VUKOPOR® S Ceramic Foam

Main Characteristics

VUKOPOR® S ceramic foam filters are designed for filtering castings of cast iron, bronze, brass and copper-alloys. The maximum recommended temperature of the application is 1480°C.

The filters owe their qualities to the opened 3D structure of their ceramic matrix formed of a system of interconnected cells. They have very good heat conductivity, stability and resistance to sudden temperature changes. Chemical properties of the ceramic body allow very fast “priming” without any negative effect on
metal. Ceramic foam filters generally help to produce higher quality castings at lower production costs.

Enhanced quality of castings:

  • Better quality of casting surface
  • Improved mechanical properties of castings
  • Improved precision of dimensions and shapes of castings

Costs reduction:

  • Reduced amount of scrap
  • Reduced costs of finishing operations
  • Simpler design and gating system

Special Features:

VUKOPOR® S can be used in “filter prints” of the gating system as well as for direct pouring on the filter in combination with exothermic sleeves. Moreover, they can be used in filter bowls for filtering of copper-alloys in casting campaigns.

When choosing a size, shape, dimensions and porosity of a filter, you should keep to the generally applicable rules and principles. The same applies to choosing the type of the “filter print”, space
for the filter placement and its orientation.

High metallurgical purity of the melt within casting is achieved through the efficient filtration ability of “filter cake” formation on the face and deep filtration mechanism inside of the filter body.

VUKOPOR® ceramic foam filters make it possible to reduce the turbulence of the flow during mould filling
and so prevent from creation of new inclusions and undesired defects of castings. This is possible because of turbulent flow of molten metal is transformed into laminar flow behind the filter. 

Technical Specification

Chemical Composition:

SiC, Al2O3 ,SiO2

Bond:

Ceramic

Colour:

Grey

Porosity:

10, 20, 30 ppi

Application Temperature:

max. 1480°C

Basic Shapes:

Square, circle, rectangle

Special Shapes:

According to request from customer

Tolerance of Dimensions:

Note: measured with callipers equipped with flat contact elements (46x30 mm)

+ 0,5 / - 1,5 mm   (up to 99 mm)

+ 0,5 / - 2,5 mm (above 100 mm)

Closed pores, cracks and holes in the effective areas of the filter are not allowed. The surface area of the sidewalls can be filled with ceramics.

Quality Control Process

The ceramic foam filters are manufactured in compliance with the quality control standards ISO 9001 : 2008.

Dimensions and Technical Parameters

The values shown in the table apply to casting of grey cast iron and ductile iron and are based on so-far performed tests and information available. They can vary depending on the actual conditions in foundries e.g. temperature, metal contamination level, filter position in gating system and other variables.

When choosing a size, shape, dimensions and porosity of a filter, you should keep to the generally applicable rules and principles. The same applies to choosing the type of the “filter print”, space for the filter placement and its orientation. The basic rules and recommendations are given in the Application List “How to design gating system with filters”. Atypical applications should be consulted with the Sales Department.

 

Dimension

(mm)

 

Thickness

(mm)

 

Capacity

(kg)

Flow Rate

(kg/s)

Capacity

(kg)

Flow Rate

(kg/s)

Capacity

(kg)

Flow Rate

(kg/s)

Capacity

(kg)

Flow Rate

(kg/s)

10 ppi 10 ppi 20 ppi 30 ppi
nodular iron   grey iron  

40x40x

15, 18, 22

32

3

74

4

52

3

43

2

50x50x

15, 18, 22

50

4

115

6

81

3,5

67

3

55x55x

15, 18, 22

60

5

139

7

98

5

82

4

60x60x

15, 18, 22

72

6

166

9

117

6

98

5

67x67x

15, 18, 22

89

7

206

11

145

8

121

6

75x50x

15, 18, 22

75

6

173

9

122

6

102

5

75x75x

18, 20, 22

113

9

259

14

182

10

152

8

80x80x

18, 20, 22

128

11

295

16

208

12

173

10

100x50x

18, 20, 22

100

8

230

12

162

9

135

7

100x75x

18, 20, 22

150

12

345

18

243

13

203

11

100x100x

20, 22, 25

200

16

460

24

324

18

270

15

125x125x

22, 25, 30

312

25

718

38

506

28

422

23

133x133x

22, 25, 30

353

29

813

43

573

32

478

26

150x100x

22, 25, 30

300

24

690

36

486

27

405

22

150x150x

22, 25, 30

450

36

1035

54

729

40

608

33

ø 35x

15, 18, 22

19

2

44

2

31

2

26

1,5

ø 40x

15, 18, 22

25

2

58

3

41

2

34

2

ø 50x

15, 18, 22

39

3

90

5

64

4

53

3

ø 60x

15, 18, 22

56

5

130

7

92

5

76

4

ø 70x

18, 20, 22

77

6

177

9

125

7

104

6

ø 75x

18, 20, 22

88

7

203

11

143

8

119

6,5

ø 90x

20, 22, 25

127

10

293

15

206

11

172

9

ø 100x

22, 25, 30

156

13

361

19

254

14

212

12

ø 125x

22, 25, 30

244

20

565

30

398

22

331

18

ø 150x

22, 25, 30

352

29

813

43

573

32

477

26

 

Transportation, Storing and Handling:

The cardboard boxes and packages with ceramic foam filters are transported in covered means of transport. They can only be stored in covered and dry storage rooms. It is only allowed to stack seven layers on each other. If during the transport the filters were exposed to high humidity, they have to be dried at the temperature of 110°C. Ceramic foam filters are fragile and should be handled accordingly. Take a filter out of the package and carefully remove possible ceramic particles by hand or blow them off with pressure air.

Packaging and Marking:

The foundry filters are packed in cardboard boxes protecting them from damage. Layers of filters are separated with a soft tissue. Space is left between individual filters to prevent contact in the box. The box with filters must be delivered undamaged without apparent defects. Each box has a filter identification tag containing data on: filter type, porosity, dimension, production date, production order number, number of the inspection worker, additional label, etc.