The molten metal aluminium filter is mainly ceramic foam filter. The ceramic foam filter is a filtering device that uses ceramic foam as the filter medium. Ceramic foam is an open-cell mesh with a sponge-like structure for filtering aluminum melt.
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The ceramic foam filter is installed in the molten aluminium filter box between the static furnace and the casting table. The depth of the filter box is generally not less than 200mm. The molten aluminum flows from the static furnace to the crystallizer after being filtered by the filter box.
The flow characteristics of ceramic foam depend on the pore characteristics and the size of the ceramic plate. For a ceramic foam filter board with a size of 305mm×305mm×50mm and a number of holes of 30 holes/in, the filtration capacity is about 1.7 – 3.0 kg/s. When filtering aluminum melt, the main filtration parameters of foam ceramics are filtration accuracy 2um, filtration efficiency 99%, initial pressure head 50~150mm, and effective working pressure head 50mm. It can be seen from the above that the foam ceramic filter has the advantages of high filtration accuracy, high filtration efficiency, light weight, small footprint, convenient operation and use, and good working conditions. However, the foam ceramics are discarded once used and cannot be regenerated, and the texture is relatively brittle, so the mixing of fragments should be avoided during installation.
Aluminium Ceramic Filter Advantages:
Because of these advantages, it is widely used in food, medicine, molten metal filtration, powder transportation, environmental protection, dust collection, sewage treatment, radioactive waste treatment, and other fields.
Aluminum alloys are widely used in industries like aerospace, automotive, construction, and many others due to their lightweight, high strength, and corrosion resistance. However, during the production process, impurities like oxides, inclusions, and other particles can be introduced, which affect the quality and properties of the end product. Alumina ceramic foam filters are one of the solutions to this problem as they effectively remove these impurities from the molten aluminum alloy. These filters offer numerous advantages that contribute to improved product quality and overall operational efficiency. In this article, we will explore the key benefits of alumina ceramic foam filters in the aluminum alloy industry.
Aluminium Ceramic Filter Plate
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Alumina ceramic foam filters play a vital role in improving the quality of the molten aluminum alloy. These filters effectively remove impurities and non-metallic inclusions from the liquid metal, resulting in a cleaner and more refined final product. The ceramic foam structure consists of interconnected channels and small pores, which act as a physical barrier, capturing and retaining impurities as the molten metal passes through the filter. By removing impurities, the filters help enhance the mechanical properties, surface finish, and overall integrity of the aluminum alloy.
One of the primary advantages of alumina ceramic foam filters is their ability to promote sound casting integrity. By effectively filtering out impurities, the filters help prevent defects such as shrinkage, gas porosity, and slag inclusions in the cast aluminum parts. These defects can significantly compromise the mechanical strength, structural integrity, and overall performance of the final product. By using ceramic foam filters, the aluminum alloy industry can ensure a higher degree of casting integrity, reducing the need for costly rework or scrap and improving overall production efficiency.
Alumina ceramic foam filters offer the advantage of controlled filtration efficiency. The filters are available in various pore sizes, allowing the industry to choose the most appropriate filter for specific casting applications. Different casting processes and alloys may require different filtration requirements, and ceramic foam filters provide the flexibility to meet those needs. This controlled filtration efficiency ensures that the filters can effectively remove larger impurities while still allowing the desired flow rate of the molten metal, optimizing the casting process.
The porous structure of alumina ceramic foam filters facilitates uniform metal flow and filling during the casting process. The filters promote a laminar flow pattern, preventing turbulent flow and minimizing the risk of metal splash, vortex formation, or erosion of the mold walls. This controlled flow helps ensure uniform distribution of the molten metal, reducing the occurrence of casting defects such as cold shuts, misruns, and uneven wall thickness. The result is a more consistent and reliable casting process, leading to higher-quality aluminum products.
Alumina ceramic foam filters offer a longer service life compared to traditional filter media. The filters are highly resistant to thermal shock, erosion, and chemical attack from the molten metal, ensuring prolonged durability in the demanding aluminum casting environment. The robust nature of alumina ceramic foam filters allows for multiple uses, reducing the frequency of filter replacement and minimizing downtime during the casting process. This extended service life contributes to cost savings and improves operational efficiency in the aluminum alloy industry.
Another significant advantage of alumina ceramic foam filters is their compatibility with a wide range of aluminum alloys. Whether it is pure aluminum, aluminum-silicon alloys, or aluminum-magnesium alloys, these filters can effectively remove impurities and provide the desired level of filtration. This versatility makes alumina ceramic foam filters a preferred choice for the aluminum alloy industry, as they can be used across different casting processes and alloy compositions, ensuring consistent quality across the board.