NATIONAL UNIVERSITY OF

ENGINEERING

DIAGRAMS

COLLEGE OF GEOLOGICAL, MINING AND

METALURGICAL ENGINEERING

MINING ENGINEERING PROGRAM

EFFECT OF THE USE OF FILTERS

IN STEEL CASTING

Flow Chart of Foundry Process

Course: Fundicin
Faculty: Quionez Leoncio
Members

Table 2: Process cost without filter Table 3: Process Cost

with Filter

ESCALANTE VILLANUEVA, JAVIER

NUEZ- MELGAR LEON, PABLO
PEREZ CABRERA, JOSE ARNALDO
CHINGEL JULCA, JHONY
INGA YAURI, CESAR

OBJECTIVES
1.
2.
3.
4.

To verify the advantages ceramic filters give in the manufacturing of

steel pieces in comparison with the traditional method.
To notice the defects without using ceramic filters.
To recognize the factors involved in the casting process.
To learn the right pouring technique to get the best fluidity.

WHAT IS A FILTER?
Foam Filters are based on a system of mutually linked cells in the shape of
pentahedron. Foam filters are produced by filling a polyurethane foam matrix with a
suitable ceramic suspension. After firing the foam, a ceramic filter frame is created.
The filters differ in their pore sizes, wich are given by the porosity of the foam porosity
used.
The density of filters is chosen with respect to metal liquidity (running quality) and the
rate of clogging. For alloys with low liquidity and allows with a high quantity of
inclusions, filters with larger pores (density 10 or 20 ppi) should be chosen, and for
alloys with good liquidity, thicker filters (20-30 psi) are suitable. The flow profile of
foam filters depends on the robustness of ceramic frame, and it usually makes up to
80% of the total filter area.

WHY FILTERING?
To produce a high-quality product, it is necessary to produce a casting that has the
prescribed shape and dimensions, without any external/internal defects, including all
the required mechanical, technological, structural, and other properties.

1er Mtodo: Mtodo de los Mdulos (Wlodawer)

Para comenzar a aplicar este mtodo necesitamos calcular el volumen
de la pieza y el rea en contacto pues esos son los parmetros que
intervienen en el clculo del mdulo de la pieza. Recordemos que:

2do Mtodo: Mtodo de la Circunferencia Inscrita

Este mtodo nos dice que el dimetro del alimentador est en funcin a la
mxima circunferencia que se puede inscribir en el espesor de la pieza.

DIRECT POURING ONTO FILTER

Pouring cups are provided with a filter in the bottom, which serves as the
pouring basin, and when pouring is finished, as a riser. Metal from the
pouring cup enters directly the casting, and using this method replaces the
whole gating system.
Pouring cups are usually made of light-weight heat-insulating materials with
many advantages: Directional solidification, high exploitation of molten metal,
high exploitation of frame area, lower fettling costs.

WHAT IS FILTRATION?
The term filtration refers to the separation of inclusions that are present in the metal.
The filter may be used, for example, when reladling the metal from the melting
furnace to the holding furnace, and it can be positioned as a partition between the
reservoir of molten metal and the furnace outlet, but the filter is most frequently
inserted into the gating system of each mould.

HOW INCLUSIONS ARE HARMFUL IN A CASTING

Inclusions can be found on the casting surface or inside the casting. Some inclusions
have the shape of compact particles, while other inclusions form thin films but of large
surface dimensions. Some inclusions are separate particles, whereas other inclusions
agglomerate into compact clusters. Depending on all this, the negative effect of
inclusions can manifest itself in various ways.
1. Deterioration of casting surface quality.
2. Deterioration of mechanical properties.
3. Deterioration of machinability.
4. Casting leakage.
5. Gas bubbles.

EQUATIONS

Table 1: Foam Filter Properties

CONCLUSIONS
1. Son un medio rentable, se disminuye el costo.
2. Se aumenta la eficiencia, al disminuir el sistema de alimentacin y el
peso en los mismos.
3. Se mejora la calidad de la pieza, al disminuir las porosidades y los
defectos se omiten las etapas de mecanizado y soldadura.