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• FC Mold X is an electromagnetic flow-control solution designed to boost productivity, expand product mix flexibility, and improve quality—even when casting conditions vary—during the production of thin and medium-sized slabs
• Built on ABB’s proven FC Mold platform, FC Mold X was developed by SMS group and ABB to fit smoothly into the SMS CSP^® Nexus advanced casting and rolling concept
• Together, ABB’s expertise in slab casting metallurgy and SMS group’s CSP^® know-how deliver a solution that can be scaled to help customers stay competitive and improve day-to-day performance

ABB AB Sweden and SMS group GmbH have agreed to work in partnership to jointly market and further develop FC Mold X (Flow Control Mold X), an electromagnetic flow-control system for thin and medium slab continuous casting. This builds on ABB’s long track record of supporting the continuous casting industry with stirring and braking solutions.

The cooperation brings together ABB’s strengths in electromagnetic stirring and braking technologies for slab casting and SMS group’s CSP^® Nexus casting-and-rolling concept (CSP^® Compact Strip Production) to create a solution customers can scale up as needed. The goal: an optimized energy balance, higher productivity, more flexibility in product mixes and steel grades, including the high-end segment, as well as better surface quality for low-carbon steel production.

CSP^® Nexus is SMS group’s integrated casting and rolling line that separates roughing and finish-rolling—supporting a wider range of steel grades and enabling carbon-neutral production options. This variability requires precise and adaptable flow control in the mold.

Dr. Jochen Wans, Head of Casting Flat, SMS group: “The modular hardware and control algorithms make FC Mold X a flexible, future-proof platform for adaptive casting strategies and digital integration. Its design supports further extensions and tuning to evolving production and quality requirements.”

Casting thicknesses with CSP^® Nexus normally range between 110 and 160 millimeters at the mold exit in a vertical liquid bending continuous caster (VLB), featuring a maximum throughput of 8.5 tons per minute.

FC Mold X was co developed by ABB and SMS group with a focus on mechanical design, electromagnetic performance, and control—so mold flow control works in sync with how CSP^® Nexus runs and adapts to different operating requirements.

The system uses two separate electromagnetic fields in the mold: a lower DC magnetic field helps slow down the jet as it exits the nozzle, and an upper field supports controlled stirring and stabilization of the meniscus, working with both AC and DC functions at the same time. This provides flexibility in braking, stirring, and combinations of both to achieve an optimal mold flow regardless of casting conditions. The system’s modular design means it can be easily adapted to different casting thicknesses and throughput rates.

Modes for maximum adaptability
FC Mold X supports various operating modes that are tailored to different casting conditions and enable maximum versatility through seamless mode transition. During braking, for example, only the EMBR (electromagnetic brake) is activated. This mode is designed for steel grades produced at fast casting speeds and high productivity levels.

In the combined mode, the EMS (electromagnetic stirrer) and the electromagnetic brake EMBR operate simultaneously, which is particularly suitable for grades that are prone to surface defects at medium throughput rates.

Direct added value for plant owners
FC Mold X supplements CSP^® Nexus as a key functional unit when it comes to shaping and quality assurance, boasting compatibility with parallel and funnel-shaped molds. For CSP^® Nexus plant owners, FC Mold X offers precise adaptability to different casting scenarios while maintaining high product quality and productivity. Defect formation and rejects can be minimized, even under conditions where high levels of production and product mix flexibility are needed.