Large-sized silicon carbide foam ceramic filter plate can be customized according to your own request!

Silicon carbide foam ceramic filter plate is made from high-purity silicon carbide powder as the main raw material, with polyurethane sponge as the framework.

✅It is formed through coating, drying, and high-temperature sintering.

✅It is a three-dimensional interconnected mesh-like porous ceramic.

✅It is specially designed for large pouring or large-tonnage molten iron pouring conditions.

✅It belongs to an ultra-large-sized casting filter plate, replacing multiple small filter sheets for assembly, eliminating the problems of iron leakage and slag running.

✅It mainly targets the purification of high-temperature metal liquids such as: ductile iron, gray iron, and copper alloys.

Core material indicators 

1. Main ingredients: SiC ≥ 92%, with added alumina and silica as high-temperature bonding phases. 

2. Temperature resistance: Long-term use is up to 1500℃, and it can withstand a 1550℃ blast of molten iron for a short period of time. 

3. Porosity: 82% - 90%, three-dimensional interconnected pores, rectification + double filtration 

4. Resistance to thermal shock: Water cooling cycle at 1100℃ for ≥ 6 times, with no cracking during pouring.

Mainstream specifications of the large board

Key points:

✅Conventional pouring: Thickness 25 - 30mm.

✅High-flow, thick castings: The thickened version is 40-50mm in thickness, offering higher bending strength and being less prone to collapse.

✅10PPI: The largest mesh size, with the strongest flow capacity, suitable for large-tonnage gates, and filtering of ductile iron large plates.

✅15PPI: General model, suitable for both water flow and slag removal. Grey iron and alloy cast iron are the preferred choices.

✅20PPI: Fine filtration, capturing minute oxide inclusions.

Core Advantage (Large Plate vs. Small Filter)

1. High overall integrity, no joint gaps

The entire piece is formed as a single piece without the need for multiple pieces to be joined together. This completely eliminates the leakage of molten iron through the joints, significantly reduces the occurrence of slag inclusion defects in the castings, and increases the qualified rate of large-scale castings by over 60%. 

2. Larger flow cross-section

A single large plate covers the entire cross-section of the horizontal pouring channel, ensuring smooth metal liquid flow with minimal turbulence, thereby reducing secondary oxidation. 

3. Higher structural strength at high temperatures

The SiC matrix resists iron water erosion. Compared to the alumina large plate, it is more resistant to iron water corrosion and is suitable for long-term continuous pouring. 

4. Simple installation

A single piece can be directly placed in the gate box, eliminating the need for cutting and assembling processes, thus saving workshop working hours.

Applicable working conditions 

1. Casting materials: ductile iron, gray iron, high alloy iron, molten copper (not suitable for steel water above 1600℃, the steel water is made of zirconium oxide material). 

2. Technology: Resin sand production line, large-scale manual molding, large-scale pouring in frequency induction furnace, large-scale batch production of castings by assembly line. 

3. Industry: Automotive chassis components, valve bodies, pump bodies, large components of machine tools, and cast iron parts for construction machinery.

Production process

1. Base material: High-density perforated polyurethane sponge, cut into large sheet blanks 

2. Pulping: Silicon carbide powder + high-temperature binder are mixed to prepare a high-solid-content slurry. 

3. Vacuum suction of slurry: The sponge is fully soaked with the ceramic slurry, and the excess slurry is squeezed out to ensure uniform material distribution on the framework. 

4. Low-temperature drying: Slow dehydration to prevent large plates from cracking and deforming extensively. 

5. High-temperature kiln sintering at 1420℃: The sponge-like organic matter is completely burned off, forming a pure silicon carbide network-like ceramic framework. 

6. Finish the edges and trim the dimensions: The tolerance for size deviation is strictly controlled within ±1.5mm.