Optimization of Water Channel Design in Beam-blank Molds

The magnitude and uniformity of the hotface temperature greatly affects the life of continuous casting molds, in addition to affecting surface defects in the product, such as longitudinal cracks. In this work, several different designs for the cooling channels of a beam-blank mold are evaluated using two-dimensional finite-element heat conduction models in order to minimize hotface temperature and to improve its uniformity around the mold perimeter. The maximum hotface temperature is found near the meniscus at the concave internal “corner” of the web where heat flow converges. It is controlled by the maximum distance from the hotface to the cooling water. The best design involves a large-radius annulus formed by putting half-moon shaped copper inserts into a drilled cylinder. Existing molds can be improved by drilling a small extra hole near the critical location. The improved mold designs have been found to improve performance in service at operating beam-blank casters.