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<p>The continuous casting of Ti-stabilized austenitic stainless steel presents significant challenges due to strong steel–slag interfacial reactions, flux composition instability, and inadequate lubrication when conventional CaO–SiO<sub>2</sub>-based mold fluxes are used. In this study, a novel mold flux was established by extracting value-added oxides (Fe<sub>2</sub>O<sub>3</sub>, TiO<sub>2</sub>, Na<sub>2</sub>O, and Al<sub>2</sub>O<sub>3</sub>) from red mud and critically mixing them to achieve a composition tailored for the casting of Ti-stabilized steel. Thermodynamic calculations were performed using FactSage software to predict phase evolution and ensure the formation of beneficial crystalline phases. The prepared flux was melted at 1300&#xa0;°C and systematically characterized using heating microscopy and thermogravimetry/differential scanning calorimetry (TG–DSC) analysis. Heating microscopy revealed a progressive morphological evolution from an intact cylindrical pellet to deformation (989&#xa0;°C) to sphere formation (1010&#xa0;°C), hemispherical collapse (1051&#xa0;°C), and complete flow (1217&#xa0;°C), indicating a broad softening-to-flow temperature interval. TG–DSC analysis revealed continuous weight loss up to 500–600&#xa0;°C, attributed to moisture evaporation and fluoride-containing phase reactions, followed by a comparatively stable mass profile with only minor weight reduction up to 1200&#xa0;°C. Laboratory experiments and kinetic modeling using Ti-containing molten steel (0.7 wt% Ti) were performed to assess the chemical interaction between mold flux and the steel. Ti losses of approximately 7.3 wt% (experimental) and 15 wt% (predicted) after 30&#xa0;min of interaction at 1550&#xa0;°C indicate that the mold flux possesses acceptable chemical stability in contact with Ti-bearing steel. The results underline the potential of red-mud-derived mold fluxes as a sustainable and performance-effective solution for casting high-alloy Ti-stabilized steels, demonstrating promising technical feasibility and potential sustainability advantages under laboratory-scale conditions.</p> Graphical Abstract <p></p>

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Red-Mud-Derived Mold Flux for Continuous Casting of Ti-Stabilized Stainless Steel

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Prasenjit Singha,
  • Preeti Prakash Sahoo,
  • Mayuresh Lohani,
  • Sunil Yadav,
  • Chenna Rao Borra,
  • Manas Paliwal

摘要

The continuous casting of Ti-stabilized austenitic stainless steel presents significant challenges due to strong steel–slag interfacial reactions, flux composition instability, and inadequate lubrication when conventional CaO–SiO2-based mold fluxes are used. In this study, a novel mold flux was established by extracting value-added oxides (Fe2O3, TiO2, Na2O, and Al2O3) from red mud and critically mixing them to achieve a composition tailored for the casting of Ti-stabilized steel. Thermodynamic calculations were performed using FactSage software to predict phase evolution and ensure the formation of beneficial crystalline phases. The prepared flux was melted at 1300 °C and systematically characterized using heating microscopy and thermogravimetry/differential scanning calorimetry (TG–DSC) analysis. Heating microscopy revealed a progressive morphological evolution from an intact cylindrical pellet to deformation (989 °C) to sphere formation (1010 °C), hemispherical collapse (1051 °C), and complete flow (1217 °C), indicating a broad softening-to-flow temperature interval. TG–DSC analysis revealed continuous weight loss up to 500–600 °C, attributed to moisture evaporation and fluoride-containing phase reactions, followed by a comparatively stable mass profile with only minor weight reduction up to 1200 °C. Laboratory experiments and kinetic modeling using Ti-containing molten steel (0.7 wt% Ti) were performed to assess the chemical interaction between mold flux and the steel. Ti losses of approximately 7.3 wt% (experimental) and 15 wt% (predicted) after 30 min of interaction at 1550 °C indicate that the mold flux possesses acceptable chemical stability in contact with Ti-bearing steel. The results underline the potential of red-mud-derived mold fluxes as a sustainable and performance-effective solution for casting high-alloy Ti-stabilized steels, demonstrating promising technical feasibility and potential sustainability advantages under laboratory-scale conditions.

Graphical Abstract