Zirconia foam ceramic filters solve planetary carrier inclusion defects
2026-08-18 09:31Foam ceramic filters are widely adopted in steel casting production and have become an essential process measure for medium and high-end castings. The filters can purify molten steel, reduce entrapment porosity defects, and minimize secondary oxidation slag caused by molten steel flow via flow rectification.
Ⅰ. Advantages of Zirconia Foam Ceramic Filters
Excellent high-temperature performance: Serviceable at temperatures up to 1700℃, chemically inert to molten metal, high strength and resistant to erosion by molten steel.
High porosity: Porosity exceeds 80%, ensuring smooth passage of molten steel.
High room-temperature strength: Prevent filter breakage and falling residues.
Stable product quality: Manufactured in continuous kilns with production controlled strictly in accordance with quality management system.
Ⅱ. Customer Overview
A domestic foundry mainly producing coal mining machinery adopts the alkaline phenolic resin no-bake sand process. Its steel planet carriers have long suffered from unqualified flaw detection results. SEM analysis confirmed that the failures are caused by inclusion defects. Zirconia foam ceramic filters were introduced to optimize the casting process.
Ⅲ. Casting Process Parameters
| Item | Parameter | Remark |
|---|---|---|
| Casting Name | Planet Carrier | |
| Material | ZG40CrMo | Low Alloy Steel |
| Total Pouring Weight | 3000 kg | |
| Net Casting Weight | 1500 kg | |
| Pouring Temperature | 1580℃ | |
| Pouring Time | 60 s | |
| Filter Specification | Φ200×35, 10 PPI | Qty: 4 pcs |
| Filter Seat | CPS-S Φ200-80 | Qty: 4 sets |
Ⅳ. Key Guidelines for Filter Application
When using filters, the pouring temperature shall be controlled above 1570℃.
Refractory fiber shall be used to fix the filter at three points to fill the clearance between the filter and filter seat, avoiding displacement and collision damage during mould closing and turnover.
Tap the filter gently to remove surface debris before installation, and inspect for cracks or breakages.
Preheat the filter with hot air for 40 minutes prior to pouring to avoid chilling effect.
Skim slag thoroughly from molten steel multiple times and implement rapid pouring.
XINDA Foam Ceramic Filters
Xinda supplies a full portfolio of foam ceramic filtration solutions:
Alumina Filters: Ideal for iron castings and non-ferrous alloy castings
Silicon Carbide Filters: Cost-effective choice for small & medium iron castings
Zirconia Filters: Designed for all types of steel castings, featuring superior high-temperature resistance and erosion resistance against molten steel
Dual-layer Composite Filters: Combine outstanding anti-shock performance and deep molten metal purification
Xinda filtration products help eliminate casting defects such as inclusions, porosity and secondary oxidation slag, and steadily improve the qualification rate of casting non-destructive testing.