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The axisymmetric steady‐state convective‐diffusive thermal field problem associated with direct‐chill, semi‐continuously cast billets has been solved using the dual reciprocity boundary element method. The solution is based on a formulation which incorporates the one‐phase physical model, Laplace equation fundamental solution weighting, and scaled augmented thin plate splines for transforming the domain integrals into a finite series of boundary integrals. Realistic non‐linear boundary conditions and temperature variation of all material properties are included. The solution is verified by comparison with the results of the classical finite volume method. Results for a 0.500[m] diameter Al 4.5 per cent Cu alloy billet at typical casting conditions are given.

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