STELEX ZR IN-LINE FILTRATION

F I LT E R S E N S U R E - C L E A N C A S T I N G S
STELEX* ZR
Calculation of the gating F I LT E R S F O R S T E E L A N D I R O N C A S T I N G S
system
In gating systems using STELEX* ZR The front face area must be large Valve housing
foundry filters, the cross-section of the enough to ensure that casting cavity is design, filtered
downsprue should be the smallest filled with molten metal before the filter “in-line“ with
or controlling section of the running becomes blocked. Foseco recommends STELEX ZR
system. The calculation of this choke the front face filter area be at least Ø 75x75x25/10ppi
area (CA) is based on the “general 3.0 times larger then the calculated located using
ingate formula”. choke area (CA). It is also important to filter print STELEX
ensure the exit face of the filter is well FP 7
22,6 x supported. A support area of at least
A = 40% of the front face area should be
applied. Valve housing
A : downsprue area (cm²) filtered “in-line“
22,6 : constant for acceleration Further information regarding filter with STELEX ZR
: poured weight (kg) sizes, flow rates and filter capacities Ø 75x75x25/10ppi
: friction factor can be obtained from your local Foseco located using
: steel density (g/cm³) Company. filter print STELEX
t : required pouring time (s)
FP 7
H : effective pressure or
pouring height (cm) Our experienced team is ready to assist
you in obtaining excellent casting
The following relationship between the results. We will help you select the most
gating system components has proven suitable product and/or application
successful in practice: process. Foseco commits to work
together with your foundry experts to
ensure projects are completed to a Reduced
Downsprue 1,0
timely and successful conclusion. Hub casting made finishing
Ratio of runner 1,1 of GJS, filtered
with six STELEX ZR
Ratio of ingates 1,2 Ø 200x35/10ppi Reduced
weld repair

Cleaner
casting surfaces

Lower
production costs
Planet Carrier
filtered using two
Ø 200x35/10ppi
STELEX ZR filters
within the hollow
ware gating
system.

Foseco International Limited, PO Box 5516, Tamworth, Staffordshire, England B78 3XQ,
Phone: +44 (0)1827 262021, Fax: +44 (0)1827 283725, www.foseco.com
04/2007 · re 500 e

Please contact your local Foseco Company

*Foseco, the Logo and STELEX are Trade Marks of the Foseco Group of Companies, used under licence. All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written
permission of the copyright holder. All statement, information and data contained herein are published as a guide and although believed to be accurate and
reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly or
impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to
meet local legislation. The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/
seller are based on their respective conditions of sale available on request. ©Foseco International Limited 04/07

L O W E R T U R B U L E N C E M O U L D F I L L I N G - “ F I LT E R “ C L E A N C A S T I N G S
STELEX ZR - FILTERS

S U I TA B L E F O R T H E F I LT R AT I O N O F A L L C O M M O N F E R R O U S A L L O Y S

STELEX ZR ceramic foam filters are Advantages of STELEX ZR Application of

manufactured from Zirconia. They have
been specially developed for the filtration
of molten steel and are suitable for
castings temperatures up to 1680C.
Increasingly, due to their combination of
high mechanical strength and superior
filtration capacity, STELEX ZR filters are
applied on large ductile and grey iron
castings.
STELEX ZR filters minimise molten metal
turbulence within the mould cavity,
helping to prevent reoxidation.
Using STELEX ZR filters in your gating
systems will help to prevent non-metalic
materials reaching the mould cavity.
This reduces the need for additional
finishing such as the removal and repair
of slag inclusions, shortening the total
processing time.
foundry filters
Cleaner casting surfaces
- reduced grinding
Less inclusions
- reduced weld repair
- no additional heat treatment
Reduced machining allowance
- extended machine tool lifetime
Reduced cleaning time
- shorter lead times
Lower inspection costs
STELEX ZR filters
Filtration effectiveness largely depends upon
the correct application of STELEX ZR filters.
When applying filters we always recommend
using STELEX filter prints which have been
developed in close co-operation with foundry Selection of
men and Foseco experts. Typically, these filter STELEX ZR
prints are placed on the parting line. Positioned filters
horizontally in the runner system and close to
the downsprue, STELEX ZR filters will prime
quickly, thereby ensuring a consistent flow
through the whole filter area.
In order to avoid turbulence, abrupt changes
in the direction of metal flow behind the filter STELEX ZR
should be avoided at all costs. This is especially filters for
important when casting steel alloys, because investment
a turbulent flow will lead to reoxidation and casting
risks the development of new non-metallic
inclusions within the casting cavity.

Unfiltered
crusher head
casting with
poor surface
quality

Filtered
crusher head
casting with
superior surface
finish

STELEX filter prints:

Filtered castings
are significantly
cheaner. The
need for weld
repair can
be virtually
eliminated.

