THE USE OF CERAMIC FOAM FILTERS IN HIGH TEMPERATURE CASTING APPLICATIONS

700 Shepherd Street Hendersonville, North Carolina 28792 U.S.A. Telephone: (828) 697-2411 Telefax: (828) 693-1868

BRC94-02

CONTENTS

Page INTRODUCTION Who Is SELEE Corporation? WHY FILTER? Benefits to Using Ceramic Foam Filters CASTING CASE HISTORIES Corrosion Resistant Valve Body Casting Companion Hydraulic Piston & Cylinder Castings SOURCES OF INCLUSIONS IN STEEL CASTINGS HOW DOES STEEL FILTRATION WORK? Inclusion Separation Theory Why Inclusions Can Not Be Reliably Removed In Gating Systems Why Filters Are More Effective How Solid Inclusion Removal Works How Liquid Inclusion Removal Works HIGH TEMPERATURE CERAMIC FOAM FILTERS Characteristics of Reticulated Ceramic Foam Filters Refractory Filter Materials for Steel Casting Applications SELECTING THE PROPER PORE SIZE FILTER FILTER SIZING CALCULATIONS Flow Rate Filter Capacity 1 1 2 2 2 2 3 5 5 5 5 5 5 8 10 10 10 11 11 11 11

STANDARD SIZE STEEL FILTERS FILTER INSTALLATION Basic Filter Installation Design Plastic Gating Components for Standard Size Filters TECHNICAL SUPPORT Customer Technical Support Metallurgical Analysis Filter Proposals REFERENCES

13 15 15 15 19 19 19 19 20

INTRODUCTION
Who Is SELEE Corporation?
SELEE Corporation is a wholly owned subsidiary of North Americas largest producer of ceramic foam filters for ferrous and nonferrous foundry casting operations. SELEE Corporation is the only ISO 9001 certified and Ford Q-1 assessed supplier for these products. Founded in 1978, SELEE Corporation is located in Hendersonville, North Carolina along the edge of the Blue Ridge Mountains. Ownership of the company is comprised of employees and three outside minority investors. Included among investors are The North Carolina Enterprise Corporation and Leventis Overseas Ltd. Leventis is the leading producer, bottler and distributor of Coca-Cola in Western Africa, Ireland, Greece and Eastern Europe. Company facilities include 135,000 square feet of modern manufacturing space, a 25,000 square foot Technology Center and a joint venture manufacturing facility in Venezuela. The Technology Center located in North Carolina is the worlds only research facility dedicated to the development of new and improved ceramic foams. The company devotes almost $0.10 of every sales dollar to research and development. The state-of-the-art Technology Center is equipped with a fully analytical scanning electron microscope, x-ray diffraction and a complete metallurgical laboratory to serve both research and customer requirements. New products introduced in 1993 included an advanced filter for single crystal superalloy airfoil casting. The Corporate Team is made up of 130 employees. Ninteen people are dedicated to research activities while an additional nine are utilized on full time Applications Engineering efforts working with our customers to help improve processes, lower costs and improve quality.

SELEE's manufacturing facility in Hendersonville, North Carolina.

The 25,000 square foot Technology Center demonstrates SELEE's commitment to excellence.

WHY FILTER?
Benefits of Using Ceramic Foam Filters Efficient and economical production of clean steel castings is becoming increasingly important in todays competitive global market. The presence of non metallic inclusions is one of the most troublesome problems in the production of premium quality steel castings and is a significant part of the overall processing cost. The presence of non metallic inclusions can impair mechanical properties such as tensile strength, ductility, fracture toughness and fatigue resistance. In addition the presence of surface or subsurface inclusion material can significantly impair the machinability and pressure tightness of the casting. The following is a partial list of some of the benefits attributed to using ceramic foam filters: Reduced scrap rate Reduced casting returns from customer Increased casting yield through use of shorter runner systems Elimination of slag inclusions Reduced rework time and materials Improved mechanical properties Reduced micro-inclusion content Improved product quality Reduced machine shop scrap Reduced machine tool breakage and wear Improved machine surface quality and integrity Improved cosmetic surface quality Reduced casting processing time (improved on time delivery capability)

