Silicon carbide ceramic filter is an inorganic nonmetallic insulating material with many advantageous characteristics, including being lightweight, strong and resistant to thermal shock as well as having corrosion protection features and easy regeneration for long service life.
Sintered and compacted using sanctuary at normal pressure, SIC foam has the capability of dramatically cutting production costs for enterprises. Furthermore, its reuse without diminishing its filtration efficiency reduces enterprise expenses further.
High Filtration Efficiency
Silicon carbide foam ceramics were first developed in the 1970s as an inorganic nonmetallic porous filter material. Boasting high strength, thermal stability, corrosion resistance and simple regeneration with long service lives for optimal filtration and adsorption characteristics, silicon carbide ceramic filters have applications across metallurgy, chemical industry, environmental protection, energy and biology applications.
Foam ceramic filters can be an invaluable asset when it comes to filtering molten metal. By helping reduce inclusions and turbulence of molten iron, foam ceramic filters ensure only purified metal enters mold cavities for casting – improving casting quality significantly while remaining cost-effective as they can often be reused multiple times before needing replacement.
A typical SiC ceramic filter consists of three parts, including a substrate, coating and series of pores. The coating protects the substrate from chemicals while increasing bending strength of the filter; its pore size can be customized depending on application needs. Furthermore, this structure can come in various forms like tubular honeycomb or flat sheets for various applications.
Foam silicon carbide ceramic features three-dimensional pores with great mechanical strength, making it easy to handle and process. Furthermore, its low permeability can be used to decrease pressure loss during gravity or low-pressure casting processes and ultimately reduce manufacturing costs. Furthermore, its resistance to acids and alkalis prevents pollution of filtered metal liquids.
Long Lifespan
Silicon carbide ceramic filters boast long lifespans that require reduced maintenance and replacements costs, leading to lower overall treatment costs. Their hard and durable nature allow it to withstand pressure and temperature extremes for extended periods. Furthermore, this material has excellent chemical stability which means that many different contaminants can be tolerated safely, making it suitable for drinking water filtration, where they can remove bacteria as well as organic and inorganic compounds to meet regulatory standards.
Silicon carbide ceramic foam filters play an essential role in many industrial applications, from metallurgy to copper smelting smelting smelting, copper smelting to improving cast copper parts quality, as well as chemical processing industries to filter corrosive chemicals and prevent contamination.
Molding processing performance of foam silicon carbide ceramic is excellent, with diamond tools easily cutting it with diamond blades. When necessary, grinding with a diamond wheel is also convenient – these characteristics make silicon carbide ceramic foam an attractive candidate to replace traditional silica, alumina and activated carbon as catalyst carriers in diesel engine soot traps. Low pressure loss, high heat/thermal shock resistance as well as oil fume collection efficiency also make silicon carbide ceramic foam an appealing material choice.
Excellent Thermal Stability
Silicon Carbide (SiC) is one of the hardest materials ever created by human hands, second only to diamond on Mohs scale. Thanks to its great chemical and thermal stability, SiC is ideal for filter applications in high temperature environments – making it suitable for industrial processes like molten iron castings.
SiC is highly durable ceramic material that remains intact under extreme temperatures, enabling reliable filtration performance without frequent replacement needs, cutting operating costs and improving productivity. This allows it to provide efficient filtration performance without incurring high replacement costs – thus cutting operating costs and increasing productivity.
Foam silicone carbide ceramics are widely acclaimed as highly corrosion-resistant materials that can withstand acid and alkali attacks without losing their filtration efficiency, making them the go-to material in many metallurgical applications – copper casting being just one example – because of these properties. Their superior corrosion resistance allows them to significantly lower scrap rates for these castings while being available in various sizes to fit every application perfectly.
Porous ceramics can be created by mixing silicon carbide powder with a binder and pore-forming agent in a solvent, drying and shaping the mixture, then sintering to form solid ceramic pieces. Binder materials often consist of mullite, cordierite or zirconia while bentonite is typically the agent responsible for creating pores in porous ceramics. Finally, depending on their application the ceramics may then undergo curing for cross-linking under specific atmospheric conditions.
High Resistance to Molten Iron
Silicon carbide ceramic foam filters possess special characteristics that make them indispensable tools in many fields, from drinking water treatment to industrial wastewater treatment and metal casting foundries purification of molten iron and other liquids. Their superior thermal stability and chemical resistance enable them to endure extreme temperatures as well as harsh chemicals without fail.
Preparing a ceramic foam filter requires creating a slurry composed of various ceramic precursors. More specifically, this includes specific ratios of refractory aluminosilicate, colloidal silica, fumed silica and modified bentonite. Once formed, this slurry is dried before being formed into its desired filter shape for sintering to produce porous ceramic material.
Once a ceramic foam filter has been manufactured, it is tested for its ability to capture and retain molten metal oxide slag. A sample is taken and evaluated using energy dispersive spectroscopy for any signs of penetration into its ceramic foam structure. Results of the test showed that an inventive ceramic foam filter captured and retained significantly more metal oxide slag than a standard filter under identical operating conditions.
Ceramic foam filter innovation lies in its innovative pore structure and composition, which provides excellent resistance against molten iron while at the same time providing good flowability of slag through its pores.