Zirconium oxide (ZrO₂) ceramic foam filter has become the core material for melt filtration of high-end cast steel (such as stainless steel, high-temperature alloys, etc.) due to its excellent high-temperature stability, chemical inertness and thermal shock resistance. This paper introduces the preparation process, key performance parameters, selection methods and cast steel application cases of zirconia ceramic foam filter in detail, and finally discusses the future development trend of this field.
Core Characteristics of Zirconia Ceramic Foam Filter
Material advantages
Compared with alumina (Al₂O₃) and silicon carbide (SiC) filters, zirconia foam ceramics have the following irreplaceable advantages:
- Ultra-high temperature resistance: melting point up to 2700℃, long-term stable operation in molten steel environment of 1600-1750℃.
- Chemical inertness: does not react with active elements such as Cr, Ni, Mn in molten steel to avoid secondary inclusions.
- Thermal shock resistance: can withstand rapid cooling and heating of >800℃/min.
- Controllable pore structure: three-dimensional mesh porous structure (porosity 75%-90%), effectively intercepting 20-100μm inclusions.
Preparation Technology and Customized Design of Zirconia Ceramic Foam Filter
Preparation Process
Raw material processing: Use stable ZrO₂ powder to avoid sintering cracking.
Molding process:
- Organic foam impregnation method: Impregnate the polyurethane template with ZrO₂ slurry, dry it and sinter it at high temperature (1500-1600℃).
- 3D printing: Precisely control the pore structure, suitable for complex special-shaped parts (such as turbine blade filters).
Customized solution
Special-shaped cutting: Suitable for special casting systems such as fan-shaped and ring-shaped (such as continuous casting tundish).
Conclusion and Prospect
Zirconium oxide ceramic foam filter is a key functional material for improving the quality of high-end steel castings. Its future development directions include:
- Low cost: reduce manufacturing costs through raw material optimization (such as recycling ZrO₂).
- Intelligent: combine Internet of Things technology to achieve filter life prediction.
- Multifunctional: develop a composite filter with both filtration and desulfurization/deoxidation functions.