Continuous Casting


Schedule

16–19 October 2017 • Courtyard by Marriott Fort Wayne Downtown • Fort Wayne, IN, USA

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Monday, 16 October 2017

4–6 p.m.

Registration

Tuesday, 17 October 2017

7 a.m.

Registration and Breakfast

8 a.m. 

Historical Perspective of Continuous Casting
Jack Young, Hatch Ltd.
A review of the historical development of continuous casting and the solidification process.

8:45 a.m.

Break

9 a.m.

Continuous Casting Design and Technology (Slab and Long Products)
Dewey Humes, Primetals Technologies USA LLC
The presentation will cover the basics of machine and equipment design for continuous casting technology. Both flat and long product technologies, equipment, and machines will be explained. A brief introduction to process models affecting quality will also be provided.

10 a.m.

Break

10:15 a.m. 

Principles of Mold Flux Technology — An Operators Guide to Continuous Casting Flux
Marc McClymonds, Imerys Metal Casting Solutions
A discussion of the functions and key properties of mold flux. Other topics covered are flux design, production, application practices and selection criteria. 

11 a.m.

Initial Solidification and Oscillation Mark Formation
Brian Thomas, Colorado School of Mines

Noon

Lunch

1 p.m. 

Sources of Reoxidation and Why to Avoid
Ron O’Malley, Missouri University of Science and Technology
To produce high-quality cast products, steel must be protected from reoxidation. Reoxidation can occur in the ladle, at secondary ladle metallurgy operation, and also in the transfer operations from ladle to tundish and tundish to the mold. Various techniques are described that can be used to minimize reoxidation.

2 p.m. 

Break

2:15 p.m.

Caster Breakouts
Bill Emling, SMS USA LLC
Review of various causes for breakouts and discussion of systems and solutions designed to prevent them. This talk will closely follow the chapter in the Making, Shaping and Treating of Steel, 11th Edition, Casting Volume.

3:15 p.m. 

Break

3:30 p.m.

Caster Quality Defects and Their Potential Causes — Slab and Billet Quality
Ron O’Malley, Missouri University of Science and Technology
The surface and internal quality of continuously cast slabs and billets is intimately linked to the caster design and to the operating and maintenance practices employed in the continuous casting process. Common causes for five classes of continuous casting defects (longitudinal cracking, transverse cracking, slivers and lamination defects, internal cracking, and segregation defects) will be reviewed and linked to these design and practice influences.

5 p.m. 

Adjourn

Wednesday, 18 October 2017

7 a.m. 

Breakfast

8 a.m.

Mold Copper Alloys, Design and Influence of Operating Factors on Performance
Ian Bakshi, KME America Inc.
The requirements that molds must fulfill on a steel continuous casting machine, the copper alloys used, details of their design, various operating factors that affect mold life and typical mold problems will be presented.

9 a.m.

Break

9:15 a.m.

Mold and Copper Maintenance, Mold Coatings
Chad Donovan, SMS Technical Services LLC
Basics of continuous caster mold maintenance and specifics related to mold copper repairs. Historical and current overview of mold copper coating options available in North America.

10:15 a.m.

Break

10:30 a.m.

Caster Roll Maintenance and Overlay Technologies
Jeff Brower, Primetals Technologies USA LLC
Caster roll and segment life can be significantly increased through the use of customized weld overlays and base materials. This session details the operational impact on caster rolls and technologies developed to improve roll performance.

11:30 a.m.

Lunch

12:30 p.m.

Plant Tour of Steel Dynamics Inc. – Structural and Rail Division

4 p.m. 

Panel Discussion
Panelist:

  • Yury Krotov, Steel Dynamics Inc. – Flat Roll Group Butler

  • Ron O’Malley, Missouri University of Science and Technology

  • Bill Schlichting, SKW North America

  • Rick Besich, ArcelorMittal Indiana Harbor

  • Ian Deeks, Nucor Steel–South Carolina

5 p.m. 

Reception

Thursday, 19 October 2017

7 a.m. 

Breakfast

8 a.m.

Billet and Bloom Caster Operations and Maintenance
Bill Schlichting, SKW North America, and Ian Deeks, Nucor Steel–South Carolina
Detail review of casting billets and blooms from an operational and metallurgical perspective.

9 a.m.

Break

9:15 a.m.

Caster Hydraulics — Failure Modes and Preventive Maintenance
Mark Cook, Yates Industries Inc.
Cylinders used in casters, failure modes, preventive maintenance, effective cylinder reconditioning program.

10 a.m.

Break

10:15 a.m.

Caster Secondary Cooling and Water Treatment and Spray Nozzles for the Steel Industry
Eric Rosenow, NALCO Water, An Ecolab Company, and Steven Swoope, Delevan Spray Technologies
The water treatment challenges and needs of a continuous caster secondary cooling system will be reviewed along with the potential impacts that secondary water quality can have on the operational and maintenance key performance indicators of a caster. The presentation will also be a review of the hydraulic and two-fluid nozzles used in steel production highlighting the basic use of atomizers focusing on the various technologies, operations and maintenance uses.

11:15 a.m.

Caster Bearings — Types of Bearings, Failure Modes and Preventive Maintenance
Paul Brda and Bimal Nathwani, NSK Corp.
Types of bearings, failure modes and preventive maintenance.

Noon

Conference Adjourn