QUALITY PROBLEMS IN

CONTINUOUS CAST PRODUCTS &

REMEDIAL MEASURES
LONG PRODUCTS
SHAPE
RHOMBODITY OF SQUARE BILLETS

CHARACTERISTICS

• Difference between length of

two diagonals > 10 mm
• More pronounced in steel grades
with C from 0.15 to 0.30%
• May lead to breakout in extreme
cases
 RHOMBODITY OF SQUARE BILLETS .. Contd.
CAUSES
• Misalignmentof the tundish liquid stream
• Non uniform mould water cooling channel gap
•Variable mould copper wall thickness
•Non uniform spray cooling
•Worn / damaged nozzles

REMEDIAL MEASURES
• Correct alignment of liquid stream into mould
• Check mould tube alignment
• Replace mould
• Identical nozzle parameters such as water flow, spray angle
and height of all nozzles on each side of the billet
• Check for clogged nozzles
• Check nozzle performance
 CONCAVITY : BILLETS & BLOOMS

CHARACTERISTICS
• Depression in one ore more side

CAUSES
• Excessive secondary cooling spray
intensity
• Worn / damaged nozzles

REMEDIAL MEASURES
• Reduction of secondary cooling spray intensity
• Check nozzle performance
SURFACE DEFECTS
SURFACE DEFECTS : BILLETS, BLOOMS &
ROUNDS

CHARACTERISTICS

1. Longitudinal mid face crack

2. Longitudinal surface crack
3. Longitudinal corner crack
4. Longitudinal off-corner crack
5. Transverse surface crack
6. Transverse corner crack
7. Fine cracks
1. LONGITUDINAL MID FACE CRACK
CHARACTERISTICS
• Most prone for Carbon levels 0.08 to 0.14%

CAUSES
• Liquid stream into the mould can produce a
thinner shell in the centre region
• Uneven mould lubrication
• Too strong secondary cooling below the mould,
billet faces want to contract laterally at the
transition from weak to strong cooling but are
prevented by the hot interior of the strand.
Tensile strain develops which can lead to surface
cracking
• Incorrect nozzle spray distribution causing cold
spot, thermal strain leads to cracking
• Worn / damaged nozzles
1. LONGITUDINAL MID FACE CRACK .. Contd.

REMEDIAL MEASURES
• Correct alignment of liquid stream into
mould
• Even mould lubrication
• Reduce secondary cooling intensity below
mould
• Check spray nozzle distribution for
irregularities
• Check nozzle performance
2. LONGITUDINAL SURFACE CRACKS : ROUNDS

CHARACTERISTICS
• Rounds are very sensitive to longitudinal
cracks giving rise to breakouts
• Cracks are usually associated with
depression on billet surface
Diameter • Most prone for Carbon levels 0.08 to 0.14%
2. LONGITUDINAL SURFACE CRACKS : ROUNDS
… contd.
CAUSES
• Non uniform cooling in the mould through
incorrect mould taper
• Non uniform cooling in the mould through
uneven mould cooling water channel gap
• Uneven mould lubrication
Diameter • Uneven secondary cooling intensity
• Worn / damaged nozzles
REMEDIAL MEASURES
• Correct mould tapers
• Check mould tube alignment
• Ensure even mould lubrication
• Check spray nozzle distribution for irregularities
• Check correct sprayed overlaps for even distribution
• Check nozzle performance
3. LONGITUDINAL SURFACE CRACKS : BILLETS
& BLOOMS
CAUSES
• Liquid stream flow in the mould can produce a
local thinner shell
• Uneven mould lubrication
• Too strong secondary cooling below the mould,
billet faces want to contract laterally at the
transition from weak to strong cooling but are
prevented by the hot interior of the strand.
Tensile strain develops which can lead to
surface cracking
• Incorrect nozzle spray distribution causing cold
spot, thermal strain leads to cracking
• Misaligned nozzles
• Clogged nozzles
• Worn / damaged nozzles
3. LONGITUDINAL SURFACE CRACKS : BILLETS
& BLOOMS .. Contd.
REMEDIAL MEASURES
• Correct alignment of liquid stream into mould
• Even mould lubrication
• Reduced secondary cooling intensity below
mould
• Check spray nozzle distribution for
irregularities
• Check nozzle alignment
• Check clogged nozzles
• Check nozzle performance
4. LONGITUDINAL CORNER CRACKS : BILLETS
& BLOOMS
CAUSES
• Normally originates in the mould together with
rhombodity
• Can occur with weak mould taper, bulging in
the mould occurs which can produce internal
corner crack, this can grow out to surface
• Can be caused by rhombodity / distortion of
copper mould tube
4. LONGITUDINAL CORNER CRACKS : BILLETS
& BLOOMS .. Contd.
REMEDIAL MEASURES
• Correct alignment of liquid stream into mould
• Check mould tube alignment
• Replace mould
• Identical nozzle parameters such as water flow,
spray angle and height of all nozzles on each
side of the billet
• Check for clogged nozzles
• Check nozzle performance
 5. LONGITUDINAL OFF CORNER CRACKS :
BILLETS & BLOOMS
CAUSES
• Incorrect mould taper leading to bulging in the
mould which produce internal cracking. These
cracks can open up below the mould when the
bulge is rolled back by the foot rolls
• Uneven mould lubrication causing local
reduced heat transfer and shell thinning /
depression

