Molten Metal Filter Boxes

Molten Metal Filter Boxes, typically utilizing ceramic foam filters, are essential for producing high-quality die-cast aluminum components. These filters effectively remove contaminants from the aluminum before the casting process, ensuring the integrity and quality of the final product.

The Role of Ceramic Foam Filters in Aluminum Casting

Ceramic foam filters offer a sophisticated solution to capture and remove impurities from molten aluminum. These filters are designed with an open-cell structure made of ceramic, which contains voids that allow the molten aluminum to pass while filtering out inclusions. This results in cast aluminum parts that are structurally sound and free of defects that could impair their strength and durability. For more information on how our immersion heaters can benefit your casting operations, please contact us.

Challenges of Impurities in Aluminum Casting

Inclusions in aluminum can originate from several sources:
Aluminum oxide, drawn in from the surface of the molten metal.
Fragments from the furnace lining and other components that become loose and mix with the aluminum.
Other insoluble impurities such as intermetallics, borides, carbides, chlorides, etc.

These impurities can severely affect the structural integrity of die-casted parts. Furthermore, if the aluminum parts require additional processing like extruding, rolling, or forging, the presence of inclusions can compromise the efficiency and profitability of the entire manufacturing process due to increased rates of component failure or rejection.

Vertical 9KW immersion heater

Historical Methods and Their Limitations

Traditionally, molten aluminum has been filtered through methods like **glass cloth screen filtration** and **deep bed filtration** using alumina particles or balls. However, these methods come with their own set of challenges. Glass cloth filtration, for example, is limited to removing only larger inclusions and may break down due to the weakening of the glass fibers at high temperatures. Deep bed filtration can allow solid inclusions to pass through and may struggle to maintain consistent filtration levels as the pore size of the filter changes with use.

The Benefits Molten Metal Filter Boxes

Ceramic foam filters excel where traditional methods falter. They not only filter out both large and small inclusions effectively but also enhance the ductility, tensile strength, and overall finish of aluminum cast parts. Moreover, using adequately filtered aluminum can improve the productivity of the casting process by decreasing casting time and increasing yield.

At New Century Heaters, we understand the importance of precision in the casting industry. That’s why we’ve engineered our immersion heaters to work seamlessly with molten metal, enhancing every step of the casting process. For more information on how our immersion heaters can support your operations, or to explore our full catalog tailored to your specific needs, please contact us. We’re here to help you find the optimal solution for your casting requirements, ensuring that every component you produce meets the highest standards of quality.

Immersion Heating System Details

New Century Heaters has engineered our immersion heaters specifically for molten metal. These heaters coupled with specially designed protection tubes provide the most robust and efficient molten metal heat source in the industry.

Our immersion heating elements are made of heavy gage ICA wire on cast ceramic cores that guarantee wire spacing to evenly distribute the heat through high density, high conductivity, non-wetting protection tubes.

We use the heaviest gage wire in the industry to provide robust, long-lived heaters that can be operated up to 2,000 degrees Fahrenheit. The wire is recessed in separating groves that are precision cast in a ceramic core that is engineered to compliment the mating protection tube. Because of this, the coils can never touch each other and short out. Extra heavy leads are brought out and insulated away from the heater core to provide trouble free connections.

If you are a manufacturer of furnace, we want to talk to you.  Contact us today for a free, quick estimate!

If you are looking to replace your immersion heater found in a melting furnace,  contact us!