Manufacturing Process and Technical Requirements of Continuous Casting Moulds

The mould is a core component in the continuous casting process, playing a crucial role in the initial solidification of molten steel. Its quality and performance directly impact casting stability and the surface quality of billets. As the steel industry moves toward higher efficiency, longer service life, and superior product quality, the technology behind mould manufacturing continues to evolve.

🔧 Manufacturing Process: From Material Selection to Precision Machining

1. Material Selection:
   Mould tubes are typically made from high-purity oxygen-free copper (such as Cu-DHP, Cu-Cr-Zr), known for excellent thermal conductivity and machinability. The copper alloy is selected based on casting conditions and steel grades.
2. Tube Forming:
   Raw materials are processed through hot extrusion or centrifugal casting, followed by rough machining, annealing, and non-destructive testing to ensure uniform structure and freedom from cracks or shrinkage defects.
3. Precision Machining & Inner Surface Treatment:
   CNC machines are used to ensure precise dimensional tolerances and geometric accuracy. The inner surface is then chrome-plated (Cr-coating) to enhance wear resistance and prevent steel adhesion.
4. Cooling System Installation:
   The outer part is equipped with water jackets and cooling channels to ensure fast and uniform solidification. The design of these channels directly affects the service life and performance of the mould.
5. Quality Inspection & Final Testing:
   Each mould undergoes ultrasonic testing, hardness checks, hydrostatic pressure testing, and dimensional inspection to ensure compliance with international quality standards.

Key Technical Requirements

• High Dimensional Accuracy:
  Inner cavity tolerance must be within ±0.05 mm to avoid billet surface defects such as scratches or oscillation marks.
• Proper Surface Hardness:
  Chrome layer thickness is typically 0.10–0.30 mm to balance wear resistance and adhesion strength, avoiding flaking.
• Excellent Thermal Conductivity:
  Facilitates rapid and even solidification of molten steel, reducing the risk of cracks.
• Superior Thermal Fatigue and Stability:
  Able to withstand high temperatures and frequent thermal cycling, extending mould service life.

🔍 Industry Trends

With the rise of high-speed casting, high-strength steels, and special alloys, mould manufacturing is moving toward higher durability, extended lifespan, and smart monitoring. Technologies like in-mould temperature sensors, stress monitoring, composite copper alloys, and laser surface treatments are being increasingly adopted.

💡 JISTEEL’s Integrated Solutions

As a trusted supplier of metallurgical equipment and materials, JISTEEL offers a full range of round, rectangular, and square copper mould tubes tailored to customer specifications. We also provide associated equipment such as mould supports, oscillation systems, and water jackets. Our advanced manufacturing and strict quality control systems ensure durability and performance in demanding casting environments.