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High-Temperature Ceramic Filter Plates (Al₂O₃/SiC/ZrO₂) for Efficient Molten Metal Filtration in Foundry
Overview of Ceramic Foam Filters (CFFs)
Ceramic Foam Filters are essential components in modern precision casting, used to enhance the cleanliness of molten metal and improve casting quality. These filters primarily remove non-metallic inclusions such as oxides, slag, and sand particles through a combination of deep-bed filtration, adsorption, and flow stabilization.
Comparison of Key Properties Property Alumina Ceramic Filter (Al₂O₃) Silicon Carbide Ceramic Filter (SiC) Zirconia Ceramic Filter (ZrO₂) Main Composition Aluminum Oxide (Alumina) Silicon Carbide Zirconium Oxide (stabilized with Y₂O₃, etc.) Key Advantages Cost-effective, versatile, excellent chemical stability. Exceptional strength, high thermal conductivity, superior thermal shock resistance. Ultra-high temperature resistance, excellent toughness, outstanding corrosion resistance. Max Service Temp High (~1750°C) Very High (~1600°C in air, stable in molten iron with SiO₂ layer) Extremely High (>2200°C) Thermal Shock Resistance Good Excellent (rapid heat dissipation) Exceptional (phase transformation toughening) Mechanical Strength High Very High (high hardness & wear resistance) Extremely High (highest fracture toughness) Chemical Stability Excellent in oxidizing atmospheres; resistant to many molten metals. Stable in oxidizing atmospheres; may corrode in strong oxidizers/alkalis. Outstanding resistance to corrosive/active molten metals. Typical Cost Economical Moderate to High Premium Application Guidelines & Selection
1. Alumina (Al₂O₃) FiltersPositioning: The All-Rounder – Best balance of performance and cost.
Ideal Applications:
Aluminum & Magnesium Alloy Casting (most common, cost-effective).
Cast Iron & General Steel filtration.
Copper & Zinc Alloy casting.
Summary: The default, reliable choice for a wide range of non-ferrous and some ferrous applications where cost is a consideration.
2. Silicon Carbide (SiC) Filters
Positioning: The High-Strength Thermal Shock Resistor.
Ideal Applications:
High-Temperature Molten Iron (e.g., ductile iron, compacted graphite iron) – excellent resistance to thermal shock.
Large castings or long pouring times requiring sustained filter integrity.
Applications demanding very high mechanical strength and abrasion resistance.
Summary: The preferred choice for demanding ferrous metal casting where thermal shock and mechanical stability are critical.
3. Zirconia (ZrO₂) Filters
Positioning: The Premium Specialist for Extreme Conditions.
Ideal Applications:
Superalloys & High-Temperature Alloys (e.g., nickel-based, cobalt-based).
Reactive/alloy steels (e.g., stainless steel, high-manganese steel) to avoid contamination.
Titanium alloy melting (in specific processes).
High-integrity castings for aerospace, medical, or investment casting where ultimate purity is required.
Summary: The top-tier solution for the most challenging environments involving the highest temperatures and most corrosive/active molten metals.
Summary & Recommendation
Filtering Aluminum, Prioritizing Cost → Choose Alumina.Filtering High-Temperature Iron, Prioritizing Durability → Choose Silicon Carbide.
Filtering Specialty Steels/Alloys, Prioritizing Purity & Performance → Choose Zirconia.
Note: Final selection should also consider pore size (e.g., 10 PPI, 20 PPI), filter dimensions, and specific casting parameters. Consultation with a technical specialist is always recommended.
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Ceramic Foam Filter Zirconia 70*22mm 60*15mm 60*20mm for Steel and Alloys Casting
Zirconia foam ceramic filter is made of high-quality and high-purity zirconia, using unique formula and advanced environmental protection technology. It has a uniform three-dimensional network structure, high strength, stable texture, no slag dropping, high temperature resistance, and thermal shock resistance ect excellent performance. Suitable for purification and filtration of stainless steel, carbon steel, copper castings and other high temperature alloy solutions below 1700C. Can filter non-metal slag inclusions and slags as small as micrometers, making the surface of steel castings smoother and reducing machining losses; the filter can make the molten steel fill the cavity more uniformly, and the molten metal has a higher turbulence during pouring tendency, the turbulent flowing through the three-dimensional pore structure is finally converted into a very stable laminar flow. Laminar flow fills the cavity better, which reduces the impact corrosion of the metal solution on the casting cavity, and significantly reduces the reject rate, reduces production costs, and improves labor productivity.
