Material Engineering & Performance
Structural Specifications
Base Material: Oxygen-free copper (C10200, 99.95% purity)
Porosity: 75-85% with graded pore structure (0.5-3mm channels)
Sintering Temperature: 950-1050°C in reducing atmosphere
Thermal Stability: <1% dimensional change at 1300°C
Mechanical Strength: 8-12 MPa at operating temperatures
Key Performance Advantages
✔ 3X Longer Service Life vs. ceramic foam filters
✔ 50% Higher Flow Rate than conventional mesh filters
✔ Active Filtration Mechanism: Captures inclusions via adhesion & interception
✔ Thermal Shock Resistance: Survives rapid temperature cycling
✔ Non-Wetting Surface: Prevents alloy penetration
Industrial Applications
1. Aluminum Foundry Operations
Engine Component Casting:
Removes oxide skins and TiB₂ clusters
Improves fatigue life by 40% in cylinder heads
Aerospace Alloys:
Filters 10-50μm inclusions in Al-Li alloys
Essential for premium quality aircraft parts
2. Copper & Bronze Casting
Electrical Conductor Production:
Eliminates slag particles degrading conductivity
Critical for oxygen-free copper (OFHC) refining
Art Casting & Sculptures:
Preserves fine detail by removing impurities
Reduces surface defects in large artworks
3. Specialty Alloy Production
Titanium Investment Casting:
Withstands superheated Ti melts (1650°C+)
Ceramic-coated versions available
Precious Metal Refining:
Gold/silver purification without contamination
Reusable for multiple batches
Products Description
Aperture | 0.1mm-10mm (can customized) |
Porosity | 60%-98% |
Through porosity | ≥98% |
Bulk density | 0.1-0.8g/cm3 |
PPI | 5-130 |
size | Customized |
Tensile Strength | 5-18KPa |
compressive strength | ≥250KPa |
mechanical strength | ≥2-5KPa |
High temperature resistance | ≥900℃ |
Heat transfer coefficient | >6W/(m2k) |
Technical Comparison
| Parameter | Cu Foam Filter | Ceramic Foam | Glass Mesh | Cored Brick |
|---|
| Max Operating Temp | 1400°C | 1100°C | 800°C | 1500°C |
| Inclusion Removal | 90-95% | 80-90% | 60-75% | 50-70% |
| Thermal Shock Resist | ★★★★☆ | ★★☆☆☆ | ★☆☆☆☆ | ★★★☆☆ |
| Metal Flow Rate | 25-35 kg/s·cm² | 15-20 | 30-40 | 5-10 |
| Service Life | 200-300 casts | 50-80 | 1-5 | 300-500 |
Manufacturing Process
High-Purity Powder Preparation: Gas-atomized copper powder
Space Holder Mixing: Controlled particle size distribution
Cold Isostatic Pressing: 200-300 MPa forming pressure
Sintering: 8-12 hour cycle in hydrogen atmosphere
Quality Control:
X-ray tomography for pore structure verification
Molten aluminum immersion testing
Operating Guidelines
Preheating: 600-800°C recommended before first use
Positioning: Install in choke areas of gating systems
Maintenance: Visual inspection every 50 casts
End-of-Life: Visible erosion at pore throats indicates replacement
Industry Validation
Aluminum Castings:
▶ 92% inclusion removal in A356 alloy (LiMCA testing)
▶ 35% reduction in machining tool wear
Copper Applications:
▶ 99.99% pure copper achieved in single filtration pass
▶ 0.05% max oxygen content maintained
Durability Testing:
▶ 250+ casting cycles in automotive foundry trials
▶ <0.1mm erosion per 50 casts in brass production
Future Developments
Smart Filters: Embedded temperature sensors
Nano-Coated Versions: For sub-micron filtration
Recycling Program: Closed-loop material recovery
Alloy-Specific Designs: Optimized pore structures