REMEDIAL MEASURES
• Correct mould taper
• Even mould lubrication
6. TRANSVERSE SURFACE CRACKS : BILLETS,
BLOOMS & ROUNDS
CAUSES
• Usually occur on micro alloyed steels at
base of oscillation marks due to
bending / straightening within
temperature related low ductility region
• Cracks on outer radius face caused by
bending
• Cracks on inner radius face caused by
straightening
6. TRANSVERSE SURFACE CRACKS : BILLETS,
BLOOMS & ROUNDS .. Contd.

REMEDIAL MEASURES
• Modify strand thermal profile to avoid low
ductility region
OK AVOID OK
100
Plain C

Ductility(%)
V
Nb
Nb-V

50

0
500 600 700 800 900 1000
Surface Temperature (C)
7. TRANSVERSE CORNER CRACKS : BILLETS,
BLOOMS & ROUNDS

Corner
CAUSES
• Usually occur on micro-alloyed
steels at the base of the
oscillation marks due to
bending / straightening within
the temperature related low
ductility region.
• Over spraying of corners.
• Cracks on outer radius corners
caused by bending.
• Cracks on inner radius corners
caused by straightening.
7. TRANSVERSE CORNER CRACKS : BILLETS,
BLOOMS & ROUNDS … contd.
REMEDIAL MEASURES
• Modify strand thermal profile
Corner
to avoid low ductility region.
• Check nozzle spray angle and
or height.

OK AVOID OK
100
Plain C

Ductility (%)
V
Nb
Nb-V

50

0
500 600 700 800 900 1000
Surface Temperature (C)
8. FINE CRACKS : BILLETS, BLOOMS & ROUNDS

CAUSES
• The cracks develop in
aluminium killed steels and are
located at the boundaries of
the primary austenite grains
where aluminium nitride
precipitates. Surface
temperature is below or
oscillating about austenite
transformation temperature
(Ac3 temperature)
8. FINE CRACKS : BILLETS, BLOOMS & ROUNDS
… contd.
REMEDIAL MEASURES
• Ensure strand thermal
profile is above the austenite
transformation temperature
(Ac3 temperature).
Avoid surface temperature
oscillation in this area.
Micro-alloyed grades –
increases carbo-nitride
precipitation at grain
boundaries and reduces
ductility.

High carbon grades –

increases the risk of
thermally induced cracking.
INTERNAL DEFECTS
 TYPES OF INTERNAL DEFECTS

1. Longitudinal corner cracks.

2. Longitudinal off corner cracks.
2 3. Halfway cracks.
4 4. Spider cracks.
5
1
5. Diagonal cracks
3
3

33
1. LONGITUDINAL CORNER CRACKS ASSOCIATED
WITH RHOMBODITY – BILLETS & BLOOMS
CHARACTERISTICS
• May lead to breakouts in extreme cases;
severity varies with steel grade, most
troublesome with 0.15 to 0.30% carbon
steel grades

CAUSES
• Misalignment of the tundish liquid stream.
• Non uniform mould water cooling channel gap.
• Variable mould copper wall thickness on all four faces.
• Non uniform spray cooling
• Clogged nozzles.
• Worn / damaged nozzles
 1. LONGITUDINAL CORNER CRACKS ASSOCIATED
WITH RHOMBODITY – BILLETS & BLOOMS .. Contd.
REMEDIAL MEASURES
• Correct alignment of liquid stream
into mould.
• Check mould tube alignment.
• Replace mould.
• Identical nozzle parameters such
as water flow, spray angle and
height of all nozzles on each side of
the billet.
• Check for clogged nozzles.
• Check nozzle performance.
2. LONGITUDINAL OFF CORNER CRACKS – BILLETS &
BLOOMS
CAUSES
• Incorrect mould taper leading to
bulging in the mould which
produces internal cracking.
• Uneven mould lubrication
Crack shown in a breakout shell. causing local reduced heat transfer
and shell thinning / depressions.
• Excessive bulging due to lack of
support rolls.
• Roll support length too short.
• Roll gap too large.
2. LONGITUDINAL OFF CORNER CRACKS – BILLETS &
BLOOMS .. Contd.
REMEDIAL MEASURES
• Correct mould tapers.
• Ensure even mould lubrication.
• Reduce casting speed.
• Check roll gap and alignment
Crack shown in a breakout shell.
3. HALFWAY CRACKS – BILLETS, BLOOMS & ROUNDS

CAUSES
• Excessive surface temperature
reheats.
• Excessive bulging in billets and
blooms.
• Excessive pinch roll loads if
cracks are vertical at top and
bottom.
• Clogged nozzles.
• Excessive nozzle misalignment
3. HALFWAY CRACKS – BILLETS, BLOOMS & ROUNDS

REMEDIAL MEASURES
... Contd.
• Check strand thermal profile and
correct.
• Reduce pinch roll loads.
• Reduce casting speed to reduce
bulging.
• Check for clogged nozzles.
• Check nozzle alignment
4. SPIDER CRACKS – BILLETS, BLOOMS & ROUNDS

CAUSES
• Centre cools faster than surface,
radial tensile strains induce
cracking.
4. SPIDER CRACKS – BILLETS, BLOOMS & ROUNDS
... Contd.

