May, 10

STELEX* PrO
Ceramic Foam Filters For Carbon & Low Alloy Steel Castings
Product STELEX PrO ceramic foam filters are comprised of a carbon-alumina-ceramic
Description matrix that possesses unique physical properties of low thermal mass, high
thermal shock resistance, high hot strength and high resistance to thermal creep.
STELEX PrO filters are also resistant to chemical attack by most common slags
and deoxidizers. This unique combination of physical properties is ideally suited
for carbon and low alloy steel castings poured through conventional gating
systems.

STELEX PrO filters smooth the flow of molten metal to the mold cavity while
removing non-metallic inclusions such as slag, refractory materials, molding sand,
and products of reoxidation and deoxidation from the metal stream. They prime
over the full range of pouring temperatures for carbon and low alloy steel
minimizing the need for superheating. STELEX PrO filters are intended for use
with all common carbon and low alloy steel grades at pouring temperatures to
3050°F.

Filtration improves or maintains casting quality and can increase foundry

productivity and profitability. Proper use of STELEX PrO filters reduces internal
welding and cleaning costs, reduces the rate of casting returns, improves casting
machinability and cutting tool life, and reduces scrap. Filtration is one of the most
cost-effective and flexible means of satisfying the need for clean castings.

Product Filter Size Product Packaging Length / Frontal Thick-

Range (mm) Code (pcs/ctn) Width Area ness
(in) (in2) (in)
50 Diax20/10 PPI 133450 240 1.95 +/- .06 2.98 0.79
60 Diax20/10 PPI 141480 117 2.34 +/- .06 4.30 0.98
75 Diax25/10 PPI 312730 117 2.91 +/- .08 6.65 0.98
90 Diax25/10 PPI 654030 117 3.51 +/- .08 9.86 0.98
100 Diax25/10 PPI 420060 54 3.86 +/- .08 11.70 0.98
125 Diax30/10 PPI 594020 40 4.91 +/- .09 18.93 1.18
150 Diax30/10 PPI 707430 16 5.90 +/- .09 27.25 1.18
175 Diax35/10 PPI 107960 14 6.89 +/- 0.12 37.28 1.38
200 Diax35/10 PPI 408000 9 7.87 +/- .12 48.65 1.38
50x50x20/10 PPI 108070 240 1.95 +/- .05 3.80 0.79
55x55x25/10 PPI 111090 240 2.15 +/- .05 4.62 0.98
75x75x25/10 PPI 116090 117 2.95 +/- .08 8.70 0.98
100x100x25/10 PPI 120080 54 3.90 +/- .08 15.21 0.98
125x125x30/10 PPI 124570 40 4.91 +/- .09 24.11 1.18
150x150x30/10 PPI 130130 16 5.90 +/- .09 34.81 1.18

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA

Product DEOXIDATION PRACTICE
Application The level of deoxidizers—particularly Al, Ti, and Zr—should be minimized.
“Clean” metal practices increase the filtration capacity of steel filters and reduce
filtration costs.

POURING TEMPERATURE
To ensure consistent filter priming and metal flow, metal should be poured at a
minimum of 75°F above its liquidus temperature. A typical minimum pouring
temperature for carbon steel and low alloy steels is 2830°F.

SUPERHEAT
The unique physical/thermal properties of STELEX PrO filters make it
unnecessary to superheat carbon and low alloy steels to minimize the risk of mis-
runs. Nevertheless, reasonable precautions should be taken to minimize pouring
temperature variations to ensure consistent filter performance.

FOUNDRY PRACTICE VARIATIONS

STELEX PrO filter performance can change significantly with variations in pouring
temperature, pouring rate from the ladle, metallostatic pressure, metal chemistry,
and filter placement in the gating system. Filter users are strongly encouraged to
conduct trials to determine obtainable flow rates and filtration capacities for each
filter size when using various foundry practices.

MANUAL DETERMINATION OF FILTER SIZE

Initial selection of filter size is a simple three-step process. Refer to Tables 1 & 2
for filter dimensions and performance characteristics.

