1. Introduction

The monoblock stopper rod is a critical flow-control refractory component used in modern continuous casting operations. Installed in the tundish, it regulates molten steel flow into the submerged entry nozzle (SEN) by precise vertical movement. Compared with traditional multi-piece stopper systems, monoblock stopper rods offer advantages such as improved structural integrity, better sealing performance, and more stable casting control.

 tundish Stopper

However, cracking of monoblock stopper rods remains one of the most common and serious operational problems. Cracks can lead to premature failure, unstable flow control, steel leakage, casting interruptions, and even major safety incidents. As casting speeds increase and steel cleanliness requirements become more stringent, preventing stopper rod cracking has become a key concern for steelmakers and refractory engineers.

This article provides a comprehensive analysis of why monoblock stopper rods crack and, more importantly, how to avoid cracking through proper design, material selection, manufacturing control, installation, and operation.

2. Structure and Working Conditions of a Monoblock Stopper Rod2.1 Basic Structure

A monoblock stopper rod is typically composed of:

• Rod body main structural part)
• Stopper head working end contacting the SEN)
• Refractory material matrix Al₂O₃–C, MgO–C, or composite)
• Optional zirconia or high-purity alumina insert at the head
• Steel anchoring or connecting system at the top

Unlike assembled stopper rods, the monoblock design integrates these elements into a single refractory body, which reduces joint-related failures but increases sensitivity to internal stresses.

2.2 Service Environment

During operation, the monoblock stopper rod is exposed to:

• Molten steel temperatures above 1550 °C
• Severe thermal gradients
• Chemical attack from steel and slag
• Mechanical loads from opening/closing movements
• Vibrations and impact during casting

These extreme conditions make the stopper rod highly susceptible to cracking if not properly designed or handled.

3. Common Types of Cracks in Monoblock Stopper Rods

Understanding crack types helps identify preventive strategies.

3.1 Thermal Shock Cracks

• Occur during rapid heating or cooling
• Usually surface-initiated
• Often propagate longitudinally along the rod body

3.2 Structural Stress Cracks

• Caused by internal residual stresses
• Often originate near material transitions or inserts
• Can be invisible initially and grow during service

3.3 Mechanical Damage Cracks

• Caused by improper handling, collision, or misalignment
• Common near the stopper head or connection zone

3.4 Chemical Degradation-Induced Cracks

• Result from oxidation of carbon
• Slag or steel penetration weakens the matrix
• Leads to spalling and crack propagation

4. Material Selection to Prevent Cracking4.1 Use of Carbon-Containing Refractories

Most monoblock stopper rods use Al₂O₃–C or MgO–C materials, because carbon:

• Improves thermal shock resistance
• Reduces elastic modulus
• Enhances crack arrest capability

However, excessive carbon can increase oxidation risk, so balance is essential.

4.2 Optimized Antioxidant System

To prevent carbon oxidation, effective antioxidants should be added, such as:

• Aluminum powder
• Silicon metal
• Boron carbide (B₄C)

A well-designed antioxidant system reduces decarburization, which otherwise leads to embrittlement and cracking.

4.3 Functionally Graded Materials

Advanced stopper rods use graded compositions, such as:

• High-purity zirconia or alumina at the stopper head
• Toughened Al₂O₃–C in the rod body
• High-strength refractory near the steel connection

This reduces thermal mismatch and internal stress concentration.

5. Manufacturing Factors Affecting Crack Resistance5.1 Raw Material Quality Control

Poor-quality raw materials introduce defects that act as crack initiation sites. Strict control is required for:

• Particle size distribution
• Purity and impurity levels
• Carbon morphology and dispersion

5.2 Homogeneous Mixing and Forming

Non-uniform mixing leads to localized stress zones. Best practices include:

• High-efficiency mixing equipment
• Controlled forming pressure
• Avoidance of segregation during molding

5.3 Controlled Drying and Heat Treatment

Inadequate drying is a major cause of cracking. Moisture trapped inside the stopper rod can expand violently during preheating.

Key measures:

• Slow, staged drying schedules
• Uniform temperature distribution
• Sufficient holding time at intermediate temperatures

6. Design Optimization to Reduce Cracking Risk6.1 Geometry and Stress Distribution

Sharp corners, abrupt section changes, and sudden diameter transitions should be avoided. Smooth geometry helps:

• Reduce stress concentration
• Improve thermal expansion accommodation
• Enhance mechanical durability

6.2 Insert Compatibility

When zirconia or alumina inserts are used at the stopper head:

• Thermal expansion coefficients must be compatible
• Bonding interfaces must be well engineered
• Transition layers should be introduced if necessary

Poor insert design is a common cause of radial cracking.

6.3 Reinforced Neck and Connection Zones

The area near the steel connection experiences high mechanical stress. Reinforcement strategies include:

• Increased material density
• Fiber or whisker reinforcement
• Optimized anchoring design

7. Installation Practices to Avoid Cracking7.1 Proper Handling and Transportation

Monoblock stopper rods are large and heavy. Cracking often occurs before installation due to:

• Dropping or impact
• Improper lifting points
• Vibration during transport

Soft padding, dedicated lifting tools, and strict handling procedures are essential.

7.2 Accurate Alignment in the Tundish

Misalignment between the stopper rod and SEN leads to uneven load and localized stress. Correct installation ensures:

• Uniform contact at the stopper head
• Smooth opening and closing motion
• Reduced bending stress

8. Preheating and Operational Control

 tundish stopper rod

8.1 Controlled Preheating

Rapid heating is one of the main causes of stopper rod cracking. Proper preheating should:

• Follow a controlled temperature ramp
• Avoid direct flame impingement
• Ensure uniform heating of the entire rod

Temperature gradients must be minimized.

8.2 Avoiding Thermal Cycling Shock

Repeated opening, closing, and exposure to air can cause thermal fatigue. Operational best practices include:

• Minimizing unnecessary stopper movements
• Maintaining stable steel levels
• Avoiding prolonged exposure of hot stopper rods to air

9. Chemical Protection During Casting9.1 Slag and Steel Chemistry Control

Highly oxidizing slags accelerate refractory degradation. Control measures include:

• Low FeO and MnO slag
• Proper calcium treatment of steel
• Stable tundish slag composition

9.2 Argon Protection

Argon purging near the stopper head can:

• Reduce oxygen contact
• Prevent inclusion buildup
• Stabilize steel flow

This indirectly helps reduce chemical-induced cracking.

10. Inspection and Predictive Maintenance

Regular inspection helps detect early crack formation:

• Visual inspection before installation
• Post-casting examination
• Monitoring of stopper movement resistance

Data-driven analysis of stopper rod life helps optimize future designs and operating parameters.

11. Conclusion

Cracking of monoblock stopper rods is not caused by a single factor, but by a combination of material, design, manufacturing, installation, and operational influences. Avoiding cracks requires a systematic approach covering the entire lifecycle of the stopper rod.

Key Strategies to Avoid Cracking:

• Select refractory materials with high thermal shock resistance
• Use optimized antioxidant systems
• Apply graded and composite designs
• Ensure strict manufacturing and drying control
• Handle and install stopper rods correctly
• Use controlled preheating and stable operating practices
• Maintain proper steel and slag chemistry

By integrating these measures, steel plants can significantly extend monoblock stopper rod service life, improve casting stability, reduce downtime, and enhance overall operational safety.

Tundish Refractory Material

Functional Refractory Items In The Tundish