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This work investigates the critical correlation between electromagnetic stirrer (EMS) operation in a continuous casting mold and the formation of internal defects in cast billets. While EMS intensity must be increased, particularly for square billet formats, to achieve sufficient molten steel agitation and homogenization, this study highlights the detrimental side effects of such intensification. The analysis focuses on the generation of strong azimuthal (rotational) flows, which can entrap inclusions and gas bubbles, leading to defect clustering. Furthermore, the intensified fluid dynamics significantly increase friction and shear stress at the billet solidifying corners, exacerbating corner crack formation and subsurface defects. The findings underscore the need for a finely tuned balance between stirring intensity and flow pattern control to optimize billet internal quality.