When a heat of steel is melted and refined, it is necessary to solidify it into useful forms for further processing or final use. Ingot casting remains the preferred method for certain specialty, tool, forging, and remelted steels. This article discusses the methods, equipment, and theory for pouring, solidifying, and stripping steel ingots. It describes two basic types of pouring methods, top pouring and bottom pouring, and provides information on equipment such as hot tops, ingot molds, and stools. The design of the ingot is dictated by the application and type of steel involved. The article concludes with information on the applications of solidification simulation.

This article describes the presses, transportation equipment, and manufacturing processes associated with cogging. It discusses the practical and metallurgical issues encountered during the conversion of ingot to billet. The article explains the use of numerical modeling as part of the continuing efforts to reduce the cost and time associated with developing new cogging sequences, increase the yield, make the processes more robust, and increase the quality of the produced product.

Ingot casting is the vital conduit between molten metal provided by primary production and recycling and the manufacture of aluminum and aluminum alloy products. A number of ingot casting processes have been developed to ensure the soundness, integrity, and homogeneity required by downstream manufacturing processes. This article starts with a review of the different forms of ingot and the molten-metal processing techniques involved in ingot casting. It then describes the open-mold casting and direct chill (DC) ingot casting processes. The process variations and solidification in the DC process are summarized. The article explains continuous processes, namely, twin-roll strip casting, slab casting, and wheel-belt processes. It concludes with information on postsolidification processes, including stress relief and scalping, and a discussion of safety practices for ingot casting.