 0.5 1 1.5 2 2.5 3 1200
Time (Hrs) Flux D
and below the constricted line, there are Flux B
1100
ripple-like marks running nearly parallel to Flux C

the constricted line and at intervals Fluxes having a higher solidification 1000 Flux A

narrower than the oscillation marks. temperature produce a thicker crystalline

900
layer in the flux film between the steel shell 0 5 10 15

Figure 6 describes the process of a sticking and the mold, decreasing the heat transfer Al203 (wt%)

breakout (5). In Part 1, a portion of cast rate. The effect that reduce heat flow
Strand A is stuck near the meniscus, and through the mold is shown in Figure 8 (7).
the 2
The combination of viscosity and Carbon has a significant effect on melting Effect of Casting Conditions on
solidification temperature effects the speed, sintering tendency, thermal Mold Flux Requirements
lubrication and heat transfer. A crystalline insulating properties, and slag rim. Flux
film is more porous than a glassy film melting characteristics are affected by the The casting speed, oscillating cycle, and
which is a factor in the reduction in heat carbon type (due to difference in burning mold design are some of the key operating
transfer. The type of mold plating, air gap temperature). parameters that affect the design of a
and hydrogen levels also influence the rate The amount of fine carbon particles in a suitable mold flux.
of heat flow (11). mold flux helps determine its melting
mode. Casting Speed
As the casting speed increases, the flux
Fig. 14 Effect of Oxide on Flux Solidification The alpha type melting mode with a
Point Ts consumption is reduced as shown in Figure
greater proportion of fine carbon particles 16 (15). If flux consumption is too low, a
1200
(13), form discrete droplets in the half breakdown in the lubricating film may
molten slag layer. These fluxes melt rapidly occur, resulting in sticking.
1150
Ca0
and are especially suitable for high speed
casting and unstable mold conditions. The
Ts (C)

1100
1050
1000
0 2
Fluxes are composed primarily of slag
formers (or fillers), fluxing agents, and
carbonaceous materials. The effect of an
increase for various oxide additions on the
viscosity and solidification point of fluxes
are shown in Figures 13 and 14 (12).
Fig. 13 Effect of Oxide Additions on Flux Viscosity
(12)
6 0.55
Mg0
Al203 Low casting speeds may also have negative
Si02
beta type melting mode with a greater effects. The reduced steel flow rate can
proportion of coarse carbon particles, form lead to cold spots in the mold which may
4 6 8 10 12
a partially sintered half molten slag layer. result in steel floaters or bridging. Floaters
Oxide Addition (%) These fluxes supply slag slowly, steadily, may cause quality problems such as cracks
and have been shown to be suitable for or blow holes while complete bridging will
casting crack sensitive steels at low or lead to sticking. Special attention to the
intermediate casting speeds. insulating properties of the flux is required
to prevent problems at low casting speeds.
Fluxes (powder, fritted or granular) with an
incorrect carbon system may have Oscillation Cycle
inadequate slag depths during speed High oscillation frequencies and shorter
chang stroke lengths have reduced the oscillation
mark depth while helping to eliminate
Fig. 16 Influence of Casting Speed on Flux
Consumption (15) transverse cracking problems. A higher
oscillation frequency reduces the negative
Steel Grade: Low Carbon Al Killed
strip time which in turn reduces the flux
Flux Consumption Rate (kg/t)

consumption in a similar way to higher

Viscosity (Poise at 1300 C)

5 0.5

4 Si02 0.45 casting speed (16). As a consequence,

Mg0

3
Ca0 0.4
Flux A
Flux B changes in oscillation cycles may require
Al203
0.35
flux modification in order to prevent
2
0.3
sticking.
1 0.25
0 2 4 6 8 10 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2
Oxide Addition (%) Casting Speed (m/min) Mold Design
Mold plating has been adopted to improve
slab surface quality by reducing star
The effects of changing the chemical changes. Figure 15 shows a flux with the cracking. Mold life has also increased
composition on the flux properties are correct amount and types of carbon (14). because of the wear resistant facing
shown in Table III. The changes in the flux An adequate liquid flux depth is provided by plating (17). Chrome plating
properties are general and pertain to maintained during and after the speed has often been replaced by nickel based
typical flux chemistries. The flux melting change. materials due to spalling problems.
point is affected not only by the flux However, nickel has a significant negative
chemistry but also by the mineralogical Fig. 15. Change in Thickness of Molten effect on heat flow through the mold. A
make up. Slag Layer with Increasing Casting flux providing increased heat transfer may
Speed, Type A 14 be needed.
Table III. Effect of Chemical Composition
on Mold Flux Properties.
Fig. 15 Change in Thickness of Molten Slag
Mold Flux Requirements and
Layer with Increasing Casting Speed, Type A (14) Design by Steel Grade
Increase Viscosity Solidification Melting
Point Point
Molten Slag Layer Thickness (mm)

