How Ceramic Filter Technology Has Benefited Foundries?

The metal melting processes are carried out in the furnaces, such as electric furnaces, rotary furnaces and gas crucible furnaces. Then, the metals of various types are used for castings. There could be types of ferrous and non-ferrous. However, before those casting operations take place, there is a vital stage of molten metal filtration. This filtration procedure decides the quality of the casting.

Realizing a longstanding demand of foundries, the researchers and scientists came up with the ceramic filter technology. Earlier, poor metal filtration would incur various quality issues in the castings, drawing unwanted results. However, the innovation of this technology has resolved and reduced many issues.

How foundries have benefited?

There are several instances where the ceramic filter technology has benefited the foundries, directly and indirectly. Here are some of them.

1. Removal of non-metallic inclusions – There is a huge possibility of non-metallic inclusions such as sand grains hamper the quality of the casting. Here, the filters that do not have a proper design remove the big impurities, but fail to remove minute inclusions. However, the extruded filter reduces those chances of impurities by effectively removing them.
2. Reducing gas trappings – The high porosity percentage of the filters have helped in the filtration procedures for removing the gas trappings. Gas inclusions and oxide would occur when the metal is melted and after it cools down in the mould cavity, it remains as it is. Hence, there was a need of a filter technology that removes gas trappings without affecting the laminar flow of metal.
3. Longevity for strength – It is no secret that the longevity of a casting depends upon the quality of the metal. A poorly made casting would have impurities and inclusions all over. Nevertheless, the use of Zirconia ceramic filter almost eliminates those chances of impurities. With high-quality casting production, the foundries will benefit huge in profitable returns. Moreover, the quality ensures casting’s longevity.
4. Lower rejection rate – This topic involves design too. A honeycomb design, which met the approval of various experts has helped lowering the casting rejection rate by up to 85 percent. Nowadays honeycomb ceramic filters are popular in several industry, including ceramic, automotive, machinery and aerospace. It makes the castings reliable and performance-oriented.
5. Productivity – Low productivity affects a foundry industries to the core. The use of Zirconia ceramic foam filter has augmented the rate of productivity by a significant level. It has improved the process yield rate. If ordered from top quality manufacturers, the filters have high porosity, compressive strength and temperature resistance as characteristics. Ultimately, it reduces the scrap rate.
6. Minimize flaws – Casting flaws can be a headache for foundry workers. When a casting product comes out with undesirable defects, the customer’s response is obvious. Poor molten metal filtration causes these flaws and thankfully, the ceramic filters reduced those flaws in a significant percentage. These filters also manage the filtration procedure in a non-turbulent manner.

Similar benefits have managed to convince the foundries to involve ceramic filter technology for their metal castings.

Tao Lu is an expert chemical engineer and has years of experience in producing Zirconia ceramic foam filter with leading agencies. His share benefits of using ceramic filter and ideas to boost productivity essentially. He also reviews and shares the pros of using zirconia filter, extruded filter, etc in different industries.

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Steel foundries looking to order high quality Zirconia ceramic foam filter can opt for the Ca-stabilized Zirconia products made by Filtec Precision Ceramics Corporation. They are in great demand for the filtration of molten steel and its alloys.