Understanding the role water-cooling plays during continuous casting of steel and aluminum alloys

J. Sengupta, B. G. Thomas, M. A. Wells

Research output: Contribution to journalConference articlepeer-review


Water-cooling plays a major role in extracting heat from both the mold and solidifying metal during the continuous casting of steel and aluminum alloys and is characterized by complex boiling phenomena. Heat extraction rates during water-cooling, which have strong dependence on the metal surface temperature, can rapidly change with time as the strand cools down. Consequently, uncontrolled cooling may cause fluctuations in the temperature gradients inside the solidifying shell and generate tensile thermal stresses at the solidification front that can ultimately lead to the appearance of hot tears/cracks in the final product. This paper compares and contrasts the water-cooling techniques used for casting steel and aluminum and discusses their implications in terms of final product quality based on fundamental studies and predictive mathematical models. Finally, optimal practices for the control of cooling in casting processes for both steel and aluminum alloys are evaluated.

Original languageEnglish (US)
Pages (from-to)179-193
Number of pages15
JournalMaterials Science and Technology
StatePublished - 2004
Externally publishedYes
EventMaterials Science and Technology, MS and T 2004; Volume 2: AIST/TMS Proceedings - New Orleans, LA, United States
Duration: Sep 26 2004Sep 29 2004


  • Aluminum
  • Boiling water cooling curves
  • Continuous casting
  • Direct Chill casting
  • Film boiling
  • Leidenfrost temperature
  • Nucleate boiling
  • Primary cooling
  • Secondary cooling
  • Solidification
  • Spray cooling
  • Steel
  • Water-cooling

ASJC Scopus subject areas

  • Engineering(all)


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