CASTING CASE HISTORIES

The performance of ceramic foam filters in steel foundries has been well documented in the technical literature. The following examples are of two case histories detailing the benefits realized by using ceramic foam filters. Corrosion Resistant Valve Body Casting Filters were used to cast a 4" CN-7M valve body casting in an effort to reduce extensive rework (grind/weld/ heat treatment).1 Eighteen paired sets of filtered and unfiltered castings were produced and the effectiveness of filtration was evaluated based on the number of required inclusion weld repairs. Figure 1 is a drawing of the pattern plate showing the gating system and the detailed filter installation. The casting and processing parameters are summarized in Table 1. After shakeout and blast cleaning, the castings were evaluated for visible surface inclusion material and their number tabulated. These defects were then removed by grinding followed by weld repair. After weld repair the castings were given a solution anneal heat treatment. Surface defects generated by heat treatment were then tabulated again and weld repaired. A second heat treatment followed. Table 2 summarizes the number of weld repairs required for unfiltered and filtered castings. Table 2 shows that prior to the first heat treatment the 18 unfiltered castings required a total of 65 weld repairs while the filtered castings required only one weld repair. After the solution anneal the unfiltered castings required a total of 115 additional weld repairs compared to 5 for the filtered castings. Overall the use of filters reduced the number of weld repairs by 96.7%. In addition 83.3% of the filtered castings could be shipped after the first solution anneal heat treatment compared to only 5.6% of the unfiltered castings. Further, the historical inclusion scrap rate was reduced from 11.5% to 0.7%.

Figure 1: Schematic illustration of the gating system for the 100 mm valve body casting.

Companion Hydraulic Piston & Cylinder Castings Filtration trials were conducted on companion piston (4130) and cylinder (440C) castings for a mass transit hydraulic brake system.2 Both castings highly machined (>95%) followed by plating. An initial sample of 24 castings of each type was made without filters which passed visual surface inspection and met Grade B radiographic requirements. After machining the castings were plated and inspected. All of the castings were rejected for small randomly dispersed oxide macro-inclusions.

Sprue Well

Filter Print

Side Riser

Filter Print

Sprue Well

Table 1: Summary of casting processing paramaters used to produce 4" CN-7M valve body castings.
Finish Casting Weight: Casting Pour Weight: Pattern Size: Sprue Height: Number of Castings Per Mold: ASTM Casting Specification: Grade/Alloy: Pour Temperature: Filter Manufacturer: Filter Type: Filter Size: Filter Pore Size: Deoxidation Practice: 52 lb 134 lb 20 x 30 11.5 2 A744 CN-7M 20Cr-28Ni-2Mo-3Cu 2900 deg F SELEE Corporation PSZ 3 x 3 x 1 Thick 10 ppi (coarse) Zr-Si-Mn-Al-Ti + FeSe

Figure 2: Top view of the gating system for the 4130 piston casting after modification to incorporate filters. Note the absence of oxide macro-inclusions on the runner and ingate surfaces confirming the effectiveness of the filters.

Table 2: Summary of grind/weld repair history on a 4" CN-7M valve body casting.
Filtered Number of Castings Total Number of Welds before :Heat Treatment: Average Welds per Casting before Heat Treatment: Total Welds after Heat Treatment: Average Welds per Casting after Heat Treatment: Overall Total Number of Weld Repairs: Average Number of Welds per Casting: Percent Reduction in Number of Weld Repairs: Number of Castings Shipped after 1 Heat Treatment: Percent Shipped after 1 Heat Treatment:
st st

Unfiltered 18 65 3.61 115 6.39 180 10 1 5.6

18 1 0.06 5 0.28 6 0.33 96.7 15 83.3

Figure 3: Bottom view of the gating syste for the 4130 piston casting after modification to incorporate filters.

Figures 2 and 3 show the gating system for the piston casting after modification to incorporate filters. The gating system for the cylinder casting was similar. The only change from the existing gating system was the addition of a vertical filter print on each side of the sprue well. The details regarding the production parameters are summarized in Table 3. After the addition of filters, 200 pairs of pistons and cylinders were produced without any inclusion rejections following machining and plating. Figure 4 shows a transverse slice taken through both filters revealing retained oxide macro-inclusions. EDS analysis of the inclusions revealed a complex mixture of alumina deoxidation clusters embedded in a glassy Al2O3-TiO2-Cr2O3-MnO matrix. The presence of deoxidation products of Al and Ti (Al2O3, TiO2) along with Cr2O3 and MnO indicate the glassy phase formed as a result of reoxidation during metal transfer (pouring).

Oxide Macroinclusion

Figure 4 : Transverse slice of the gating system showing the filter section where oxide macro-inclusions can be seen adhering to the filter.

Table 3: Summary of casting and gating parameters for production of the companion piston and cylinder castings.

Casting Parameter Alloy Type: Mold Pour Weight: Individual Casting Weight: Number of Castings/Mold: Type of Mold: Mold Pour Time: Filtration Parameters Filter Manufacturer: Filter Type: Number of Filters: Filter Size: Pore Size: Gating Parameters Sprue Area: Runner Area: Filter Area entrance: exit: Ingate Area: Gating Ratios, As:Ar:Af:AIG:

Piston Casting AISI 4130 84 kg 9 kg 4 No-bake 20 seconds SELEE Corporation PSZ 2 50 x 75 x 25 10 ppi 645 mm sq 1,658 mm sq 7,742 mm sq 5,439 mm sq 3,871 mm sq 1:2:6:8:4:6:0

