How to Use Ceramic Foam Filter Plates

Ceramic foam filter plates are essential in many industries for filtering molten metals. They are primarily used in the aluminum industry to improve the quality of aluminum products. In this guide, we'll explore the different types of ceramic foam filter plates, their characteristics, and how to use them effectively.

Types of Ceramic Foam Filter Plates

Ceramic foam filter plates are available in three main types based on their composition:

1. Alumina Ceramic Foam Filter Plates: These filters are widely used for aluminum casting due to their excellent ability to remove large inclusions and absorb fine particles.  

2. Silicon Carbide Ceramic Foam Filter Plates: Designed for filtering cast iron, they are durable and withstand high temperatures.  

3. Zirconia Ceramic Foam Filter Plates: Zirconia filters are suitable for high-temperature alloys like steel, as they maintain structural integrity under extreme heat.

Key Features of Alumina Ceramic Foam Filters

- High Efficiency: Alumina ceramic foam filters can effectively remove large inclusions in molten aluminum and absorb micron-sized particles.  

- Enhanced Product Quality: These filters improve surface quality, product performance, and yield by creating cleaner aluminum profiles, foil, and alloys.  

- Homogeneous Structure: Alumina ceramic foam filters have a 3D solid network homogeneous bone structure that ensures consistent filtration.

Step-by-Step Instructions for Using Ceramic Foam Filter Plates

1. Clean the Filter Box  

Before using the ceramic foam filter plate, ensure that the filter box is thoroughly cleaned to prevent contamination.

2. Place the Filter Plate in the Box  

Gently place the ceramic foam filter plate into the filter box. Press the sealing gasket around the filter plate to ensure that no molten aluminum flows by the filter.

3. Preheat the Filter and Equipment  

Preheat both the filter box and the ceramic foam filter plate to a temperature close to the molten aluminum. Preheating is essential to remove moisture and ensure effective filtration. This can be done using electric or gas heating, and typically takes 15–30 minutes.

4. Monitor the Aluminum Hydraulic Head  

During casting, pay close attention to the change in the aluminum hydraulic head. The initial pressure head should be 100–150 mm. When the aluminum starts to flow through, the pressure head will drop to 75–100 mm and then gradually increase.

5. Avoid Disturbing the Filter During Filtration  

Ensure that the ceramic foam filter plate is not knocked or vibrated during the filtration process. Additionally, maintain a steady flow of aluminum in the launder to avoid disturbing the molten metal.

6. Clean the Filter Box After Filtration  

Once filtration is complete, remove the ceramic foam filter plate and clean the filter box thoroughly to maintain cleanliness for future use.

Conclusion

Using ceramic foam filter plates is a straightforward yet essential process for ensuring high-quality metal casting. Whether you're using alumina, silicon carbide, or zirconia filters, proper installation and maintenance are crucial for effective filtration and optimal product performance.

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