Positioning Ceramic Foam Filters In Gating System for Casting Alloy Filtration

E.Bagherian*, M.K.A.Ariffin*, S.Sulaiman*

M.R.Yas** and A.R.Mojavertoosi **
* Department of Mechanical and Manufacturing Engineering Universiti Putra Malaysia
43400 UPM Serdang, Malaysia
** Fars Iran Company, No.4, Vahabi St, Apadana Ave, Tehran, Iran
E-mail: ehsanreza@gmail.com
Abstract
Currently with developments in melting technology, nucleation and alloy processes,
temperature control, molding and core making practices have fundamentally improved
the quality of liquid metal in the foundry. During the same period, alloy filtration is now
an integral part of casting technology. The main difficulties of filter application are
included blocking, cracking, bending and erosion of filters after pouring molten metal
into the mould cavity due to unsuitable filter type with improper properties such as lower
refractoriness than type of cast metal because of production process at the
manufacturers or incorrect filter application. This paper reviews the effective factors for
optimum filter application to get the best result such as filter type and pore size selection,
true position of ceramic foam filters in gating system involves direct and indirect pouring
on filter, calculation of filter gating system dimensions, determine filter area and number
and shape of filter can be use in gating system and another useful factors.
Keywords: Ceramic Foam Filter; Gating System; Pouring Technology; Casting
Technique; Metal Filtration.
Introduction
As a filter is applied to a gating system, the major encountered negative effect is flowing
through filter. Generally, during the pouring of molten metal in mould cavity, pore size of
filters will be tight and it can change the flow of liquid metal through the filter as shown
in Figure 1 [1]. With reference to the figure 1 the filter holes are open fluid of molten
metal is increased sharply in initial stage. The flow will continue in second stage but it
will decreased gradually due to the capturing of inclusion and finally the flow is block in
third stage because of filter blockage.

Fluid flow through a filter can be described by Darcy`s law [2] using equation 1:
Q=

K ( A dp)
L n

=R

A dp
n

(1)

Where Q = flow rate

A = filter area
dp = pressure difference across filter
n = fluid viscosity
L = filter thickness
P = permeability of filter media
R = filter resistance
According to equation (1) by measuring flow rate, the filter resistance can be determined,
although for different filters, the initial flow rate may be different [3, 4].

Figure1. Schematic pattern of flow through a ceramic foam filter [1]

Basically the blockage wills results an increase of pouring time and can cause casting
defect such as sand buckling [5] and cold shut [6]. So, the running system should be
designed to fill the mould cavity before the blocking filter occurred. This paper is concern
about the effectiveness of the parameters setting for the filter application.
Review of filter application technology
Usually selection suitable filter type is depends on casting materials
included [7]:

Silicon carbide ceramic foam filters for filtration nodular cast iron,
malleable cast iron, grey cast iron and other iron casting.
Zirconia ceramic foam filters for filtration stainless steel and other steel
alloy.
Magnesia ceramic foam filters for filtration magnesium alloy.
Alumina ceramic foam filters for filtration aluminium alloy and other
non-ferrous alloy.

Beside the filter type, application and installation of ceramic foam filter
in gating system is performed in three steps which consist of (a) filter

pore size selection, (b) filter sizing calculation and (c) filter installation
[8].

1. Filter pore size selection

Generally standard holes size of ceramic foam filter is related to
casting materials, weight and quality. Figure 2 shows commercially
ceramic foam filter used in casting with three pore size ranges [8]:

Coarse size with approximate filter pore size 3.5 5.0 mm

Medium size with approximate filter pore size 2.0 3.0 mm
Fine size with approximate filter pore size 1.0 1.4 mm

Filter can decrease the velocity of liquid metal [9] for example by
increasing the filter coarseness from 30 ppi (pore per inch) to 20 ppi and finally to 10 ppi
the flow-rate is reduced [10]. However, too fine filter will reduce the velocity [9]. In
addition as the pore size number increases, the size of individual pores
decreases and the internal filter surface area increases [8]. As
discussed above, the filter pore size is generally determined by casting
materials and the alloy type to be poured as following
recommendation: [1, 11, 12, 13].

10 ppi or coarse ceramic foam filter is suggested that for

ductile cast iron, Ni-resist iron, SiMo ductile iron, copper
alloy, steel and aluminium.
Use 20 ppi or medium size ceramic foam filter is
recommended to grey cast iron and aluminium.
Fine pore size ceramic foam filter or 30 ppi is offered that
to malleable cast iron.