Cylinder Casting AISI 440C 71 kg 8 kg 4 No-bake 20 seconds SELEE Corporation PSZ 2 50 x 75 x 25 10 ppi 645 mm sq 1,658 mm sq 7,742 mm sq 5,439 mm sq 3,871 mm sq 1:2:6:8:4:6:0

SOURCES OF INCLUSIONS IN STEEL CASTINGS

Sources of non-metallic inclusions in steel castings include eroded molding sand, ladle/furnace slag and/ or refractories, deoxidation and reoxidation products as well as oxide macro-inclusions. The most troublesome type of inclusion in steel castings is the oxide macro-inclusion or ceroxide (ceramic oxide). In commercial steel castings ceroxides are observed to range in diameter from 1/8" to greater than 2" and form surface depressions as deep as 1/ 4" or more. These defects are nearly always located on either the cope casting surface, or beneath a cored surface (Figure 5). The formation of oxide macro-inclusions has been the subject of numerous investigations over the last 35 years. (3-8) Studies by the Steel Founders Society of America (SFSA) and researchers at Union Carbide produced findings on the problem which warrant review. (5,7,8) the mold cavity, and during pouring, entrained silica sand grains present in the gating system. Upon entering the mold cavity the inclusions float to the cope casting surface resulting in an embedded surface defects.
SiO2

20

80

40

60

60

40

80

20

MnO & FeO

Al2O3 Commercial steel casting with Al addition. Experimental castings without Al addition. Experimental castings with Al addition.

Casting Surface

Figure 6: Composition of oxide macro-inclusions identified in commercial and experimental steel castings plotted on a pseudo SiO2-Al2O3-MnOFeO ternary phase diagram.5 Glassy slag phase Slica Sand

Two other significant conclusions were reached; 1. Oxide macro-inclusions will be generated as long as oxygen is present in either the air or in the refractory materials which come in contact with molten steel, and 2. Their elimination would involve mechanical removal in the gating system prior to the mold cavity. The mechanism of formation of both deoxidation and reoxidation inclusions was studied by workers at Union Carbide. They established that the large oxide inclusions were the result of reoxidation during pouring. (7) In addition they concluded that reoxidation products are significantly larger than deoxidation products and are rich in the weaker deoxidizers of silicon and manganese. The initial reoxidation inclusions formed in aluminum deoxidized steel were large alumina clusters. As reoxidation further proceeded, the inclusion contained smaller quantities of aluminum and increasing amounts of manganese and silicon. Figure 7 illustrates the proposed mechanism for the formation of both reoxidation and deoxidation inclusions in aluminum deoxidized steel. One of the conclusions reached was that the solution to the problem would be of a mechanical nature rather than chemical. Changing

Figure 5: Scanning electron photomicrograph of a typical oxide macro-inclusion extending below the casting surface. EDS analysis indicated silica sand grains embedded in a glassy MnO-Al2O3-SiO2 matrix which formed due to reoxidation during pouring.

SFSA sponsored work in the early 1960s at Battelle Memorial Institute established the primary source of oxide macro-inclusions to be oxidation of the molten steel during pouring and fluxed ladle refractories.(5) Figure 6 shows the composition of ceroxides from both commercial and experimental test castings plotted on a pseudo SiO2-Al2O3-MnO+FeO ternary phase diagram. The chemical composition was observed to be strongly influenced by the base steel composition (primarily the Mn/Si ratio) and the additions of strong deoxidizers (Al, Ti, Zr). It was concluded that oxide macro-inclusions formed outside

the deoxidation practice would alter the composition of the reoxidation inclusion, but not prevent its formation. A recent industry sponsored investigation by SFSA established once again that reoxidation was still the major cause of oxide macro-inclusions in steel castings. (8) Investigation of commercial and test plate castings poured in production foundries established that reoxidation was the source of 83% of oxide macro-inclusions. Figure 8 shows the distribution and
DEOXIDATION
Oxygen Aluminum Silicon

origin of the various oxide macro-inclusions identified by this investigation. All of the above cited investigations into the origin of oxide macro-inclusions identified reoxidation as the major cause. Whenever molten steel is poured through an atmosphere containing oxygen the formation of reoxidation inclusions will be unavoidable. Changing the deoxidation practice would therefore not prevent its formation, only the chemical composition. Therefore filtration in the runner system is an attractive and technically sound technology for eliminating the troublesome problem of oxide macro-inclusions in steel castings.

100

Manganese

90

Percent of Carbon and Low Alloy Macro-Inclusions, 395 Total

83% 80

Alumina Galaxy

70

60

REOXIDATION
Oxygen

50

Aluminum Silicon

40

Manganese

30

20 14% 10 2% Molding Material 1% Refractory 1% Deoxidation

Large Alumina Galaxy

Multiphase Globule

1st Stage

2nd Stage

3rd Stage

Figure 7: Schematic illustration of the mechanism of formation of deoxidation and reoxidation inclusions in steel castings.7

Figure 8: Sources of oxide macro-inclusions in carbon and low alloy steel castings.8

Reoxidation

Slag

Single Phase Globule

HOW DOES STEEL FILTRATION WORK?

