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:	Bagherian, Ehsaanreza
Format:	Thesis
Language:	English English
Published:	2009
Subjects:	Ceramics Filters and filtration Foamed materials
Online Access:	http://psasir.upm.edu.my/id/eprint/7824/1/ABS_-----__FK_2009_101.pdf
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spelling	my-upm-ir.78242013-05-27T07:36:38Z Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes 2009 Bagherian, Ehsaanreza 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. Ceramics Filters and filtration Foamed materials 2009 Thesis http://psasir.upm.edu.my/id/eprint/7824/ http://psasir.upm.edu.my/id/eprint/7824/1/ABS_-----__FK_2009_101.pdf application/pdf en public masters Universiti Putra Malaysia Ceramics Filters and filtration Foamed materials Faculty of Engineering English
institution	Universiti Putra Malaysia
collection	PSAS Institutional Repository
language	English English
topic	Ceramics Filters and filtration Foamed materials
spellingShingle	Ceramics Filters and filtration Foamed materials Bagherian, Ehsaanreza Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
description	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.
format	Thesis
qualification_level	Master's degree
author	Bagherian, Ehsaanreza
author_facet	Bagherian, Ehsaanreza
author_sort	Bagherian, Ehsaanreza
title	Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
title_short	Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
title_full	Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
title_fullStr	Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
title_full_unstemmed	Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes
title_sort	development of a ceramic foam filter for filtering molten aluminum alloy in casting processes
granting_institution	Universiti Putra Malaysia
granting_department	Faculty of Engineering
publishDate	2009
url	http://psasir.upm.edu.my/id/eprint/7824/1/ABS_-----__FK_2009_101.pdf
_version_	1747810713650331648

Development of a Ceramic Foam Filter for Filtering Molten Aluminum Alloy in Casting Processes

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