2 20
Casting Speed (Vr (m/min)

Ca0 Decrease Increase Increase Low Carbon Aluminium Killed (LCAK)

Si02 Increase Decrease Decrease 1.5
Casting Speed
(C<0.08%)
10
Ca0/Si02 Decrease Increase Increase Slag Thickness
1 LCAK steels exhibit good high temperature
Al203 Increase Decrease Increase
mechanical properties, cracks not usually
Na20 Decrease Decrease Decrease 0.5
0 10 20 30 40 50 60
0
being a serious problem. However, high
F Decrease Increase Decrease Time (mins) production rates require increased casting
Fe203 Decrease Decrease Decrease speeds. Requirements for these grades are
Mn0 Decrease Decrease Decrease good surface quality, good internal quality,
Mg0 Decrease Decrease Decrease and prevention of stickers. This is achieved
B203 Decrease Decrease Decrease by fluxes having good insulating properties,
Ba0 Decrease Decrease Decrease
good absorption of non-metallics, good
Li20 Decrease Decrease Decrease
lubrication, and stable properties.
Flux stability, the ability to absorb Al203
Ti02 No Change Increase Increase
without an adverse effect on viscosity is
K20 Decrease Decrease Decrease
very important, especially at higher casting
j
3
speeds. A lower viscosity and/or Table IV. Mold Flux Properties by Steel 8. J.S. Powers, S.C. Sander, P.A. Ripper,
solidification point helps the flux provide Grade. H.D. Baker and M.D. Leitholf, "Continuous
sufficient lubrication at higher casting Refinement of LTV's Quality System",
speeds. Casting Viscosity
Steel
Speed (POISE)
Ts T2 Proceedings of the Sixth International
Grade (°C) (°C)
(m/min) (1300°) Iron and Steel Congress, 1990, Nagoya,
Medium Carbon (MED C) (C 0.08% -
ISIJ.
0.18%) LCAK 0.8-1.4 2.5-1.0 1120-1060 1140-1060