INCLUSION SEPARATION THEORY The separation of inclusions from molten steel is a two step process:9 1. Transport of the oxide inclusion to an interface such as the refractory ladle walls, the ladle slag, or any surface within the gating system (sprue, runner, filter, ingate). 2. Separation of the inclusion at the interface. The key to effectively removing inclusions from molten steel is to have a very short separation distance. Separation of inclusions in traditional runner systems relies on inclusion particle transport to one of the runner surfaces. Filtration relies on the flowing metal to bring the inclusion close to the filter structure where contact can occur. wall is usually less than 1/16". This short separation distance combined with the tortuous flow path of ceramic foam filters provides a high level of filtration efficiency.

Metal Flow Direction

WHY INCLUSIONS CAN NOT BE RELIABLY REMOVED IN GATING SYSTEMS Traditional gating systems are designed to remove inclusion material in the runner system by flotation. However, due to restriction of the flask size, yield considerations, as well as sprue and ingate locations, runner systems are often very short. The combination of short runner bars, relatively high runner velocities and highly turbulent flow conditions make effective inclusion separation by flotation difficult, particularly for very small inclusions. WHY FILTERS ARE MORE EFFECTIVE Figure 9 schematically illustrates the filtration process where inclusion particles smaller than the cell or pore openings are retained in the depth of the filter structure. The primary reason filtration is more effective than flotation is the small separation distances between the inclusion and filter surface. The inclusion separation distance in runner bars is typically on the order of .75 to 2.5", which given the high metal velocities and short runner lengths makes effective inclusion separation difficult to impossible to achieve. Filtration is very effective because the separation distance between an inclusion particle and the filter

Figure 9: Schematic illustration of inclusion particle retention in a ceramic foam filter.

HOW SOLID INCLUSION REMOVAL WORKS When a solid inclusion comes in contact with the internal filter wall there must be a mechanism for the inclusion to adhere, otherwise subsequent release may occur. Whether an inclusion will adhere to a filter wall is dependent on the interfacial energy relationship between the molten metal (m), the inclusion (i) and the filter (f): (15) G = if - mf - mi (1)

where G = Gibbs free energy = interfacial energy

M = MOLTEN METAL S = FILTER OR INCLUSION

Region of Liquid Metal Withdrawal

SM
Filter Substrate Solid Inclusion Particle

WETTING < 90 DEG.

Figure 11: Capillary withdrawal of molten steel from the interstitial regions between the filter substrate and inclusion for the condition where both the filter substrate and inclusion particle are non wetted by the melt.

M S
SM
Filter

Region of Capillary Withdrawal Sand Grain

NON WETTING > 90 DEG.

Figure 10: Schematic illustration showing the shape of a liquid droplet on an oxide substrate for non wetting ( > 900) and wetting conditions ( < 900) conditions. When the Gibbs free energy (G) is less than zero then surface forces will hold the inclusion to the filter surface. Figure 10 schematically illustrates the relationship between the various surface components and the contact wetting angle () for wetting ( < 90 o) and non wetting conditions ( > 90o). Under the condition where both the filter material and solid inclusion particle are non wetted by the melt the inclusion will separate from the melt. As a result there will be a capillary withdrawal of molten metal in the interstitial region between the inclusion and the filter wall as illustrated in Figure 11. Partially stabilized zirconia foam filters are non wetted by molten steel or nickelbase alloys ( 122) and therefore are very effective in removing solid inclusions. Figure 12 is a scanning electron photomicrograph showing the capillary withdrawal of the metal where a silica sand grain is in contact with the filter surface.

Figure 12: Backscattered electron image showing an eroded silica sand particle adhering to the filter surface. Note the capillary withdrawal of molten metal from the interstitial contact area between the silica sand grain and the filter.

HOW LIQUID INCLUSION REMOVAL WORKS The removal of liquid inclusions relies on a high work of adhesion ((WA)IF) between the liquid inclusion (i) and the filter (f):17,18 (WA)if = mi(1 + cosfi-im) where (WA)if = work of adhesion mi = interfacial energy between the melt and the liquid inclusion cos()fi-im = contact wetting between the liquid inclusion and the filter (2)

The work of adhesion is defined as the amount of work required to physically separate a liquid inclusion from the filter surface and create new metal/filter and metal/ inclusion interfaces. Equation 2 shows that maximum liquid inclusion adhesion to a filter will occur at a low contact wetting angle (). In other words maximum inclusion adhesion is obtained when the liquid inclusion wets the filter (Figure 13). Generally liquid oxide in

clusions have low contact wetting angles on refractory oxide surfaces indicating that they can readily be removed by filtration.(9) Figures 14 - 18 show examples of various types of liquid inclusions, including oxide macro inclusions, which have wetted and adhered to partially stabilized zirconia foam filters.
Oxide Macro-inclusion

IM

Metal

Liquid Inclusion ( I) Filter

IF

MF

Filter Metal

Figure 13: Sessile drop of a liquid inclusion on a filter substrate. The contact wetting angle between the filter and liquid inclusion is denoted by .

