| Customization: | Available |
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| Material: | Zirconia Material |
| Refractoriness (℃): | Refractoriness<1700ºC |
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High Temperature Resistance Zirconia Ceramic Foam Filters for Provide Molten Metal Laminar Flow
With its internal interconnected three-dimensional structure, the foam ceramic filter can fully embody its four major filtration mechanisms of rectification, mechanical screening, "filter cake" and adsorption when filtering molten metal. At the same time, the filter material has good chemical stability , does not react with the alloy liquid, thereby effectively removing or reducing inclusions in the metal liquid such as copper parts and iron parts, thereby improving the purity of the metal melt, making the surface of the poured metal castings smooth, improving the strength, and reducing the scrap rate,Reduce machining losses.
ZrO zirconia foam ceramic filter has the characteristics of high strength, good thermal stability, large surface area and high dimensional accuracy. Suitable for the production of various grades of steel casting, it can effectively filter out the macroscopic impurities in the metal liquid, but also make use of its huge surface:
The absorption of microscopic inclusions makes the metal liquid fill smoothly. Has the following significant advantages
1, a wide range of applicable processes, can be used for sand, shell and precision casting ceramic type and other processes.
2, the maximum use temperature 1700ºC, and can significantly simplify the traditional pouring system.
3, the special three-dimensional mesh structure has an excellent rectification effect on the metal turbulence, so that the casting organization is evenly distributed.
4, efficient filtration of small non-metallic impurities, improve the machining performance of parts
5. High comprehensive mechanical properties of castings, such as surface hardness, tensile strength, fatigue resistance and elongation.
>>Selection of pore size: When using a filter, the pore size of the filter (number of pores per inch of product, PPI) must be determined based on the casting material, casting size, pouring temperature, and the number of inclusions in the molten metal; The pore diameters are mainly: coarse pores (10PPI, 15PPI), intermediate pores (20PPI), and fine pores (25PPI, 30PPI). Ductile iron parts generally use 10 PPl or 15 PP products, gray iron and copper castings generally use 15 PPI or 20 PPI products, and aluminum alloy castings generally use 20 PPI or 30 PPI products.
>>Size selection: The greater the thickness of the foam ceramic filter, the better the strength of the filter and the higher the filtration efficiency of the filter, but the higher the cost of use. Considering the most suitable strength and filtration efficiency, the general recommendations are as follows: Size: 40MM~75MM, Thickness: 15MM~22MM Size: 75MM-120MM, Thickness: 22MM~25MM Size: 120MM~150MM, Thickness: 25MM~30MM Size: > 150MM, thickness 30MM~40MM
>>Filtration capacity: The filtration capacity per unit area of the filter generally does not exceed: gray cast iron 1.5-2kg/cm², ductile iron 1-1.5kg/cm² (due to differences in casting system processes, try to design with the lower limit value to increase the insurance factor) .
>>Filter area: The cross-sectional area of the sprue where the filter is placed should be appropriately expanded. Generally, the cross-sectional area of the normal sprue is 2 to 4 times.
>>Placement location: The foam ceramic filter can be placed in various parts of the pouring system. It should be selected according to the characteristics of the parts and production conditions, and should be as close as possible to the casting to achieve the best filtration effect. In practical applications, according to different castings and requirements, the following methods can be used:
1)Place it at the sprue cup of the mold shell: reserve a filter table at the sprue cup of the mold shell. After the mold shell is roasted, place the filter at the gate position, or bake the filter with the shell before pouring. Heat helps the metal liquid start to pass through, and the use effect is better. In order to make it easy to place the filter, the filter base needs to be designed, that is, there should be a gap of 2 mm between the place where the filter is placed in the mold shell and the outer edge of the filter, and a base with a width of more than 5 mm should be left on the supporting surface.
2)Place the foam ceramic filter in a special ceramic sprue cup. During the shell making process, connect the sprue cup to the casting. When pouring, place the filter in the sprue cup for pouring; in addition, the filter and The gap between the sprue cup walls should be controlled between 0.5mm and 1mm, as small as possible to prevent side flow.
3)Place the foam ceramic filter in the pouring system. Make the pouring system shell with the filter in advance, and reserve openings at corresponding positions on the tube shell to facilitate placing the filter in the mounting base. During the shell making stage, it is placed in a seat and sealed with water glass or silica sol. After curing and drying, it can be cast and tested. In addition, the pouring temperature of the molten metal should be controlled at the upper limit of the process range as much as possible, and the pouring speed should reach the maximum as soon as possible to avoid casting defects such as cold shut and insufficient pouring.
Physical and Chemical Index
| Material | Alumina/ALO | Silicon carbide/SIC | Zirconia/ZrO |
| Color | White | Gray | Yellow |
| Pore Density | 8-60ppi | 8-60ppi | 8-60pp |
| Porosity | 80-90% | 80-90% | 80-90% |
| Refractoriness | ≤1100ºC | ≤1500ºC | ≤1700ºC |
| Flexure Strength | >0.6Mpa | >0.8Mpa | >1.0Mpa |
| Compressive Strength | >1Mpa | >1Mpa | >1.5Mpa |
| Density | 0.3-0.48g/cm³ | 0.35-0.5g/cm³ | 0.9-1.5g/cm³ |
| Resistance to Heat Shocks | 6times/1100ºC | 6times/1500ºC | 6times/1700ºC |
| Application | Aluminum alloys And Others Nonferrous Metal Alloys. | Nodular Cast Iron Malleable Cast Iron Gray And Other Cast Iron |
Metal Alloys with High Melting Points, Such As Steel Alloy Steel Stainless Steel |
Q1: What information should I let you know if i want to get a quotation?
A: The required material dimension (Thickness*Width*Length,diameter*length; if possible, please kindly supply us drawings).
The required more information, such as Surface Condition, Tolerance Request, The Quantity, and other mechanical and technical details.
If it is possible, please also provide the application of products, we will recommend the most suitable products with details for confirmation.
Q2: How do you gurantee the quality of the products?
A: Each step of production and finished products will be carried out inspection by QC department before storing in the warehouse. NG goods are not allowed in the completed goods warehouse.
Q3: Can you guarantee the prompt delivery?
A: Yes, when we get your inquiries, not only we will evaluate the more competitive price, but also we can get the most reasonable delivery time. So the prompt delivery can be guaranteed.
Q4: What is your lead time?
A : It usually needs about 15- 20 days after receiving the PO.
Q5 : What is your payments terms?
A : T/T, Western Union, etc., could be acceptable.
Q6 : Can we visit your company?
A : Yes, for sure, It's my pleasure to visit our company.
Q7 : What is the shipping cost?
A: The shipping cost is determined by the destination port, weight, packing size, total CBM of the products, we will try best to get the most reasonable shipping cost from the forwarders or express couriers to help you save more money.
Q8 :What is the transportation way?
A:If the Gross Weight ≤45kg, it's better by express such as TNT, DHL, FedEx,, etc.
If the Gross Weight between 45kg to 100kg, by express or by air to your nearest airport can be both considered.
If the Gross Weight ≥ 100kg ,you can choose by Air or Sea to the nearest port.
Q9 :How service you can offer your clients?
A:We provide presales service in various forms, for example, making investment budget,manufacturing planning,etc.so that customer make a reasonable plan with less cost. Moreover,we will also provide after sale service ,for example,free training about machine applications ect.
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