FC Mold X: Adaptive mold flow control for thin to medium slab casting
Built on ABB’s proven FC Mold platform and co-developed with SMS group to support flexible and stable CSP® Nexus casting
Overview
FC Mold X extends ABB’s proven slab mold flow control expertise into thin to medium slab casting. Built on the FC Mold platform for CSP® Nexus, it offers multiple electromagnetic braking and stirring combinations enabling adaptable control of flow behavior across varying casting conditions. The result is more stable operation, improved surface quality and greater flexibility supporting a broader range of grades and throughput requirements.
Key benefits
Improved surface quality for demanding steel grades
<p>More stable mold flow and meniscus conditions help reduce mold powder entrapments, inclusions and surface‑related defects, supporting higher slab and coil quality</p>Higher productivity at high casting speeds
<p>Calmer mold flow at elevated casting speeds enables increased throughput while maintaining metallurgical stability in thin to medium slab casting</p>Reduced defect formation and downgrade risk
<p>Controlled flow conditions help limit turbulence, flow asymmetry and excessive penetration depth, reducing the likelihood of defects that lead to downgrades or rejects</p>Greater flexibility in product mix and operating conditions
<p>Adaptive mold flow control supports stable production across different steel grades, slab thicknesses and throughput targets on the same caster</p>More stable and repeatable casting conditions
<p>Improved control of mold flow contributes to greater process stability, supporting consistent quality across varying operating scenarios</p>Lower adoption threshold and phased capability
<p>Built on ABB’s proven FC Mold platform, FC Mold X also supports a phased approach. Start with braking and expand capability as your requirements evolve</p>Features
FC Mold X applies three electromagnetic fields to enable adaptable flow control functions in the mold across varying casting conditions:
- Lower DC braking field dampens and stabilizes flow below the submerged entry nozzle
- Upper DC stabilizing field reduces fluctuations at the meniscus
- Upper AC stirring field controls meniscus flow speed
Multiple operating modes are available to support both quality-critical and throughput-oriented production. FC Mold Control enables seamless transitions between modes without disturbing mold flow:
- Braking mode is typically used for high-throughput conditions where stronger damping of flow is required. For higher casting speeds, the lower coil can be lifted to increase the braking effect on the steel jet
- Dual braking mode, using upper and lower DC fields, provides an additional configuration for very high casting speeds, facilitating stable flow behavior across varying conditions
- Combi mode supports surface‑defect‑sensitive grades at moderate casting speeds. Upper and lower coils work together with simultaneous AC and DC magnetic fields to control flow and stabilize penetration depth and meniscus behavior
The coil system is mounted externally on a manipulator and retracted during mold changes, avoiding added mold weight and reducing mold change impact compared with mold‑mounted solutions.
In braking mode, the lower DC coil can be repositioned to optimize braking strength at high casting speeds, improving meniscus stability and jet control under demanding conditions.
FC Mold X was co‑developed with SMS group to align electromagnetic mold flow control with CSP® Nexus casting behavior, slab thickness range and operating flexibility.
Customers focused on high-throughput production can start with braking functionality, FC Mold X Brake, to stabilize flow under demanding conditions. As production requirements evolve toward more surface-sensitive grades or wider operating windows, additional stirring and stabilization capabilities can be added to support more advanced flow control.
FC Mold X is built on ABB’s established FC Mold platform, extending proven electromagnetic mold flow‑control principles into thin to medium slab casting.
The FC Mold X integrates with ABB Ability™ Optimold Control for real-time, automatic flow adjustments based on mold temperature and process data.
With no moving parts in the mold area, FC Mold X is designed for reliable, long-term operation with minimal maintenance requirements.
FC Mold X is backed by ABB’s global metallurgy organization, providing commissioning, optimization and lifecycle support based on 80+ years of electromagnetic stirring and braking expertise across 1900+ installations worldwide.