Oxide Macro-inclusion

Figure 16: Backscattered electron image showing an oxide macro-inclusion with silica sand grains embedded in a manganese-silicate (2MnOSiO2) matrix which has wetted to the filter. Note the capillary withdrawal of metal at the inclusion filter interface. Mold Material: green sand.

Filter

Reoxidation Inclusion

Filter

Figure 14: Backscattered electron image showing an oxide macro-inclusion with silica sand grains embedded in a manganese alumino-silicate matrix which has wetted to the filter. Mold Material: green sand

Filter

Metal

Figure 17: Large oxide macro-inclusion which has wetted the filter structure. EDS anslysis at high magnification indicated the inclusion to be alumina clusters embedded in a manganese silicate (2MnOSiO2) matrix. Mold Material: green sand
Liquid Ca Aluminates

2-phase Oxide Macro-inclusion

Sand

Liquid Ca Aluminates

Filter

Filter Filter
Sand

Figure 15: Backscattered electron image showing an oxide macro-inclusion with silica sand grains embedded in manganese-silicate matrix which has wetted to the filter. Mold Material: green sand

Figure 18: Backscattered electron image showing calcium aluminates which have wetted to the filter structure. EDS anslysis indicated the inclusion to be a mixture of 3CaOAl2O3 and 12CaO7Al2O3. Deoxidation: Al + Ca wire injection
9

HIGH TEMPERATURE CERAMIC FOAM FILTERS

CHARACTERISTICS OF RETICULATED CERAMIC FOAM FILTERS Figure 19 is a scanning electron photomicrograph showing the three dimensional interconnecting polyhedral cell structure of a reticulated foam filter. For molten metal to flow to an adjacent cell it must pass through an aperture which is characteristically one third the cell diameter. As a result, the flow from one cell to the next dramatically reduces the inclusion particle transport distance for removal. The interconnecting three-dimensional cell structure creates a tortuous flow path further increasing the probability of inclusion contact and adhesion to the filter surface. Ceramic foam filters are available in a range of standard pore or cell sizes. Figure 20 shows the relative pore size of No. 10, 15, and 25 foam filters which are commonly used for steel casting applications. REFRACTORY FILTER MATERIALS FOR STEEL CASTING APPLICATIONS The molten environment encountered in steel sand casting applications is quite severe in terms of the refractory filter material requirements. The refractory filter material must be able to withstand the initial metallostatic priming head and thermal shock without spalling of filter fragments or breaking down. The filter material must have extremely high thermal shock resistance to withstand the nearly instantaneous 2800 - 3100 F thermal transit encountered in steel sand casting applications where the filter can not be preheated. In addition, the filter must have sufficient high temperature strength, creep resistance and resistance to corrosive attack by both the molten steel and slag. Partially stabilized zirconia (PSZ) using magnesia (97% ZrO2-3% MgO) as a stabilizer offers the best combination of hot strength, creep resistance, thermal shock resistance and resistance to chemical attack. The combination of these properties allows for fabrication of low density filters which will easily prime without excessive superheat or filter preheat. Pure zirconia exhibits a martensite phase transformation at approximately 1000 C. This phase change results in a 9% volume increase during cooling in the firing process, thereby initiating microcrack toughening. Partial stabilization of the high temperature tetragonal phase to the appropriate level (60% monoclinic, 40% tetragonal) with magnesia (MgO) results in high strength and increased resistance to crack propagation, while the dispersed monoclinic phase contributes to the high thermal shock resistance of the filter.

Figure 19: Scanning electron photomicograph showing the three-dimensional structure of a reticulated foam filter.

No. 10

No. 15

No. 25

Figure 20: Relative pore size of No. 10, No. 15 and No. 25 ceramic foam filters.

10

SELECTING THE PROPER PORE SIZE FILTER

The selection of the optimum pore size filter requires a decision involving a trade-off between product quality (melt cleanliness) and the size and cost of the filter required. In addition metal fluidity has to be carefully considered. Aluminum deoxidized carbon and low alloy steels have limited fluidity requiring coarse (No. 10), low density (L grade) filters to be used in order to reliably prime. Finer pore size filters offer significantly higher filtration efficiency and improved casting cleanliness, but larger surface areas are required to offset their higher flow resistance.

