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Foam ceramic plate for foundry technology
1. Introduction:
Foam Ceramic are mainly used for filtration of aluminium and aluminium alloys in foundries and cast houses . With their excellent thermal shock resistance and corrosion resistance from molten aluminum, they can effectively eliminate inclusions, reduce trapped gas and provide laminar flow, and then the filtered metal is significantly cleaner. Cleaner metal results in higher-quality castings, less scrap, and fewer inclusion defects, all of which contribute to bottom-line profit.
2. Size available:
7″, 9″, 12″, 15″, 17″, 20″, and 23″, with porosities from PPI 10 to PPI 60(PPI ie pores per inch).
Other special sizes could be produced on request.
Foam ceramic plates are widely used in foundries to improve casting quality by removing impurities from molten metal. They are made from refractory materials and have a porous, open-cell structure that traps inclusions while allowing the metal to flow through smoothly.
Key Features of Foam Ceramic Plates for Foundries:
- Material Composition:
- Typically made from alumina (Al₂O₃), zirconia (ZrO₂), silicon carbide (SiC), or a combination.
- High refractoriness to withstand extreme temperatures (up to 1700°C+).
- Porosity & Pore Size:
- Open-cell foam structure with controlled pore sizes (usually 10–60 PPI – pores per inch).
- Effective at trapping slag, oxides, and other non-metallic inclusions.
- Benefits in Foundry Applications:
- Improved Casting Quality: Reduces defects like inclusions, porosity, and turbulence.
- Enhanced Metal Flow: Provides laminar flow, minimizing oxidation.
- Increased Yield: Reduces scrap rates by improving filtration efficiency.
- Compatibility: Works with various metals (iron, steel, aluminum, copper alloys).
- Common Applications:
- Ferrous Castings: Steel, ductile iron, gray iron.
- Non-Ferrous Castings: Aluminum, copper, magnesium alloys.
- Investment & Sand Castings: Used in gating systems to filter molten metal before it enters the mold.
- Types of Foam Ceramic Filters:
- Standard Filters: For general-purpose filtration.
- High-Efficiency Filters: Finer pores for critical applications.
- Special Shapes: Custom sizes and geometries for specific molds.
How to Use Foam Ceramic Plates in Foundry:
- Placement: Installed in the gating system (usually in the sprue or runner).
- Preheating: Often preheated to avoid thermal shock when molten metal flows through.
- Compatibility Check: Ensure the filter material matches the metal being cast (e.g., alumina for aluminum, zirconia for steel).
Advantages Over Other Filters (e.g., Mesh or Extruded Ceramic Filters):
- Better inclusion removal due to 3D porous structure.
- Higher thermal shock resistance.
- Longer durability in high-temperature applications.
Material Specifications
Material | ZrO2 | SiC | Al2O3 |
Colour | Yellow | Grey Black | white |
ore density (ppi) | 10~60 | 10~60 | 10~60 |
Porosity (%) | 80~90 | 80~90 | 80~90 |
Operating temperature(°C) | 1700 | 1500 | 1100 |
Compression Strength(MPa) | 1.2 | 0.9 | 0.8 |
Density(g/cm3) | 0.90-1.50 | 0.35-0.50 | 0.30-0.45 |
Thermal Shock Resistance(1100-20°C) | >6 times | >6 times | >6 times |
Application | steel | iron | Non-Ferrous Alloy and Aluminium |
4. Alumina Physical Properties:
Working | ≤1200°C |
Porosity | 80~90% |
Compression Strength | ≥1.0Mpa |
Volume Density | ≤0.5g/cm3 |
Thermal Shock Resistance | 800°C—Indoor temperature 5 times |
Application | non-ferrous and alumina alloys, |
5. Pouring Rate and Filtration Capacity
1) Alumina Ceramic Foam Filters
Dimensions(mm) | Dimensions(inch) | Pouring Rate(kg/s) | Filtration Capacity(ton) |
178x178x50 | 7x7x2 | 0.2-0.6 | 5 |
228x228x50 | 9x9x2 | 0.3-1.0 | 10 |
305x305x50 | 12x12x2 | 0.8-2.5 | 15 |
381x381x50 | 15x15x2 | 2.2-4.5 | 25 |
430x430x50 | 17x17x2 | 3.0-5.5 | 35 |
508x508x50 | 20x20x2 | 4.0-6.5 | 45 |
585x585x50 | 23x23x2 | 5.0-8.6 | 60 |
2) Zirconia Ceramic Foam Filters
Dimensions(mm) | Pouring Rate(kg/s) | Filtration Capacity(kg) |
50x50x22 | 3-5 | 30 |
50x75x22 | 4-6 | 40 |
75x75x22 | 7-12 | 60 |
75x100x22 | 8-15 | 80 |
100x100x22 | 14-20 | 100 |
D50x22 | 2-6 | 18 |
D80x22 | 6-10 | 50 |
D90x22 | 8-16 | 70 |
3) Silicon Carbide Ceramic Foam Filters
Dimensions (mm) | Pouring Rate(kg/s) | Filtration Capacity(ton) | ||
Grey Iron | Ductile Iron | Grey Iron | Ductile Iron | |
40x40x22 | 4 | 3 | 65 | 32 |
50x50x22 | 6 | 4 | 100 | 52 |
75x50x22 | 9 | 6 | 150 | 75 |
75x75x22 | 14 | 9 | 220 | 100 |
100x50x22 | 12 | 8 | 200 | 100 |
100x75x22 | 18 | 12 | 300 | 150 |
100x100x22 | 25 | 16 | 400 | 200 |
150x150x22 | 50 | 36 | 900 | 450 |
