CERACAT Filter Range
for Foundry
CERACAT is a ‘composite’ ceramic it marries the positive properties of multiple materials and technologies to offset any negative aspects and give a very stable strong filter that can be manufactured at lower cost compared to zirconia but with much higher strength than Carbon Bonding alone…
How is this done?
Foam filters are manufactured by taking a soft reticulated polyurethane foam and building up layers of ceramic slurry on the foam structure , drying and re applying layers until a sufficient layer is built up that when fired gives a ceramic foam structure that will withstand its intended use.
CAT has developed a way of layering different ceramic materials within this structure. The base layer is ceramic giving good mechanical strength with a low material cost.
Subsequent layers are blends of high alumina and proprietary ingredients developed by CAT to ensure the ‘marriage’ of the dissimilar particles on firing. Carbon is also present within the structure but to a maximum of 10%
This ‘composite’ ceramic can be layered differently depending on application. This gives a material that is:
- High in Strength
- Thermally Stable for steel and heavy iron application temperatures
- High filtration affinity ie the surface will chemically attract, attach and retain oxide particles
- Lower relative manufacturing costs
- Lack of shrinkage during the manufacturing process compared to zirconia enables the cost effective manufacture of very large filters
- The overall density of the material is higher than Carbon Bonded but lower than zirconia meaning that in direct pour applications the filter floats readily and easily after casting
Steel
High Capacity Iron
Heavy Iron / Chrome Iron
What does CAT stand for?
The acronym CAT stands for Carbon Application Technology.
What are the CERACAT range of filters made from?
CERACAT is a ‘composite’ ceramic it marries the positive properties of several materials and technologies to offset the negative aspects and give a very stable strong filter that can be manufactured at lower cost compared to zirconia but with much higher strength than Carbon Bonding alone
In relation to a Zirconia or Carbon Bonded filters how does a CERACAT filter ‘Prime’?
In standard form CERACAT primes similar to a Zirconia based filter however if this is of issue we can increase the priming performance contact us to discuss your application.
Will these filters float after casting when used in a direct pour application?
Yes the CERACAT filter will float much more readily than a zirconia filter.
Is the variation in colour / different shades of grey normal?
Yes CERACAT filters are fired inside a kiln in an oxygen free atmosphere however you can see a variation in the shade of grey to black depending on the location within the kiln, it has no effect on performance and is purely cosmetic.
Do I need to worry about Carbon pick in the melt when using CERACAT? Can I use them with very low carbon steels?
The carbon content of our filters is typically 7% (unlike purely carbon bonded filters which can be typically 40%) our filters have been tested for carbon pick up in the metal to 3 decimal places and no evidence of carbon pick up in the metal has been detected.
Can you supply filter holders/ supports for use with the larger filters?
CAT can manufacture custom supports for your application with minimal tooling costs, we also have a range of ‘holloware’ filter holders Contact us to discuss your application.
Can I use CERACAT with Manganese steel?
Yes we have many customers using CERACAT with Manganese steel, please contact use for more information.
Is CERACAT hydroscopic ie. will it pick up moisture?
Like all ceramic you should try and store them in a dry location however unlike purely carbon bonded filters they are NOT Hygroscopic.