2007 January | Beautiful Ceramics And Pottery

Sintering Ceramics

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Fiber filter of practical application - Fiber Filters - Filtration and Separation Industry

In foundry, casting and other non-metallic inclusions as a result of casting defects in the general waste accounted for 50% of the total waste to 60%. Using liquid metal filter technology can reduce or eliminate one of the various non-metallic inclusions , purification liquid casting alloys.

Ceramic foam filter (CFF, which CeramicFoamFilter) polyurethane foam is used as the carrier, after hydrolysis after he dipped into the ceramic powder, binder, sintering aid agent, suspending agent and other coating made, then squeeze off excess paint, so that uniform coating ceramic coating carrier frame as adobe, and then dried green body formed by calcinations.

1 mechanism of ceramic foam filter on the three kinds of liquid metal physical chemistry, separation of liquid cast alloy inclusions, purify metal liquid effect.

1) cake mechanisms: the structure of complex ceramic foam can be high efficient mechanical slag when molten metal through the structure of complex ceramic foam filter, filter media by mechanical separation of the role of the filter surface is greater than inclusions hole filter, and make it settle in the liquid metal into the end of the filter as an integral part of the filter. With the inclusion accumulation in the filter surface, the number increased gradually formed a layer of "cake", so that metal flow Road, further thinning, thus the surface of the new filter media can filter out more small inclusions, At the same time, inside a filter media role in the run through the many holes in the ceramic body, and some showed small slit, there is some dead space, different regions of these changes are intercepted inclusions may position the filter internal There are also "filter cake" effect.

2) surface effect: when the melt is disrupted by the complex structure of the ceramic body, the divided into many small stream, increases the liquid metal inclusions in the contact area with the filter medium and the contact probability, since the filter concave surface is insignificant face, concave block size of about 1 ~ 10 m, on the inclusion electrostatic adsorption and adhesion diversion effect.

3) rectification effect: metal flow through foam ceramic filters, are broken up into small units of the stream, its smaller diameter, so that the Reynolds number (Re = vd / r) becomes smaller, so that liquid laminar flows tend to exercise. When the liquid metal in a laminar flow state, since the density of molten liquid metal is much greater than the density of inclusions, thereby inclusions have sufficient time to remove floating, ceramic foam filter that is able to assist runner slag. Casting system to place traps help to increase the flow of molten metal in the runner in the easy flow of liquid metal form is full of movement, and to reduce the flow rate is beneficial on inclusion, and to stay in the top runner.

2 Application of Ceramic Foam 2.1 Aluminum Alloy Casting aluminum alloy in the melting and the formation of filter casting process, to absorb gases and mixed with non-metallic debris, which reduces the casting performance and processing properties. Now successfully developed ceramic foam filter for the aluminum alloy castings provide a new, high-efficiency filters. Unlike the usual single-hole sieve and glass fiber mesh, but with multi-layer network and the curved hole, can adequately filter out the small aluminum melt inclusions, thereby increasing the casting quality. Ceramic foam filter for filtering molten aluminum alloy, usually used cordierite, mesh size of 0.8 ~ 1.0mm. Xian Aircraft Manufacturing Company with (90mm × 80mm × 20mm) foam ceramic filter to pump pipe head Clutch shell, shell and other castings torque converter to improve the pass rate of 40% to 70%, alone, to value the company added 2 million yuan per year, 300,000 yuan in profits and taxes.

2.2 filter non-ferrous metal casting molten copper alloy (brass, bronze, zinc, tin) in the casting process, will produce the same oxidation and non-metallic debris, a large number of waste, the use of a ceramic foam filter can be greatly reduce the rejection rate. Copper alloy melt filtration is usually used cordierite, mesh size 1.0 ~ 1.2mm.
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