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Zhuo Chen, Jiajing Zhang, Xiting Li, WEITONG DU, Jianchao Ma, and Jian Yang, A critical review on the challenges of developing continuous casting mold fluxes for high-Ti steels, Int. J. Miner. Metall. Mater.,(2025). https://dx.doi.org/10.1007/s12613-025-3176-9
Zhuo Chen, Jiajing Zhang, Xiting Li, WEITONG DU, Jianchao Ma, and Jian Yang, A critical review on the challenges of developing continuous casting mold fluxes for high-Ti steels, Int. J. Miner. Metall. Mater.,(2025). https://dx.doi.org/10.1007/s12613-025-3176-9
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A critical review on the challenges of developing continuous casting mold fluxes for high-Ti steels

Abstract: The large-scale production of high-Ti steels is limited by the formation of Ti-containing oxides or nitrides in steel–slag reactions during continuous casting. These processes degrade mold flux properties, clog the submerged entry nozzle, form a floater in the mold, and produce various surface defects on the cast slabs. This review summarizes the effect of nonmetallic inclusion on the traditional CaO–SiO2-based mold fluxes and novel CaO–Al2O3-based low- or non-reactive fluxes containing TiO2, BaO, and B2O3 additives to avoid undesirable steel, slag, and inclusion reactions, with the aim to provide a new perspective for the research and practice related to balancing the lubrication and heat transfer of mold flux, and improving the smooth operation and the surface defects on the cast slabs. For traditional CaO–SiO2-based mold flux, although the addition of solvents such as Na2O, Li2O, and B2O3 can enhance flowability, steel–slag reactions persist, limiting the effectiveness of CaO–SiO2-based mold fluxes in high-Ti steel casting. CaO–Al2O3-based low- or non-reactive mold fluxes are a research focus by reducing the SiO2 content and adding other components. Replacing CaO with BaO can lower the melting point and inhibit the crystallization, allowing the flux to maintain good flowability at low temperatures. Replacing SiO2 with TiO2 can stabilize the viscosity and enhance the heat transfer. To reduce the environmental impact, fluorides are replaced with components such as TiO2, B2O3, BaO, Li2O, and Na2O for fluorine-free mold fluxes with similar lubrication, crystallization and heat-transfer effects. When TiO2 replaces CaF2, it stabilizes the viscosity and enhances heat conductivity, while forming CaTiO3 and CaSiTiO5 phases instead of cuspidine to control crystallization. B2O3 lowers the melting point and suppresses crystallization, forming phases such as Ca3B2O6 and Ca11Si4B2O22. BaO introduces non-bridging oxygen to reduce viscosity, ensures flux flowability at low temperatures. However, further studies are required to determine the optimal mold flux contents, corresponding to the steel grades and the interactions between the various components of mold flux. In the future, the practical application of new mold fluxes for high-Ti steel will become the focus in further verification to achieve a balance between lubrication and heat transfer, which is expected to minimize the occurrence of casting problems and slab defects.

 

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