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An investigation is conducted to study the effect of Al2O3 on the melting, viscosity, and phosphorus distribution of CaO–SiO2–Fe2O3–P2O5 slag system by using Single Hot Thermocouple Technique and rotating cylinder viscometer. The results show that with the addition of Al2O3 content, the melting temperature range of slag system is first reduced and then increased, as the added Al2O3 may react with CaO to form different compounds with varied melting points. The slag viscosity increases with the addition of Al2O3 content, due to the fact that the polymerization degree of the melt slag is getting increased. Besides, the addition of Al2O3 can improve the mass percentage of P2O5 in the solid phase, but it may reduce the dephosphorization capacity of the slag due to the reduction of the total solid phase solution (2CaO · SiO2–n3CaO · P2O5) precipitation. The results of this study can elucidate the effect of Al2O3 on the property of dephosphorization slag and provide guidelines for the new slag design to achieve a better hot metal dephosphorization efficiency.

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To meet the balance between supply and demand, a Ni–Cr–Fe‐based alloy is tried to be casted using a lab‐scale continuous casting mold simulator. The results show that the temperature of mold wall increases from 73 °C (346 K) maximum to 117 °C (390 K) maximum, whereas the amplitudes of fluctuation of both temperature and heat flux generally reduces, from MF (original Mold Flux) to NF1 (New Mold Flux 1), and then to NF2 (New Mold Flux 2) mold fluxes during the casting process. Ti and Al transfer from molten alloy to mold flux cause the precipitation of high‐melting point CaTiO3 and NaCaAl3(SiO4)3 in mold fluxes, which reduce the infiltration of slags in the gap. In addition, herein, all ten oscillation marks on the alloy shells maintain a strong one‐to‐one correlation with the heat flux cycles. The irregular oscillation marks together with the depression and entrapped slag on the shell mainly result from the uneven heat transfer and slag infiltration.