CERACAT MAX large filters for heavy iron/chrome iron and high alloy steel castings
- Heavy Iron / Chrome Iron and High Alloy Steels
- 150-300mm Filter Size
- High Strength
- Low Cost
CERACAT MAX is a ceramic filter with carbon, which whilst they may look similar is very different to a carbon bonded filter.
It has the benefit of carbon to increase thermal shock, chemical resistance, refractoriness and reduce the manufacturing cost but retains the high mechanical strength of a ceramic compared to the inherently low strength of a purely carbon bonded filter. This technology allows us to make very large filters compared to zirconia based filters.
The technique of ‘Direct Pour’ where a filter is held in a sleeve or pouring bush placed directly onto the casting and then floats out of the way after pouring as not to obstruct feeding has proven to offer foundries huge benefits in increased yields, box optimisation and reduced fettling times in many applications. However this has been limited by two factors, firstly the relative cost of the filter as size increases and the increased risk of breakage especially when using bottom pour ladles.
CERACAT MAX offers high mechanical strength at a much lower cost compared to carbon bonded or zirconia based filters allowing many more foundries both steel and heavy iron enjoy the benefits of filtration.
CERACAT MAX CAPACITY DUCTILE IRON/GJS & GREY IRON/GJL
| SIZE | Min Print Ledge | DUCTILE/GJS | Grey/GJL |
| D150x30 | 5 mm | 625 KG | 1125 KG |
| D175x35 | 6 mm | 845 KG | 1521 KG |
| D200x35 | 8 mm | 1125 KG | 2025 KG |
| D255x40 | 10 mm | 1750 KG | 3150 KG |
| D300x50 | 12 mm | 2500 KG | 4500 KG |
| 150x150x30 | 5 mm | 810 KG | 1458 KG |
| 175x175x30 | 6 mm | 1075 KG | 1935 KG |
| 200x200x35 | 8 mm | 1400 KG | 2520 KG |
| 225x225x35 | 8 mm | 1775 KG | 3195 KG |
| 250x250x40 | 10 mm | 2200 KG | 3960 KG |
| 300x300x45 | 12 mm | 3125 KG | 5625 KG |
Note: Filter sizes above all have a PPI value of 7
CERACAT MAX Improves Production Efficiency at large UK High Chrome iron foundry…
This foundry had developed a technique of direct pouring High Chrome Iron parts via a 10 tonne bottom pour ladle using 200mm & 250mm Diameter Carbon Bonded (CB)filters placed in the bottom of a sleeve/feeder head, individual parts typically 1-2tonne in weight and cast at 1350-1420 deg C (2460-2600 F). The technique gives big advantages in terms of yield, sand metal ratio, moulding time and finishing cost. However they would occasionally have a filter break resulting in the casting being scrapped.
CERACAT MAX was introduced and run like for like against the carbon bonded (CB) filter for many months, during this time incidents of the CB filter breaking were recorded but significantly no breakages occurred with CERACAT MAX. The foundry has now converted to CERACAT MAX 100% for this application.