REMEDIAL MEASURES
• Increase secondary cooling
intensity.
• Extend secondary cooling length.
• Reduce casting speed.
5. DIAGONAL CRACKS ASSOCIATED WITH
RHOMBODITY – BILLETS & BLOOMS
CHARACTERISTICS
• Associated with Rhombodity
• May lead to breakouts in extreme
cases; severity varies with steel
grade, most troublesome with 0.15
to 0.30% carbon steel grades.
CAUSES
•Misalignment of the tundish liquid stream.
• Non uniform mould water cooling channel gap.
• Variable mould copper wall thickness on all four faces.
• Non uniform spray cooling; clogged nozzles.
5. DIAGONAL CRACKS ASSOCIATED WITH
RHOMBODITY – BILLETS & BLOOMS ... Contd.

REMEDIAL MEASURES
• Correct alignment of liquid stream
into mould.
• Check mould tube alignment.
Replace mould.
• Identical nozzle parameters such
as water flow, spray angle and
height of all nozzles on each side of
the billet.
• Check for clogged nozzles.
6. CENTER SEGREGATION – BILLETS, BLOOMS &
ROUNDS

CAUSES
• High ladle / tundish superheat.
• Increased casting speeds.
• Worse in smaller section size.
• Worse with increasing carbon
content of the steel being cast.
 
6. CENTER SEGREGATION – BILLETS, BLOOMS &
ROUNDS ... Contd.

REMEDIAL MEASURES
• Reduce ladle / tundish superheat.
• Electromagnetic stirring (EMS).
• Reduce casting speed.
• Increasing secondary cooling
intensity and extend secondary
cooling length may help.
• Mechanical soft reduction for
blooms.
• Thermal soft reduction for billets.
 
SURFACE DEFECTS
TYPES OF SURFACE DEFECTS
1. Longitudinal mid face
cracks.
2. Longitudinal surface
cracks.
3. Longitudinal corner cracks.
4. Longitudinal off-corner
cracks.
5. Transverse surface cracks.
6. Transverse corner cracks.
7. Fine cracks
1. LONGITUDINAL MID FACE CRACKS (CAN BE
ASSOCIATED WITH DEPRESSION – SLAB
CAUSES
• Carbon levels 0.08 to 0.14% most
prone.
• Offset liquid stream flow into mould in
the centre region.
• Wrong casting powder.
• Uneven mould lubrication.
• Uneven mould cooling.
Deep cracks up to 25mm
deep 0.5 to 10 m long in
• Uneven secondary cooling in upper
central area of slab width. cooling zones.
• Clogged nozzles.
• Incorrect spray overlaps.
1. LONGITUDINAL MID FACE CRACKS (CAN BE
ASSOCIATED WITH DEPRESSION – SLAB ... Contd.
PREVENTIVE MEASURES
• Correct alignment of liquid stream into
mould.
• Deep cracks up to 25mm deep 0.5 to 10
m long in central area of slab width.
• Check casting powder and evenness of
application. Check mould cooling.
• Check sprays nozzle distribution for
Deep cracks up to 25mm
deep 0.5 to 10 m long in
irregularities.
central area of slab width. • Check for clogged nozzles.
• Check nozzle alignment, position,
height and spray overlaps.
INTERNAL DEFECTS
 TYPES OF INTERNAL DEFECTS

1. Longitudinal off corner cracks.

2 2. Transverse near surface cracks.
3 3. Transverse near centre cracks.
1
4. Centreline cracks.
5
4 5. Triple point cracks.
1. LONGITUDINAL OFF CORNER CRACKS

CAUSES
•Incorrect mould taper
leading to bulging in the
mould which produces
internal cracking.
•Uneven mould lubrication
Crack shown in a causing local reduced heat
breakout shell transfer and shell thinning /
depressions.
•Incorrect roll gap – too
large.
1. LONGITUDINAL OFF CORNER CRACKS
REMEDIAL MEASURES
• Correct mould tapers.
• Ensure even mould
lubrication.
• Correct roll gap.

Crack shown in a
breakout shell
2. TRANSVERSE NEAR SURFACE CRACKS

CAUSES
• Mould to roll misalignment
• Roll to roll misalignment.
• Bent roll.
• Excessive inter roll bulging.
• Strand bending if near outer
radius face.
• Excessive pinch roll loads.
• Excessive surface reheats.
• Clogged nozzles.
• Misaligned nozzles.
2. TRANSVERSE NEAR SURFACE CRACKS .. Contd.
REMEDIAL MEASURES
• Check machine alignment.
• Reduce bulging by
decreasing casting speed or
increasing secondary cooling
water flows.
• Reduce pinch roll loads.
• Check strand thermal
profile and correct.
• Check for clogged nozzles.
• Check nozzle alignment.