Figure.2. different porosity of ceramic foam filter [11]

2. Filter size selection

By increasing the active filter area, the flow-rate reduction decreases

[9]. Thus filter area is determined by total weight of metal through the
chosen filter area as following equation [14]:
Required total filter area ( cm 2 ) =
Total weight

be filtered(kg)
Selected filtration capacity factor (kg/cm 2)

(2)

Selected filtration capacity factor is listed in Table 1. According

equation (2), result is possible to convert into the number and shape of
filter (rectangular, square or circle) that can be applied to gating
system. For example, if 300 kg grey iron is total weight to be filtered
then by choosing selected filtration capacity factor from table it is easy
to find number of filter can be use in gating system as the following
calculation:
Approximate filter area = 300 (kg)/ 4( kg /cm2 ) = 75

cm

Then filter option (mm) are: 175100 = 25075 = 35050. But in

principle filter option is depends on the actual pattern plate layout.
Alloy
Ductile iron
Grey cast iron
Malleable iron
Ni-resist iron
Carbon steel
Steel alloy
Aluminum alloy

Selected filtration capacity

2
factor kg /cm )

1.4 2
4
4
0.8 1
1 - 1.2
1.5
12

Table.1.Selected filtration capacity factor

3. Filter placement
There are two categories for possibilities of positioning the filter in
gating system which included direct pouring and indirect pouring
technique [14].
Direct pouring: in this technique molten metal can be
directly pass through the filter, position of filter is bellowing
the sprue as shows as in Figure 3. Actually this technique is
not require to specially design for gating but this design is
a problem when the sprue is very high or when pouring

from a ladle with bottom outlet use. In addition if this

method is applied, only one filter can be use in one mould.

Figure.3. Direct pouring technique [14]

Indirect pouring: this system is suitable for use more than

one filter, so filter is placed in specially chamber in gating
system which is consist of in perpendicular to flow
direction, parallel with inflowing metal and slanting as in
Figure 4, this technique is suitable for use more than one
filter in mould but sometimes danger of filter clogging is
the problem related to this method.

a) Vertical position of filter close to the sprue

b) Vertical position of filter in the distribution runner

c) Horizontal position of filter

d) Slanting position of filter

Figure.4.Indirect pouring technique [14]

Choke area calculation.
Choke area of the gating system is suggested to following ratio to use
[15]:
Down sprue:

Runner:

Gate:

1, 0

1, 1

1, 2

The choke area of the gating system when ceramic foam filter applied
is calculated same to ingate without filters, by using the following
formula:

Da =

22.6 G
t H

(3)

Where: Da = down sprue area ( cm 2 )

22, 6 = constant for acceleration
G = poured weight (kg)
= friction factor (0.2 to 0.6 depends on gating system and
mould geometry)
= density of metal (kg/ dm
= required pouring time (s)

H = effective pressure or pouring height (cm)

As discussed above ceramic foam filter can be located anywhere within
the pouring system; however for steel filtration filter should be
installed in runner system. So to achieve the best result it is
recommended put filter in runner rather than in the pouring basin or
directly under the sprue [8]. For iron it is suggested that to place filter
as close as possible to the mould cavity, however filter area for grey
iron is recommended to at least two times of down sprue area and also
three time for ductile iron.[11]. For aluminum alloy, the filter can be
placed as close as possible to the mould cavity to catch oxide film and
non-metallic inclusion at the last possible moment [16]. Also filter does
not become a choke because a little pressure or metallostatic head is
require to prime filter. Alternative location of filter in down-sprue may
be preferred [1].
Conclusion
Currently, liquid metal filtration in casting process is a common refining technology in
ferrous and nonferrous alloy casting. The filtration technique removed the inclusions in
the melts and therefore improves the mechanical properties of the product such as yield,
machinability. Furthermore this will also improved the surface finish and tightness of
castings product, thus it reduced the rework cost. Eventually the filter must be chosen
correctly, in particular position, dimension, type and pore size of filter by alloy type to
be filtered.
Acknowledgment
Authors would like to thank Mr. Ahmad Shaifudin, technician of
materials forming lab in the department of Mechanical and
Manufacturing Engineering Universiti Putra Malaysia (UPM) for his help
in this paper.
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