Challenges Faced By Foundry Industry Before Ceramic Foam Filter Happened

What happens when filtration goes? Huge losses. Bad productions. And what not. None of the people would have anticipated this much of loss of reputation when a casting product fails a minimum criteria of quality. Similarly, there was a heavy score of challenges when ceramic filtration technology didn’t come over. Neither the designs nor the attributes compensated the final product quality. The following discusses several issues before a ceramic foam filter was ready for its various applications.

Causes of casting defects

Here, the popular causes are mentioned:

Blow holes – One of the major casting defects which were caused due to moisture in the molding sand that were used for producing castings. Similarly, rust, bad vents, etc. reasons contributed to poor filtration.

Porosity – It always remains a hot topic whenever metal filtration is discussed by expert metallurgists and chemical scientists. Gas inclusions became a prominent reason of defects in the final casting product.

Cold shuts – Earlier, lack of fluidity caused irregular casting production, which had an alarming rejection rate. In addition, faulty designs and faulty gating systems contributed a lot to the cause.

Turbulence – Absence of laminar flow and excess of turbulence when pouring of metal occurs during a filtration procedure would produce a poor quality casting at the end.

Impurities – Removal of slag particles is an imperative for quality filtration, but the mission failed over and over again. Dirt and swarf held into the molten metal, which was discovered in the end product too.

Lack of efficient filter and problems

It became a delightful advantage of the foundry industries when Zirconia ceramic foam filter was introduced for filtering various kinds of metals. However, before that, these industries were mired in several problems. The following mentions some of them.

Low productivity – Inefficiency became a regular habit due to poor quality molten metal production. Therefore, the productivity levels hit an all-time low and incurred losses for industries.

Unsatisfied clients – A customer never wishes to see a bad quality product after investing a good amount of money in it. Improper surface finish, lack of strength and durability in the castings left the clients unsatisfied.

Expensive machine scraps – When Zirconia filter didn’t come into prominence, the rejection rate was extremely high and the filtration process gave expensive machine scraps. Of course, quality testing was time-consuming, making the entire operation highly inefficient.

How ceramic filter changed the scenario?

Technically, the industries find a boon in ceramic filtration technology. It brought efficiency in operations, increased production yields, eliminated time-consuming procedures and enabled potential for profitable results. The makers of ceramic filters were great for finding out a much-needed solution for foundries.

Statistically, the market of metal casting was on a decline and it had an apparent impact on the sales. But, inception of ceramic filters had a major role to play in current and future markets. Indeed, the good castings would have a flourishing market in this industry and others as well.

About Author:-

filtec promotions is an expert ceramic engineer and has years of experience in manufacturing Zirconia ceramic foam filter for various manufacturing industries. He has written several informative articles about ceramic foam filter. From his experience, he tells that the ceramic Zirconia filter has largely benefited the foundry industry in various aspects.

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.