FILTER SIZING CALCULATIONS

FLOW RATE To obtain the proper mold fill time it is essential to calculate the proper size filter. The effective filter area (AF) must be large enough so the filter does not choke the flow of molten metal or become blocked with retained inclusions prior to the end of the pour. Filter sizing models have been developed based on a Bernoulli mechanical energy fluid flow model using filter pressure drop curves. Figure 21 shows the metallostatic pressure drop curves for 10, 15 and 25 ppi filters. Figure 22 shows the influence of the filter area/choke area ratio on the percent of the original unfiltered flow. These curves were calculated from the metallostatic pressure drop curves in Figure 21. At small filter area/choke area ratios (AF/AC < 4), the filter acts as a choke and restricts the rate of mold fill. At a high AF/AC ratio (AF/AC > 6), the choke in the gating system controls the rate of mold fill. Figure 23 shows that for finer pore size filters additional surface area is required to maintain the same mold fill rate. Table 4 contains the minimum recommended filter area to choke area ratios based on achieving 90% of the original unfiltered flow rate. To determine the minimum filter size which will maintain at least 90% of the original unfiltered mold fill rate, multiply the appropriate AF/AC ratio in Table 4 by the choke area of the gating system. For instance for a gating system with a choke area of .75 in2 where a No. 15 ppi pore size filter has been selected, the minimum filter surface is calculated as follows: Filter Area = 8 X .75 in2 = 6 in2 FILTER CAPACITY The second sizing factor to consider is whether the filter will become blocked or plugged with retained inclusion material prior to the end of the pour. The amount of molten steel a filter will pass is dependent on the filter pore size and steel cleanliness. The quantity of steel which will pass through a filter is highly dependent on deoxidation practice. Deoxidation practices utilizing strong deoxidizers (Al, Zr, Ti) which form oxide galaxies or clusters will eventually cause the filter to block with retained inclusion material. Tables 5 and 6 provide guidelines for the quantity of metal that various size filters can be expected to pass depending on the type of deoxidation practice. After calculating the filter size based on both flow rate and blockage, the larger of the two values should be used.

Table 4: Minimum recommended filter to choke area ratios to obtain a minimum of 90 percent of the original unfiltered flow rate.
Filter Pore Size Number 10 15 25 Minimum Recommended Filter to Choke Area Ratio (AF/AC) 6 8 9

11

FILTER PRESSURE DROP - MM OF Fe

80 70 60 50 40 30 20 10 0 0 40 80 120 160 200 FILTER APPROACH VELOCITY 10 ppi 15 ppi 25 ppi

PERCENT OF ORIGINAL FLOW RATE

90

100 80 60 40 20 0 0 2 4 6 8 10 12 14 16 18

10 ppi 15 ppi 25 ppi

20

FILTER AREA/CHOKE AREA RATIO

Figure 21: Metallostatic pressure drop across the filter as a function of the filter approach velocity (VF) for 10 (coarse), 15 (medium) and 25 (fine) ppi foam filters.

Figure 22: Influence of the filter area to choke area ratio (AF/AC) on the percent of the original unfiltered flow rate.

Table 5: Filter sizing guidelines for steels deoxidized with either Al, Ti or Zr.
SELEE Part Number FESZ20201007L FESZ203010L FESZ303010L FESZ304010L FESZ404010L Filter Size 2x2x.75 2x3x1 3x3x1 3x4x1 4x4x1 Maximum Recommended Pour Weight Single Filter Double Filter 45 kg 68 kg 102 kg 136 kg 182 kg 91 kg 136 kg 205 kg 273 kg 364 kg Maximum Recommended Choke Area Single Filter Double Filter 310 mm sq 452 mm sq 639 mm sq 929 mm sq 1290 mm sq 619 mm sq 910 mm sq 1284 mm sq 1858 mm sq 2581 mm sq

Table 6: Filter sizing guidelines for steels not deoxidized with either Al, Ti or Zr.
SELEE Part Number FESZ20201007 FESZ20201007L FESZ203010 FESZ203010L FESZ303010 FESZ303010L FESZ304010 FESZ304010L FESZ404010 FESZ404010L Filter Size 2x2x.75 2x3x1 3x3x1 3x4x1 4x4x1 Maximum Recommended Pour Weight Single Filter Double Filter 182 kg 273 kg 409 kg 545 kg 727 kg 364 kg 545 kg 818 kg 1090 kg 1455 kg Maximum Recommended Choke Area Single Filter Double Filter 310 mm sq 452 mm sq 639 mm sq 929 mm sq 1290 mm sq 619 mm sq 910 mm sq 1284 mm sq 1858 mm sq 2581 mm sq

12

STANDARD SIZE STEEL FILTERS

Tables 7 and 8 list standard size partially stabilized zirconia (PSZ) filters produced by SELEE Corporation along with their dimensional specifications. The suffix L refers to the low density variant which should be used with carbon and low alloy steels or any other application where the filter priming is a concern.