FP 1 FP 3 FP 4 FP 7
2 3
STELEX ZR - FILTERS

S U I TA B L E F O R T H E F I LT R AT I O N O F A L L C O M M O N F E R R O U S A L L O Y S

STELEX ZR ceramic foam filters are Advantages of STELEX ZR Application of

manufactured from Zirconia. They have
been specially developed for the filtration
of molten steel and are suitable for
castings temperatures up to 1680C.
Increasingly, due to their combination of
high mechanical strength and superior
filtration capacity, STELEX ZR filters are
applied on large ductile and grey iron
castings.
STELEX ZR filters minimise molten metal
turbulence within the mould cavity,
helping to prevent reoxidation.
Using STELEX ZR filters in your gating
systems will help to prevent non-metalic
materials reaching the mould cavity.
This reduces the need for additional
finishing such as the removal and repair
of slag inclusions, shortening the total
processing time.
foundry filters
Cleaner casting surfaces
- reduced grinding
Less inclusions
- reduced weld repair
- no additional heat treatment
Reduced machining allowance
- extended machine tool lifetime
Reduced cleaning time
- shorter lead times
Lower inspection costs
STELEX ZR filters
Filtration effectiveness largely depends upon
the correct application of STELEX ZR filters.
When applying filters we always recommend
using STELEX filter prints which have been
developed in close co-operation with foundry Selection of
men and Foseco experts. Typically, these filter STELEX ZR
prints are placed on the parting line. Positioned filters
horizontally in the runner system and close to
the downsprue, STELEX ZR filters will prime
quickly, thereby ensuring a consistent flow
through the whole filter area.
In order to avoid turbulence, abrupt changes
in the direction of metal flow behind the filter STELEX ZR
should be avoided at all costs. This is especially filters for
important when casting steel alloys, because investment
a turbulent flow will lead to reoxidation and casting
risks the development of new non-metallic
inclusions within the casting cavity.

Unfiltered
crusher head
casting with
poor surface
quality

Filtered
crusher head
casting with
superior surface
finish

STELEX filter prints:

Filtered castings
are significantly
cheaner. The
need for weld
repair can
be virtually
eliminated.

FP 1 FP 3 FP 4 FP 7
2 3
STELEX ZR IN-LINE FILTRATION

F I LT E R S E N S U R E - C L E A N C A S T I N G S
STELEX* ZR
Calculation of the gating F I LT E R S F O R S T E E L A N D I R O N C A S T I N G S
system
In gating systems using STELEX* ZR The front face area must be large Valve housing
foundry filters, the cross-section of the enough to ensure that casting cavity is design, filtered
downsprue should be the smallest filled with molten metal before the filter “in-line“ with
or controlling section of the running becomes blocked. Foseco recommends STELEX ZR
system. The calculation of this choke the front face filter area be at least Ø 75x75x25/10ppi
area (CA) is based on the “general 3.0 times larger then the calculated located using
ingate formula”. choke area (CA). It is also important to filter print STELEX
ensure the exit face of the filter is well FP 7
22,6 x supported. A support area of at least
A = 40% of the front face area should be
applied. Valve housing
A : downsprue area (cm²) filtered “in-line“
22,6 : constant for acceleration Further information regarding filter with STELEX ZR
: poured weight (kg) sizes, flow rates and filter capacities Ø 75x75x25/10ppi
: friction factor can be obtained from your local Foseco located using
: steel density (g/cm³) Company. filter print STELEX
t : required pouring time (s)
FP 7
H : effective pressure or
pouring height (cm) Our experienced team is ready to assist
you in obtaining excellent casting
The following relationship between the results. We will help you select the most
gating system components has proven suitable product and/or application
successful in practice: process. Foseco commits to work
together with your foundry experts to
ensure projects are completed to a Reduced
Downsprue 1,0
timely and successful conclusion. Hub casting made finishing
Ratio of runner 1,1 of GJS, filtered
with six STELEX ZR
Ratio of ingates 1,2 Ø 200x35/10ppi Reduced
weld repair

Cleaner
casting surfaces

Lower
production costs
Planet Carrier
filtered using two
Ø 200x35/10ppi
STELEX ZR filters
within the hollow
ware gating
system.

Foseco International Limited, PO Box 5516, Tamworth, Staffordshire, England B78 3XQ,
Phone: +44 (0)1827 262021, Fax: +44 (0)1827 283725, www.foseco.com
04/2007 · re 500 e

Please contact your local Foseco Company

*Foseco, the Logo and STELEX are Trade Marks of the Foseco Group of Companies, used under licence. All rights reserved. No part of this publication may be
reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written
permission of the copyright holder. All statement, information and data contained herein are published as a guide and although believed to be accurate and
reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly or
impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to
meet local legislation. The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/
seller are based on their respective conditions of sale available on request. ©Foseco International Limited 04/07

L O W E R T U R B U L E N C E M O U L D F I L L I N G - “ F I LT E R “ C L E A N C A S T I N G S