Step 1
Flow rate requirements: A certain minimum filter area is required to achieve the
desired mold filling time. To determine the required minimum filter area, multiply
the gating system choke area by a suitable filter-to-choke ratio; typically between
4.5 : 1 and 6.0 : 1. The proper ratio will depend on metal cleanliness, ladle
practice and pouring temperature for the particular application. Referring to the
Usable Frontal Area column in Table 1, choose the STELEX PrO filter that
provides the required filter area.

Filter Area (in2) = Filter-to-Choke Ratio x Choke Area (in2)

Step 2
Filtration capacity requirements: Using the appropriate Filtration Capacity Range
column in Table 2, determine the filter that will pass a sufficient amount of steel
for the application.

Filtration Capacity (lbs) ≥ Poured Weight of the Casting (lbs)

Step 3
After determining the recommended filter size based on the flow rate and filtration
capacity requirements (Steps 1 & 2), the larger of the two filters should be used.
The user needs to confirm that the pouring ladle is capable of supplying metal to
the mold at the desired flow rate, as specified in the Nominal Flow Rate column of
Table 2, throughout the pour.

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA

 Product Table 2: Filtration Capacity and Maximum Flow Rate Values For STELEX PrO
Application Ceramic Foam Filters (average for all ladles)
(Con’t)
Maximum Filtration Capacity** Maximum Flow
Carbon and Low Alloy Steels Rate**
(Lbs) (lbs/sec)
High Level Low Level Carbon
Filter Size Deoxidation Deoxidation and
(mm) Products Products Low Alloy
“Dirty” Metal “Clean” Metal Steels
50 Diax20/10 PPI 98 147 8.4
60 Diax20/10 PPI 141 211 13.0
75 Diax25/10 PPI 220 330 23.0
90 Diax25/10 PPI 317 475 34.0
100 Diax25/10 PPI 391 586 46.0
125 Diax30/10 PPI 611 916 62.0
150 Diax30/10 PPI 880 1319 85.0
175 Diax35/10 PPI 1198 1795 109.0
200 Diax35/10 PPI 1564 2346 142.0
50x50x20/10 PPI 124 187 13.0
55x55x25/10 PPI 151 227 13.0
75x75x25/10 PPI 280 420 23.0
100x100x25/10 PPI 498 746 42.0
125x125x30/10 PPI 778 1166 63.0
150x150x30/10 PPI 1120 1680 87.0

** Flow Rate and capacity data was generated using Foseco’s METHODCALC* for steel filter application
software. The calculations for round filters assume a direct impingement application, 12-inch effective head
height, the filter as the choke, and a 2830oF pouring temperature from a lip pour ladle. The calculations for
square filters assume a FP1 filter print, 12-inch effective head height, the filter as the choke, and a 2830oF
pouring temperature from a lip pour ladle.

GATING DESIGN AND FILTER PLACEMENT

Optimal results are achieved using unpressurized gating systems. STELEX PrO
filters must be adequately supported to maintain integrity and to prevent metal
bypass. Please refer to the STELEX Filter Print Data Sheet for more details on
filter print design.

POURING PRACTICE
When pouring directly onto the face of the filter, minimize the height from which the
metal is poured. Maintain precise temperature control to minimize mis-runs.
Assure adequate metal delivery from the ladle to keep the sprue full during pouring
and prevent intermittent flow. The gating system should be designed to assure
rapid filling and be more than capable of accommodating the maximum delivery
rate from the ladle.

Patents STELEX PrO filters are covered by US patent # 7,138,084 Canadian patent # 2,413,496.
* Trademark of the Foseco Foundry Division of the Vesuvius Group, used under license.

CAUTION
FOSECO products are made from quality materials and are designed to serve with maximum efficiency and minimum risk. However, as with many substances used
in industry, health hazards may be present in the use of FOSECO products and, therefore, it is extremely important that the user familiarize himself with the warning
and handling instructions on the label and on the Occupational Safety and Health Data Sheet. Contact a FOSECO representative if further information is needed or
if the product is to be used in an unusual application.
Every effort is made to ensure the fitness of FOSECO products for their stated purpose, however, because FOSECO has no control over the use of its products, no
warranty can be made in regard to results attending their use or to possible adverse metallurgical consequences and side effects. You should read carefully the
Terms and Conditions of Sale which accompany the sale of any FOSECO product which you use.

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA
Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA