Zirconia Foam Ceramic Filter: Application on Wind Power Planet Carrier Cast Steel Components
2026-09-22 09:25The planet carrier is a core transmission component of wind power gearboxes. The casting weighs 1500 kg and is made of ZG40CrMo low alloy steel, which belongs to heavy-section cast steel parts. Subject to heavy working loads and complex stress conditions, it requires extremely high internal compactness, with ultrasonic testing as a key acceptance indicator.
During actual production, wind power planet carrier castings frequently encounter challenges. Slag inclusions and non-metallic oxide impurities are easily carried into the mold cavity along with molten steel flow, resulting in internal slag defects and high rates of failed ultrasonic inspection. Heavy workload is required for casting repair and welding, which raises overall production costs and hinders the delivery schedule of wind power castings.
In this case, the zirconia foam ceramic filter was adopted for batch production verification of wind power planet carrier castings. It purifies molten steel to eliminate slag inclusions, solve the problem of failed inspection and reduce welding repair rates.
Ⅰ. Product Information
Technical Parameters of Zirconia Foam Ceramic Filter
| Product Name | Filter Size | Pore Density | Max Operating Temperature | Porosity |
|---|---|---|---|---|
| Zirconia Foam Ceramic Filter | φ200×35 mm | 10 ppi | 1700℃ | ≥80% |
Ⅱ. Casting Information
| Casting Name | Application Field | Material | Total Pouring Weight | Net Casting Weight | Pouring Temperature | Pouring Time |
|---|---|---|---|---|---|---|
| Planet Carrier | Wind Power Equipment Casting | ZG40CrMo Low Alloy Steel | 3000 kg | 1500 kg | 1580℃ | 60 s |
Ⅲ. Production Process & Precautions
| Pouring Temperature | Above 1570℃ |
| Filter Installation | Fixed at three points to prevent collision and displacement during mold turnover |
| Pre-use Inspection | Tap off debris from the filter and check for cracks or damage |
| Drying Requirement | When hot air dryer is available, conduct hot air pre-drying for 40 minutes before pouring |
| Pouring Operation | Remove slag from molten steel repeatedly before pouring; align ladle with pouring cup for fast pouring |
Ⅳ. Core Advantages of Zirconia Foam Ceramic Filter
Excellent high-temperature performance suitable for cast steel pouring
The filter can operate stably below 1700℃ without reacting with molten steel. It features outstanding resistance to erosion by molten steel and maintains stable performance under 1580℃ pouring condition of ZG40CrMo molten steel.
High porosity for smooth filtration channels
The porosity reaches more than 80%, with no blocked or blind holes, ensuring smooth passage of molten steel without affecting pouring speed and mold filling.
High room-temperature strength, resistant to damage during installation and handling
It maintains high strength at ambient temperature, and is not easy to break and drop debris during installation and mold turnover, avoiding secondary contamination.
Reliable product quality and consistent batch performance
Manufactured in continuous kilns with strict in-process production control. Each batch of filters delivers stable performance, suitable for mass production of wind power castings.
Ⅴ. Field Application & Result Analysis
Zirconia foam ceramic filter φ200×35 (10ppi) was applied on site, with pouring temperature of 1580℃ and pouring time of 60 seconds. The total weight of poured molten steel was 3000 kg and the finished casting weighed 1500 kg.
Easy installation: Reserve installation clearance for the filter and fix it at three points. Simple installation procedure without extra molding working hours.
Elimination of inspection failure: After using the filter, the original inspection failure issue of castings is resolved, and internal slag inclusions are basically eliminated.
Greatly reduced welding repair rate: The casting welding repair rate drops by more than 90%, cutting welding working hours and material costs, and significantly lowering the overall production cost of castings.
Improved casting quality: Internal slag defects of castings are basically removed. The internal compactness meets the high-load operation requirements of wind power gearboxes, lifting both casting qualification rate and delivery efficiency.
Zirconia foam ceramic filters feature prominent high-temperature resistance, with pore sizes ranging from 10ppi to 30ppi. They are suitable for filtration of high melting point molten metal such as cast steel, widely used for manufacturing critical castings requiring superior internal quality, including wind power gearbox components, pump & valve parts, machine tool beds and automotive castings.