Table 7: Standard Size Square and Rectangular Partially Stabilized Zirconia (PSZ) Foam Filters Produced by SELEE Corporation and Product Code Numbers.
Filter Size, Inches 2 x 2 x .75 2x3x1 3x3x1 3x4x1 4x4x1 4 x 4 x 1.25 5x5x1 5 x 5 x 1.25 4x6x1 SELEE Product Code Number* FESZ2020XX07 FESZ2020XX07L FESZ2030XX FESZ2030XXL FESZ3030XX FESZ3030XXL FESZ3040XX FESZ3040XXL FESZ4040XX FESZ4040XXL FESZ4040XX125 FESZ4040XX125L FESZ5050XX FESZ5050XXL FESZ5050XX125 FESZ5050XX125L FESZ4060XX FESZ4060XXL A/max, mm 51.00 51.00 76.20 76.20 102.00 102.00 127.00 127.00 102.00 A/min, mm 48.00 48.00 73.00 73.00 98.00 98.00 122.90 122.90 98.00 B/max, mm 51.00 76.20 76.20 102.00 102.00 102.00 127.00 127.00 152.00 B/min, mm 48.00 73.00 73.00 98.00 98.00 98.00 122.90 122.90 147.00 T/max, mm 20.70 27.00 27.00 27.00 27.00 33.40 27.00 33.40 27.00 T/min, mm 17.50 23.80 23.80 23.80 23.80 30.20 23.80 30.20 23.80

* XX denotes filter pore size

13

Table 8: Standard Size Round Partially Stabilized Zirconia (PSZ) Foam Filters Produced by SELEE Corporation and their Product Code Numbers.
Filter Size, Inches 2 OD x .75 3 OD x 1 4 OD x 1 4OD x 1.25 5 OD x 1 5 OD x 1.25 SEEE Product Code Number FESZ20RDXX07 FESZ20RDXX07L FESZ30RDXX FESZ30RDXXL FESZ40RDXX FESZ40RDXXL FESZ40RDXX125 FESZ40RDXX125L FESZ50RDXX FESZ50RDXXL FESZ50RDXX125 FESZ50RDXX125L D/max, mm 51.00 76.00 102.00 102.00 127.00 127.00 D/min, mm 48.00 73.00 98.00 98.00 123.00 123.00 T/max, mm 20.70 27.00 27.00 33.40 27.00 33.40 T/min, mm 17.50 23.80 23.80 30.20 23.80 30.20

14

FILTER INSTALLATION
BASIC FILTER INSTALLATION DESIGN Filters should be installed in the runner system for the best results rather than in the pouring basin or directly under the sprue. Figure 23 shows the recommended filter installation where filter(s) are installed vertically in the gating system directly adjacent to the sprue well. A slightly over sized and deeper sprue well is utilized in order to maintain a sufficient thermal mass to prevent premature freezing of the steel until sufficient metallostatic pressure is obtained to prime the filter. With low density (grade L) partially stabilized zirconia filters, carbon steel will readily prime the filter at casting temperatures down to 2850 F. This system is normally utilized with unpressurized gating systems where the ingates are located in the cope in order to keep the gating system full of molten metal during the entire pour to minimizing air entrainment. PLASTIC GATING COMPONENTS FOR STANDARD SIZE FILTERS To simplify the pattern modifications, plastic filter prints are available which can be easily mounted on the pattern board or plate. Figure 29 shows some of the plastic filter prints which are available for both single and double runner systems. The part numbers for available plastic filter prints and the matching runner size requirements are given in Table 9.

Figure 29: Plastic filter prints for standard square and rectangular size filters for single and double runner bar systems.

Table 9: Available plastic filter prints and matching runner dimensions.

Filter Size, Inches 2 x 2 x .75 2x3x1 3x3x1 3x4x1 4x4x1 SELEE Part Number FESZ2020XX FESZ2020XXL FESZ2030XX FESZ2030XXL FESZ3030XX FESZ3030XXL FESZ3040XX FESZ3040XXL FESZ4040XX FESZ4040XXL Runner Height, mm 25.4 31.8 44.5 50.8 50.8 Runner Width, Bottom, mm 25.4 45.7 44.5 50.8 50.8 Runner Width, Top, mm 22.7 40.1 36.7 41.9 41.9 Part Number or Plastic Gating Components ACFD0043 Single ACFD0030 Single ACFD0032 Single ACFD0034 Single ACFD0036 Single ACFD0044 Double ACFD0031 Double ACFD0033 Double ACFD0035 Double ACFD0042 Double

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Figure 23: Schematic illustration showing vertical method of filter installation for single and double runner systems for steel sand casting applications.

DOWNSPRUE

DOWNSPRUE

VERTICAL FILTER PRINT VERTICAL FILTER PRINT COPE INGATE

VERTICAL FILTER PRINT COPE INGATE

DRAG RUNNER

DRAG RUNNER SPRUE WELL SIDE VIEW

SPRUE WELL SIDE VIEW

BOTTOM VIEW

BOTTOM VIEW

SCHEMATIC ILLUSTRATION OF DOUBLE FILTER/RUNNER SYSTEM

SCHEMATIC ILLUSTRATION OF SINGLE FILTER/RUNNER SYSTEM

Figure 24: Installation drawing for 2" x 2" x .75" filters for single and double runner systems.

