Alumina foam ceramic filter
The Alumina Foam Ceramic Filter is a porous ceramic material primarily composed of aluminum oxide (Al₂O₃), featuring a three-dimensional interconnected pore structure. It is manufactured using specialized replication processes, such as the organic foam impregnation method, which precisely copies the network structure of a polymeric foam template followed by high-temperature sintering. This unique structure combines the high strength and chemical inertness of corundum ceramic with the high specific surface area and low density of foam materials, making it a versatile, cost-effective, and widely used functional filter.
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Feature
| Parameter | Typical Range / Value |
|---|---|
| Pore Density (PPI) | 8 ~ 40 PPI |
| Porosity | 80% ~ 90% |
| Maximum Service Temperature | ≤ 1200°C |
| Compressive Strength (RT) | ≥ 0.8 MPa |
| Bending Strength | > 0.6 MPa |
| Bulk Density | 0.35 ~ 0.50 g/cm³ |
| Thermal Shock Resistance | ≥ 2 cycles (1100°C water quench) |
| Thermal Conductivity | ~3.1 W/(m·K) (Example) |
Explore Our Alumina Foam Ceramic Filters
| SIZE (INCH) | Filter Weight (Ton) | Flow Rate (kg/min) |
|---|---|---|
| 7*7*2 | 4.2 | 25-50 |
| 9*9*2 | 6 | 25-75 |
| 10*10*2 | 6.9 | 45-100 |
| 12*12*2 | 13.5 | 90-170 |
| 15*15*2 | 23.2 | 130-280 |
| 17*17*2 | 34.5 | 180-370 |
| 20*20*2 | 43.7 | 270-520 |
| 23*23*2 | 57.3 | 360-700 |
BI-METAL LINER & Seat & Spare Parts – Buyer FAQs
1. What is it, and what are its key characteristics?
A porous ceramic made primarily of alumina (Al₂O₃) with a three-dimensional network structure. Key traits include high porosity (80%-90%), good compressive strength (≥0.8 MPa), and excellent thermal shock resistance to withstand the thermal impact of molten aluminum.
2. What are its main advantages?
Its strength lies in its balance of performance and cost. It offers good high-temperature stability and filtration efficiency while being significantly more cost-effective than silicon carbide or zirconia filters, making it the most economical and widely used choice for aluminum casting.
3. How to choose the correct Pore Density (PPI) and size?
PPI Choice: Common grades are 10-30 PPI. Lower PPI (e.g., 10) allows higher flow for general purification; Higher PPI (e.g., 20-30) provides finer filtration for high-quality castings. Size Choice: Must match the gating system and pouring weight (e.g., the 10*10*2 inch size you provided corresponds to ~45-100 kg/min flow).
4. Which metals is it primarily used to filter?
Primarily used for filtering aluminum, magnesium, and their alloy melts. It is the standard choice in the aluminum foundry industry. It is NOT suitable for higher-melting-point metals like cast iron or steel (which require SiC or ZrO₂ filters).
5. Does it require preheating before use? Why?
Preheating is absolutely mandatory (typically to 700-900°C). The purposes are: 1. Prevent thermal shock cracking; 2. Remove moisture to avoid steam explosions or splashing upon metal contact; 3. Ensure smooth initiation of filtration.
Advantages
The Alumina Foam Ceramic Filter offers key advantages in stability, performance, and cost-effectiveness. It provides excellent chemical and thermal stability, resisting corrosion from molten metals like aluminum alloys and operating stably up to 1000°C. It features high mechanical strength and efficient deep-bed filtration for removing fine inclusions. Furthermore, due to the lower cost of alumina raw material, it delivers a superior cost-performance ratio, making it the most widely used and economical choice, especially in aluminum alloy casting.
Multi-directional applications
Alumina Foam Ceramic Filters have broad applications across key industries. In metal casting, they are essential for filtering aluminum and magnesium alloy melts to improve casting quality. In environmental and chemical engineering, their high porosity and corrosion resistance make them ideal for gas filtration and as catalyst supports. They also show growing potential in emerging energy technologies, such as components for solid oxide fuel cells.
Multi-direction Closed-Die Forging Process
This manufacturing process utilizes a polyurethane foam impregnation method, where an alumina slurry is uniformly coated onto a three-dimensional network carrier. After precise extrusion and controlled drying, the component is sintered in a kiln at over 1000°C, causing the foam carrier to vaporize and the ceramic powder to vitrify, forming a robust, interconnected skeletal structure.
These cost-saving advantages, combined with the extra durability, can mean better production rates and higher efficiency for your operations. When you succeed, we know we've succeeded.
Carrier Selection & Pre-treatment
High-quality polyurethane foam with specific porosity and PPI (Pores Per Inch) is selected as the original carrier. The foam is then cut into precise geometric shapes (blocks or discs) according to the final product dimensions to serve as the 3D skeletal framework for ceramic slurry adhesion.
Slurry Impregnation & Coating
A high-viscosity ceramic slurry is prepared by mixing zirconia powder, stabilizers, and binders. The foam carrier is fully submerged in the slurry; mechanical rollers then extrude air and ensure the slurry uniformly and firmly coats the foam fibers while removing excess slurry to maintain open porosity.
Controlled Drying & Shaping
The flashless closed-die design eliminates material waste and the need for trimming. The component is typically formed in one heating cycle and one press stroke, reducing process steps by 50% and significantly lowering costs.
High-Temperature Sintering
This is the most critical stage, where the green bodies are fired in kilns at temperatures exceeding 1700°C. During this process, the polyurethane foam carrier vaporizes completely, and the zirconia powder undergoes physical and chemical reactions to solidify into a high-strength, 3D ceramic grid structure.
High-quality foam ceramic filter
As an innovator in the field of custom multi-directional closed-die forging, Longchao Forging has been dedicated for 30 years to providing customers with the highest quality forged components and attentive service. Therefore, we strive to exceed your expectations and help you find the molten metal filtration solutions that meet your specific needs.
Experience the unique features of Longchao's molten metal filter sheets.
With over 30 years of experience in open-die forging, we combine traditional craftsmanship with modern technology to provide you with molten metal filter plates that perfectly meet your specifications. Our team will work closely with you to ensure we provide the most suitable solution for your application needs.