Molten Metal Filter with Composite Binder
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Solution Overview
Problem
Existing filters for molten metal face challenges in maintaining high temperature resistance and mechanical strength, particularly due to the limitations of carbon-based binders which provide high strength at high temperatures but low strength at room temperature and susceptibility to moisture, limiting their effectiveness across various metals like aluminum, iron, and steel.
Innovation Solution
A filter comprising an open cell porous material bonded with a refractory material and a binder, where the weight ratio of refractory material to binder and additive is optimized (20-54%:52-78%), using carbon-based materials like carbon, asphalt, or tar as binders, and alumino silica gel or silica sol, combined with refractory materials like mullite, corundum, or spinel, to enhance mechanical properties and high temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If carbon binder is used to bond refractory materials, then high temperature resistance and high temperature strength are improved, but room temperature strength deteriorates and moisture absorption increases
Solution Approach 1:
The patent employs a composite binder system comprising both carbon-based materials (graphite, carbon black, asphalt, or tar) and ceramic materials (alumina, silica, or mullite) in specific weight ratios. This composite approach combines the high temperature resistance of carbon with the room temperature strength of ceramics, resolving the contradiction between high temperature performance and ambient strength. The ceramic components provide structural integrity at room temperature while the carbon components maintain high temperature stability.
Solution Approach 2:
The patent optimizes the weight ratio parameters of binder components to resolve the contradiction. Specifically, it controls the carbon-to-ceramic ratio and the total binder content (20-40 wt% of refractory material) to achieve a balance where sufficient carbon provides high temperature resistance while adequate ceramic content maintains room temperature strength. This parameter optimization allows the filter to perform adequately across both temperature regimes.
2Temperature
If carbon binder content is increased to improve high temperature resistance, then high temperature strength is improved, but controlling binder content during processing becomes difficult
Solution Approach 1:
By using a composite binder system with both carbon and ceramic components, the patent creates a more stable and controllable formulation. The ceramic portion (alumina, silica, or mullite) provides a stable matrix that is easier to handle and process than pure carbon binders. This composite approach allows for more precise control of total binder content during manufacturing while still achieving the desired high temperature resistance through the carbon component.
Solution Approach 2:
The ceramic materials (alumina, silica, or mullite) act as intermediary substances that facilitate controlled binder application. These ceramics serve as a stable carrier matrix that makes the binder system more manageable during processing, allowing for better control of binder content while the carbon components embedded within provide the necessary high temperature resistance.
3Temperature
If carbon-based binder is used, then high temperature strength is improved, but moisture absorption increases affecting high temperature performance
Solution Approach 1:
The patent uses a composite binder where ceramic materials (alumina, silica, or mullite) form a moisture-resistant matrix that reduces overall moisture absorption. The carbon components (graphite, carbon black, asphalt, or tar) are dispersed within this ceramic matrix, maintaining high temperature strength while the ceramic portion protects against moisture ingress. This composite structure resolves the contradiction by providing both high temperature performance and moisture resistance.
Solution Approach 2:
The ceramic materials in the binder composite act as intermediary protective layers that reduce moisture absorption. These ceramics form a barrier matrix that prevents moisture from reaching and degrading the carbon binder components, thereby protecting the high temperature strength properties while reducing harmful moisture absorption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly improves the mechanical properties and high temperature resistance of the filter, enabling effective filtration of molten metals like steel, with increased tensile strength and elongation rate, and improved metallographic structure of the casts, while being economically viable and easy to produce.
Implementation Method 1
the filter comprises open cell porous material, a refractory material and a binder, wherein the refractory material is bonded to the open cell porous material by the binder
Implementation Method 2
particles of refractory material embedded in and bonded together by a carbon matrix bonding material
Implementation Method 3
sintering the open cell porous material formed with the refractory coating under a sintering temperature
Implementation Method 4
a filter for filtering molten metal, comprising an open cell porous material
Implementation Method 5
the refractory material is bonded to the open cell porous material by the binder
Data Source
AI summary
A filter used for filtering molten metal and a preparation method thereof are disclosed. The filter comprises open-pored porous material, binder and refractory material. The refractory material is bonded on the open-pored porous material by the binder, wherein the weight proportion of the binder is at least 50% and the weight proportion of the refractory material is not more than 50%. The filter has enhanced mechanical property and high temperature resisting property, while its preparation method is more cost-efficient than usual ones.