PLASTIC GATING PIECE PART NUMBER: ACFD0043

PLASTIC GATING PIECE PART NUMBER: ACFD0044

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Figure 25: Installation drawing for 2" x 3" x 1" filters for single and double runner systems.

PLASTIC GATING PIECE PART NUMBER: ACFD000031

PLASTIC GATING PIECE PART NUMBER: ACFD000030

Figure 26: Installation drawing for 3" x 3" x 1" filters for single and double runner systems.

PLASTIC GATING PIECE PART NUMBER: ACFD0033

PLASTIC GATING PIECE PART NUMBER: ACFD0032

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Figure 27: Installation drawing for 3" x 4" x 1" filters for single and double runner systems.

PLASTIC GATING PIECE PART NUMBER: ACFD0035

PLASTIC GATING PIECE PART NUMBER: ACFD0034

Figure 28: Installation drawing for 4" x 4" x 1" filters for single and double runner systems.

PLASTIC GATING PIECE PART NUMBER: ACFD0042

PLASTIC GATING PART NUMBER: ACFD0036

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TECHNICAL SUPPORT
CUSTOMER TECHNICAL SUPPORT SELEE Corporation has a staff of Metallurgical and Applications Engineers to provide full technical support for their filtration products. Technical assistance is available for filter sizing and installation design, metallurgical analysis of casting defects, inclusion identification and spent filter analysis. SELEE Corporation maintains a complete metallographic facility including a fully analytical scanning electron microscope with light element capability and x-ray diffraction for structural analysis. In addition CAD design services are available for filter installation/gating system design. Technical support can be obtained by: Writing: SELEE Corporation 700 Shepherd Street Hendersonville, North Carolina 28792 U.S.A. Phone: 1-800-438-7274 (828) 697-2411 FAX: (828) 693-1868 1. Pattern or Casting Identification Number email: cservice@selee.com 2. Alloy Type/Designation METALLURGICAL ANALYSIS Metallurgical analysis of casting defects and spent filters is available. When submitting samples the following information should be included along with the sample: 1. Description of the problem or objective of the analysis 2. Description of sample 3. Alloy Type/Designation 4. Deoxidation practice 5. Description of melting/refining/practices 6. Name and address of the individual requesting the report 3. Pouring Practice 4. Deoxidation Practice 5. Pouring Temperature 6. Mold Pour Time 7. Mold Pour Weight 8. Casting Weight 9. Number of Castings 10. Existing Gating Design a. sprue dimension & height b. Number and size of runners (cross section) c. Number and size of ingates (cross section) d. Engineering drawing of existing gating system showing sprue, runner and ingate locations.

FILTER PROPOSALS Complete CAD filter installation design proposals are available. The following information is required to prepare a detailed engineering proposal:

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REFERENCES
1. A. Friesel, R. J. Karamon and L. S. Aubrey; Filtration of High-Alloy, Corrosion Resistant and NickelBase Valve Body Castings,AFS Transactions, vol. 100, 1992, pp 209 - 219 2. L. S. Aubrey, J. R. Schmahl and M. A. Cummings; Application of Advanced Reticulated Ceramic Foam Filter Technology to Produce Clean Steel Castings, AFS Transactions, vol. 101, 1993, pp 59 - 69 3. C. A. Sanders, One Answer to the Snotter Problem, Modern Castings, (May 1956) 4. H. Blosjo, Ceroxide Defect-What it is and How its Incidence can be Reduced, Journal of Steel Castings Research, Steel Founders Society of America, Number 7, pp 1-4 (Jan 1957) 5. W. S. Lyman, F. W. Boulger,An Investigation of Factors Producing the Ceroxide Defect on Steel Castings; Part I--Composition and Sources, Steel Founders Society of America Research Report No. 48, (Feb 1961) 6. R. A. Flinn, L. H. Van Vlack, G. A. Colligan, Macroinclusions in Steel Castings, AFS Transactions, Vol 69, pp 485-512 (1966) 7. J. W. Farrell, P. J. Bilek and D. C. Hilty,Inclusions Originating from Reoxidation of Liquid Steel, Electric Furnace Conference Proceedings, AIME, Vol 28, pp 64 (1970) 8. J. A. Griffen, C. E. Bates, R. W. Monroe and J. Svoboda, Appearance and Composition of Oxide Macro-Inclusions in Steel Castings, AFS Transactions, Vol 87, pp 187-202

9. A. W. Cramb, Caster Related Product Defects: Causes and Cures, Presentation at the IMIS Steelmaking Symposium, Monterrey, Mexico, (Nov 1989)

10. A. W. Cramb and I. Jimbo, Interfacial Considerations in Continuous Casting, Iron and Steelmaker, pp 43-55, (June 1989)

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