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12″x12″x2″ Large Size Alumina Ceramic Foam Filter Plate for Filtration
Dimension (mm) Dimension (inch) Pouring rate (kg/s) Filtration capacity (ton) 178*178*50 7*7*2 0.2-0.6 5 228*228*50 9*9*2 0.3-1.0 10 305*305*50 12*12*2 0.8-2.5 15 381*381*50 15*15*2 2.2-4.5 25 430*430*50 17*17*2 3.0-5.5 35 508*508*50 20*20*2 4.0-6.5 45 585*585*50 23*23*2 5.0-8.6 60 Material Alumina Color White Pore Density 8-60ppi Porosity 80-90% Refractoriness ≤1200ºC Bending... -
Refractory Silicon Carbide Sic Plate Ceramic Foam Filter for Iron Metal Casting
Silicon carbide foam ceramic filter using German imported polyurethane foam sponge as a carrier, silicon carbide mainly squeezed into the foam sponge, and then squeeze out the slurry,the slurry around the foam fiber, after drying, baking at high temperature,polyurethane thermal decomposition, leaving foam ceramic products, namely silicon carbide foam ceramic filter. The silicon carbide foam ceramic filter, with the three- dimensional mesh interconnection structure of foam sponge, can make met... -
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Customize 10-60PPI Alumina Ceramic Foam Filter for Foundry
Dimension (mm) Dimension (inch) Pouring rate (kg/s) Filtration capacity (ton) 178*178*50 7*7*2 0.2-0.6 5 228*228*50 9*9*2 0.3-1.0 10 305*305*50 12*12*2 0.8-2.5 15 381*381*50 15*15*2 2.2-4.5 25 430*430*50 17*17*2 3.0-5.5 35 508*508*50 20*20*2 4.0-6.5 45 585*585*50 23*23*2 5.0-8.6 60 Material Alumina Color White Pore Density 8-60ppi Porosity 80-90% Refractoriness ≤1200ºC Be... -
Customize 8-60PPI SIC/Silicon Carbide Ceramic Foam Filter for Gas filtration and Purification
SiC Ceramic Foam Filters common sizes in Round shape: 40x11mm, 40x15mm, 50x15mm, 50x20mm, 60x22mm, 70x22mm, 80x22mm , 90x22mm,100x22mm, 305x25mm SiC Ceramic Foam Filters common sizes in Square shape: 40x40x11mm, 40x40x15mm, 50x50x22mm, 75x75x22mm, 50x75x22mm, 100x75x22mm, 100x100x22mm, 55x55x15mm, 150x150x22mm ● Decontaminate the melting metal liquid ● Simplified gating system ● Improve the metallurgical structure of the castings ● Reduce imparities of the castings ● Improve... -
10-30PPI Zirconia Ceramic Foam Filter for Casting
Zirconia foam ceramic filter is made of high-quality and high-purity zirconia, using unique formula and advanced environmental protection technology. It has a uniform three-dimensional network structure, high strength, stable texture, no slag dropping, high temperature resistance, and thermal shock resistance ect excellent performance. Suitable for purification and filtration of stainless steel, carbon steel, copper castings and other high temperature alloy solutions below 1700C. Can filter non-metal slag inclusions and slags as small as micrometers, making the surface of steel castings smoother and reducing machining losses; the filter can make the molten steel fill the cavity more uniformly, and the molten metal has a higher turbulence during pouring tendency, the turbulent flowing through the three-dimensional pore structure is finally converted into a very stable laminar flow. Laminar flow fills the cavity better, which reduces the impact corrosion of the metal solution on the casting cavity, and significantly reduces the reject rate, reduces production costs, and improves labor productivity.
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Zirconia Ceramic Foam Filter for Magnesium Oxide Casting Resistance 1700º C Filter Mesh for Casting
Zirconia foam ceramic filter is made of high-quality and high-purity zirconia, using unique formula and advanced environmental protection technology. It has a uniform three-dimensional network structure, high strength, stable texture, no slag dropping, high temperature resistance, and thermal shock resistance ect excellent performance. Suitable for purification and filtration of stainless steel, carbon steel, copper castings and other high temperature alloy solutions below 1700C. Can filter non-metal slag inclusions and slags as small as micrometers, making the surface of steel castings smoother and reducing machining losses; the filter can make the molten steel fill the cavity more uniformly, and the molten metal has a higher turbulence during pouring tendency, the turbulent flowing through the three-dimensional pore structure is finally converted into a very stable laminar flow. Laminar flow fills the cavity better, which reduces the impact corrosion of the metal solution on the casting cavity, and significantly reduces the reject rate, reduces production costs, and improves labor productivity.
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SIC/Silicon carbide Ceramic Foam Filter for non-ferro alloy molten metal filtration
Silicon Carbide Ceramic Foam Filters mainly for filtration of cast iron and non-ferrous alloys. With their excellent resistance to attack and corrosion from molten iron liquid, they can effectively remove inclusions, reduce trapped gas from liquid metal and provide laminar flow, and then the filtered metal is significantly cleaner. Cleaner metal results in higher-quality castings, less scrap, and fewer inclusion defects, all of which contribute to bottom-line profit. SiC Ceramic Foam Filters is available in all standard dimensions and different thickness. The most common porosities are PPI 10, 20 and 30; higher porosities are available upon request. Custom-made cut-to-size filters are also possible.
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Alumina Ceramic Foam Filter for Molten aluminium alloy filtration
Alumina Foam ceramics foundry filter are mainly used for filtration of aluminium and aluminium alloys in foundries and cast houses . With their excellent thermal shock resistance and corrosion resistance from molten aluminum, they can effectively eliminate inclusions, reduce trapped gas and provide laminar flow, and then the filtered metal is significantly cleaner. Cleaner metal results in higher-quality castings, less scrap, and fewer inclusion defects, all of which contribute to bottom-line profit.
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zirconia casting ceramic foam filter
Zirconia foam ceramic filter is made of high-quality and high-purity zirconia, using unique formula and advanced environmental protection technology. It has a uniform three-dimensional network structure, high strength, stable texture, no slag dropping, high temperature resistance, and thermal shock resistance ect excellent performance. Suitable for purification and filtration of stainless steel, carbon steel, copper castings and other high temperature alloy solutions below 1700C. Can filter non-metal slag inclusions and slags as small as micrometers, making the surface of steel castings smoother and reducing machining losses; the filter can make the molten steel fill the cavity more uniformly, and the molten metal has a higher turbulence during pouring tendency, the turbulent flowing through the three-dimensional pore structure is finally converted into a very stable laminar flow. Laminar flow fills the cavity better, which reduces the impact corrosion of the metal solution on the casting cavity, and significantly reduces the reject rate, reduces production costs, and improves labor productivity.
