AdTech is a Ceramic Foam Filters Manufacturer. We offer ceramic foam filter Pore Size（PPI）: 20/30/40/50/60. Ceramic foam filters (CFF) have been widely used for filtering impurities out of molten aluminum in cast houses. Filtration is a necessary step to optimize metal quality and downstream finished products.
Ceramic Foam Filters Manufacturing Process
The initial ceramic core is formed by coating the reticulated polyurethane precursor with a ceramic slurry. Reticulated open-cell foam, preferably polyurethane foam, is impregnated with ceramic slurry, wherein the entire structure of the reticulated open-cell foam is preferably coated with the slurry. The pore size of the foam is preferably between about 10 to about 70 PPI. The impregnated foam is preferably compressed to discharge 25% to 85% of the slurry while keeping the polyurethane struts coated. In commercial production operations, the impregnated foam can be passed through one or more preset rolls to affect the desired state of the slurry discharge from the foam, thereby leaving the desired amount of coating on the polyurethane precursor.
The impregnated foam is then heated to a degree sufficient to remove any free water to dry the slurry. The dry impregnated polyurethane is then fired to a high temperature to form a ceramic bond. The resulting ceramic foam is essentially a connection of pillars, which has internal pores left by the burning of the polyurethane foam during the firing process. This technique is well known in the art.
The free water in the impregnated foam is then removed by drying at a temperature of 35°C to 200°C for 2 minutes to 6 hours. After drying, the material is heated at a high temperature to bond or sinter the ceramic particles that make up the filter structure. The second stage is to heat to a temperature of 900°C to 1700°C, and keep the temperature in this range for 2 minutes to 10 hours to bond the ceramics. The resulting product is a molten ceramic foam with an open-cell structure, which is characterized by a plurality of interconnected voids surrounded by a ceramic mesh. Based on the configuration required for a particular molten metal filtration process, the ceramic foam can have any desired configuration.
The slurry used depends on the ceramic material required for the selected application. The final ceramic must have sufficient properties in the final product to withstand the specific application, and must have sufficient structural and/or mechanical strength to withstand high temperature use conditions.
Ceramic Foam Filters Manufacturer AdTech offers a simple, reliable, and cost-effective method to remove inclusions. Filtering with ceramic foam filter (CFF) is a supplement to metal treatment within the furnace, such as fluxing and degassing or inline filtration. Technical advances in CFF, such as fine pore filters and improved filtration systems better suited to the stringent operating conditions of the casthouse have offered an efficient method of removing inclusions from liquid aluminum in a wide range of critical applications.