Mold interface
The body geometry and contact faces must suit the casting format so the start is controlled and repeatable.
Casting start
A controlled interface between mold and starter bar
The dummy head closes the mold at start-up, connects the first solidifying strand to the starter bar, and helps pull the strand into the caster route. Small errors in shape, connection geometry, or surface condition can create start-up issues long before normal production begins.
- Custom geometry for the mold, strand format, starter bar connection, and caster route
- Machined contact and locking areas for repeatable fit during start-up and release
- Surface protection where heat, abrasion, or metal contact can shorten service life
- Replacement or reconditioning support when the original part is worn, modified, or poorly documented
Critical fit areas
Where the dummy head has to be exact
Starter connection
Hooks, pockets, pins, holes, or locking features must match the starter bar chain without forcing or loose movement.
Wear surfaces
Edges, guide areas, and contact zones can be machined, hard-faced, or repaired depending on the observed damage pattern.
Inspection points
Dimensions, surface condition, hardness, and NDT can be checked around the features that control start-up reliability.
Production route
From existing head to controlled replacement
Capture geometry
Use drawings, 3D data, photos, or the worn component to confirm the mold interface and starter bar connection.
Review damage
Identify worn faces, rounded locking areas, cracks, deformation, coating loss, and areas affected by heat or abrasion.
Build route
Choose machining, welding, hard-facing, heat treatment, grinding, or full replacement around the part condition and urgency.
Verify fit
Check the critical interfaces, finish, hardness or coating requirements, and release records before the part returns to service.
Inquiry data
What helps BRUVAL evaluate dummy heads
- Photos of the dummy head from all sides, especially the mold contact faces and starter bar connection
- Casting format, mold dimensions, caster type, starter bar chain details, and available drawings
- Key dimensions, approximate weight, material grade, hardness, coating, and previous repair history
- Current issue: poor fit, difficult release, worn contact areas, cracking, deformation, or repeated start-up problems
- Required quantity, whether the request is for repair or new production, and target shutdown window
- Inspection or documentation requirements needed by the maintenance, production, or quality team
Related capabilities
From component to complete process support
Project request
Send dummy heads requirements.
BRUVAL can review the requirement, confirm the suitable product or service route, and return the next technical step.