Continuous Castings: Manufacturing Process

Manufacturing Process Foundry:

Continuous casting is a process in which solidifying metal is extracted through an open ended mold fitted with a cooling unit. Heat is extracted and the metal exits the mold as a solid with a constant cross section. It allows lower cost production of metal sections with better quality, due to finer control through automation of the casting process. Generally a saw is set up after the withdrawal rolls, in order to cut the casting at constant lengths. The castings are semi-finished products, which are further processed in extrusion, drawing, rolling or machining operations.

Mold heat transfer is both critical and complex. Mathematical and computer modeling are typically utilized in developing a greater understanding of mold thermal conditions, and to aid in proper design and operating practices. Heat transfer is generally considered as a series of thermal resistances as follows:

  • Heat transfer through the solidifying shell
  • Heat transfer from the shell surface to the graphite sleeve
  • Heat transfer through the graphite sleeve
  • Heat transfer from the graphite sleeve outer surface to the copper cooler
  • Heat transfer through the copper cooler inner surface to the cooling water


Continuous Casting has evolved from a batch process into a sophisticated continuous process. This transformation has occurred through understanding principles of mechanical design, heat-transfer, metallurgical properties and stress-strain relationships, to produce a product with excellent shape and quality. In recent years, the process has been optimized through careful integration of electro-mechanical sensors, computer-control and production planning to provide a highly-automated system designed for ever demanding market requirements.


Rapsri have two state-of-the-art Continuous Castings machines with complete PLC controls and advanced Quick Die Change Technology.