Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
Metal casting component are found in 90 percent of manufactured goods and equipment, from critical components for aircraft and automotive industry to home applications. However, molten metal used to produce metal casting in practice generally contains impurities and inclusions which are deleterio...
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| Main Author: | |
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| Format: | Thesis |
| Language: | English English |
| Published: |
2009
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| Subjects: | |
| Online Access: | http://psasir.upm.edu.my/id/eprint/7824/1/ABS_-----__FK_2009_101.pdf |
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| Summary: | Metal casting component are found in 90 percent of manufactured goods and
equipment, from critical components for aircraft and automotive industry to
home applications. However, molten metal used to produce metal casting in
practice generally contains impurities and inclusions which are deleterious to
final cast metal product. Currently, filtration technique by using ceramic foam
filter has been accepted as a successful method of reducing inclusions from
molten metal during the casting of metal parts.
The present research has been done to fabricate and improve a ceramic
foam filter for using in filtration of molten metal, especially aluminium based
alloys. It is an objective of the present innovation to provide a ceramic foam
filter characterized by cost of raw materials. Ceramic foam filters are
produced by impregnating polyurethane foam with ceramic slurry, drying,
baking and finally firing the foam in the oven.
Experimental tests were carried out to the filters to measure dimensions,
weight, cold compression strength, and permeability properties before pouring process. After pouring process, the filter was cut into several
sections to measure the macro and microstructure of the filter and ensure
that impurity particles captured by a filter.
Thermal shock properties, obtained from pouring liquid aluminium when filter
was placed in the gating system to ensure that the filters could withstand
temperatures of aluminium alloys.
Further experiments were carried out to investigate and determine the
efficiency of produced ceramic foam filter on quality of cast products. The
result obtained in this investigation, the mechanical properties for aluminum
LM6 alloy sand casting increased when ceramic foam filter was inserted into
the gating system.
A produced filter by using new materials is economical to be produced.
Further more, the analysis data shows present innovation filter which can be
made in any shape and size, has excellent thermal shock resistance,
adequate compressive strength, acceptable density and permeability
properties. |
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