How To Solve The Biggest Problems Of Metal Filtration With Ceramic Foam Filter?

Metal filtration is the major process carried out before the molten metal goes into the mold cavity. There are several considerations for the metal filtration procedure, such as pressure, thermal temperature, gating, filling time, mold design and so on. To achieve the goals of quality filtration, the foundries may prepare adding an extra budget, as it may ultimately drive more revenues.

Problems faced during metal filtration

We will learn here about the issues the a ceramic foam filter can help with, we can understand some of the biggest problems faced during the filtration procedure. Here they are:

1. Gas inclusions – It can be also referred as gas trappings due to the gas inclusions in the molten metal. Technically, it hampers the quality of the casting at the end because gas bubbles have already been formed in the cooled metal. It reduces the strength of the metal. The gas bubbles are also known as blisters or blowholes.
2. Metal turbulence – The metal filtration procedure involves enough of the turbulence, which could be a reason for many defects in the casting. Moreover, lack of fluidity affects the entire process.
3. Thermal resistance – When a filter cannot bear the temperature of the molten metal, there is a lack of consistency. Therefore, it was a prolonged demand of metallurgists and foundry industries that a filter material with higher thermal resistance is produced.

Solutions via sic ceramic foam filter

The ceramic foam filtration technology almost brought a revolution in the filtration processes and operations. Today’s foundry industry uses various types of filters including, Glassweve, tinplate, wiremesh and so on. However, it has been discovered that the sic ceramic foam filter became more popular than any of these. The solutions it came up with for the above problems are briefed below:

1. Removal of gas trappings – A major problem of gas inclusions was reduced due to the higher porosity percentage of the ceramic filters. Nowadays, the honeycomb design is most sought for all kinds of ceramic foam filter. Thus, the problem of reduced strength is significantly reduced if not completely removed.
2. Reduced turbulence – With the use of ceramic filters, it brings a laminar flow in the molten metal without having to increase the pouring temperatures, adding the fluidity. The reduced turbulent behavior, in the end brings a uniformity instead of variation in the mold-filling.
3. Higher strength – Unlike other foam filters, sic or graphite ceramic filter for steel has higher compressive strength and thermal resistance, which means their applications is much more valuable. Ultimately, the scrap castings would reduce, leading to greater productivity.

Although, the filter selection depends upon its application for a specific process, but the ceramic filters have produced excellent results in most of the applications. In addition, they have improved the machinability. Foundry industry would need to find innovative manufacturers for their specific process applications. Using the ceramic filtration technology gives a boost to the productivity level and benefits the industry.

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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.