Why Ceramic Foam Filters?
Filtration with ceramic foam filters offers several key benefits that improve the quality of premium aluminum castings. These include:
- Improved mechanical properties;
- Reduced dye-penetrant indications;
- Reduced x-ray evidence of nonmetallics;
- Reduced rework/scrap;
- Improved machining properties.
The presence of nonmetallic inclusions is detrimental to the production of premium quality castings. High attainable mechanical properties are a key aspect that is readily lost in the presence of inclusions and oxide skins. The mechanical properties of high-strength aluminum alloys are very sensitive to notches or imperfections in the casting. Filtration effectively reduces inclusion levels and subsequent notch effects caused by inclusions. Conventional techniques for attempting to remove inclusions are ineffective, and the use of metal or fiber screens isn’t sufficient to keep the metal truly free of harmful nonmetallics.
Premium quality castings generally restrict the acceptability of surface defects that are revealed by dye penetrant inspection. Research has shown the level of such defects is reduced when ceramic foam filtration is involved. A marked decrease, or total elimination, of indications has been noted.
Another benefit that is gained from the use of ceramic foam filters is the reduction in the x-ray evidence of nonmetallics. The presence of x-ray defects under these circumstances is often the basis for the rejection of expensive castings. The most significant benefit is the reduction of defects visible in those areas that are designated as “structurally critical.”
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