Concerns and answers about alumina ceramic foam filters - LinkedIn
Concerns and answers about alumina ceramic foam filters - LinkedIn
The following are professional answers to five core questions that aluminum plant customers are concerned about, aiming to highlight the advantages of alumina ceramic filter plates and eliminate customer concerns:
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30-60ppi pore size corresponds to a filtration accuracy of 50-100 microns, which can efficiently intercept Al₂O₃ inclusions (typical size > 50μm), and the inclusion content of aluminum liquid after filtration is <0.02mm²/kg (in line with GB/T - standard), meeting the needs of aerospace (such as AMS E) and automotive parts (such as Volkswagen VW) for high-purity aluminum liquid.
Alumina ceramics have a melting point of >℃ and can work continuously for ≥72 hours in 700-800℃ aluminum liquid without softening and deformation problems (verified by SGS high temperature creep test).
Adopting gradient sintering crystal phase technology, it has passed 30 hot and cold cycles (800℃↔room temperature) test without cracks (in compliance with ISO standard), and is suitable for the frequent start-stop conditions of the foundry workshop.
Through three-dimensional interconnected holes + gradient pore size structure (surface layer 60ppi→middle layer 40ppi→bottom layer 30ppi), the air permeability reaches - L/(m²·min·Pa), achieving a flow rate of 1.5-2.2 tons/minute (adaptable to mainstream casting lines), and the filtration efficiency is >95% while ensuring production capacity.
After application in the automobile wheel hub factory, the casting efficiency increased by 15%, and the inclusion defect rate dropped to below 0.3%.
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A single foam filter plate can process 400-600 tons of aluminum liquid (depending on the impurity load), support continuous production for 5-7 days, and the replacement frequency is 50% lower than that of ceramic foam ceramics.
Although the unit price is higher than foam ceramic filters, the service life is extended by 3 times (compared with test data), the comprehensive cost is saved by 40 %+, and downtime losses are reduced.
Refractory Ceramic Foam Filter For Aluminium Casting
Instructions:
Check and clean the debris on the surface of the filter box to keep the filter box clean and free of damage, check the safety of every piece of equipment on the production line, including furnaces, launders, filter boxes and hot top casting machines.
Gently put the filter plate into the filter box, and press the sealing gasket around the filter plate by hand to prevent the aluminum liquid from bypassing or floating.
Preheat the filter box and filter plate evenly to make them close to the temperature of molten aluminum, and the preheating temperature of the filter plate is not lower than 260℃. Preheating to remove adsorbed water helps to open the initial filter pore size in an instant, preventing partial pore blockage of the filter plate due to thermal expansion and contraction. Electric or gas heating can be used for preheating, and normal heating takes 15-30 minutes.
After the molten aluminum comes out of the filter box, it passes through the launder to the next casting platform. At this time, pay attention to the changes in the aluminum hydraulic head, and maintain the normal demand for the flow of aluminum liquid. The normal initial pressure head is 100-150mm. When the molten aluminum begins to pass, the pressure head will drop below 75-100mm, and then the pressure head will gradually increase.