1.5-2.0 1.2-0.6 1060-960 1060-960

These grades are prone to cracking
because of increased shrinkage associated
with peritectic solidification. Prevention of
longitudinal and transverse cracks are of
paramount importance. This is achieved by
fluxes that reduce heat flow through the
mold and have a controlled melting speed.
High solidification point fluxes have been
effective in reducing surface cracks. The
high solidification point of the flux helps
reduce heat flow through the mold while
the low viscosity enables the flux to provide
adequate lubrication.
High Carbon (HC) (C>0.18%
The characteristics of these grades are poor
hot strength, lower casting temperature,
and typically cast at lower speeds. Flux
requirements are to reduce surface slag
scum, prevention of blow holes and
stickers. This is achieved by fluxes having
good insulating properties, correct carbon
selection, and good lubrication.
Low viscosity and melting point enables the
flux to obtain rapid melting speed. A low
flux density and the appropriate carbon
addition helps achieve good insulation to
prevent premature freeze off.
Ultra Low Carbon (ULC) (C<0.005%)
These steel grades have a thinner mushy
zone during solidification when compared
to LCAK. This increases the risk of sub-
surface defects caused by the rapid
movement of the solidification front. The
addition of titanium to the steel can lead to
a chemical reaction that alters the
properties of the mold flux. The flux must
be designed to provide good surface
quality, good internal quality and prevent
stickers. The requirements of the steel are
achieved by fluxes having increased
absorption of non-metallics, minimum
carbon pickup, improved insulation, good
lubrication, stable properties and minimal
slag entrapment, and/or attachment.
High flux basicity along with special oxide
compositions increase Al203 absorption
and decrease slag entrapment and
attachment (18). Carbon pickup can be
minimised by maintaining sufficient liquid
slag depth when combined with stable
mold conditions. Alternatively, reducing
the fixed carbon content of the mold flux
can also be effective.
Physical properties of the mold flux for
each type of steel grade are summarised in
Table IV.
MED C 0.8-1.2 5.0-0.8 1200-1100
1.3-1.6 2.0-0.8 1180-1120
HC 1.3max 2.0-0.8
ULC 0.8-1.2 2.6-1.2 1080-980
1.3-1.8 1.5-1.0 1050-950
Ts - Solidification Temperature
T2 - Melting Temperature
m/min - Meters per minute
Summary
There are many considerations in the
development, manufacture and application
of continuous casting mold fluxes. We
believe that the inter-relations between
viscosity and solidification point are
paramount. the melting mode of the mold
flux also has a significant influence on
performance. Careful consideration of
prevailing casting conditions, final steel
application, and steel chemistry is needed
to ensure mold fluxes are correctly
formulated.
References
1. R. Scheel and W. Korte, "Effect of
Different Flux Powder Composition on
Continuous Casting Slags and Casting
Practice", Metallurgy Plant and
Technology,1987.
2. H. Nakato, T. Sakuraya, T. Nozaki, T.
Emi, and H. Nishikawa, "Physical and
Chemical Properties of Casting Powders
Affecting the Mold Lubrication During
Continuous Casting", Mold Powders for
Continuous Casting and Bottom Pour
Teeming, ISS - 1987, pp 23-29.
3. H. Nakato, T. Emi and E. Ejima,
"Mechanism of Alumina Dissolution in
Molton Flux in Strand Casting Mold",
Tetsu-to-Hagane, Vol. 60, No. 4., March
1974, pp. A15-A18.
4. K. Sorimachi, M. Kuga, M.Saigusa and T.
Sakuraya, "Influence of Mould Powder on
Breakout Caused by Sticking",
Fachberichte Hythenpraxis, Volume 20,
No. 4 1982.
5. Private correspondence from Kawasaki
Steel.
6. Sugitani et al: Tetsu-to-Hagane, (12)
1979.
9. Private correspondence from Kawasaki
1190-1120 Steel.
1180-1120
1180-980 10. T.H. Bieniosek, B.S. Kupchik and K.C.
1120-1000 Ahlborg, "Ladle Slag Deoxidation with
1040-1000 Aluminium-Limestone Mixtures", 72nd ISS
Steelmaking Conference, Chicago, IL
1989.
11. P.J. Zasowski and D.J. Sosinsky,
"Control of Heat Removal in the
Continuous Casting Mould", 73rd ISS
Steelmaking Conference, Detroit, MI
1990.
13. T. Sakuraya, T. Emi, K. Emoto and T.
Koshikawa, "Development of Mold Fluxes
for High Speed Strand Casting of Slab Free
from Surface Conditioning", Second ISS -
AIME Process Technology Proceedings,
Chicago, IL 1981.
14. R.V. Branion, "Mold Fluxes for
Continuous Casting", Mold Powders for
Continuous Casting and Bottom Pour
Teeming, ISS - 1987, pp. 3-14.
15. S. Honda and H. Mutoh, "The
Development of a Continuous Flux for High
Speed Casting of LCAK Steel", Steel
Progress, Foseco International Ltd., 1988
Sixth Issue.
16. T. Emi, H. Nakato, Y. Iida, K. Emoto, R.
Tachibana, T. Imai, and H. Bada, "Influence
of Physical and Chemical Properties of
Mold Powders on the Solidification and
Occurrence of Surface Defects of Strand
Cast Slabs", 61st ISS Steelmaking
Conference, Chicago, IL 1978.
17. B.A. Otterman and J.D. Young,
"Stelco's Experience with Plated Slab
Caster Molds", 71st ISS Steelmaking
Conference, Toronto, Canada, 1988.
18. S. Honda, S. Terada, I. Mori and M.
Sugimoto, "Development of Mold Fluxes
for ULC Steel Casting", Foseco Inc., Mold
Flux Seminar - 1990.

7. Imai et al: Tetsu-to-Hagane, 1976

S543.
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1991 Steelmaking Conference Proceedings

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