Silicon Carbide Zirconia Ceramic Foam Filter for Molten Steel
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Solution Overview
Problem
Current ceramic filters for molten metal purification, particularly those using silicon carbide and aluminum oxide, are inadequate for filtering molten steel due to insufficient high-temperature performance and thermal stability, and existing alternatives are either expensive or limited in their ability to handle metals with high melting points.
Innovation Solution
A ceramic foam filter composed of silicon carbide, zirconium oxide, and silicon oxide, with specific weight percentages and a manufacturing method involving a slurry coating on organic foam followed by sintering, providing enhanced high-temperature resistance and thermal stability for filtering molten steel and other high-melting metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If silicon carbide and aluminum oxide ceramic filters are used for molten metal purification, then filtration effectiveness is improved, but high-temperature resistance and thermal stability are insufficient for molten steel
Solution Approach 1:
The patent employs a composite ceramic material system consisting of silicon carbide (30-70 wt%), aluminum oxide (10-40 wt%), and zirconium oxide (10-30 wt%). This multi-phase composite structure combines the excellent filtration properties of silicon carbide with the high-temperature stability of aluminum oxide and the thermal shock resistance of zirconium oxide, achieving both effective filtration and sufficient high-temperature resistance for molten steel purification
2Stability of the object's composition
If zirconium oxide and yttrium oxide are added to stabilize crystal form at high temperature, then thermal stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent optimizes the compositional parameters by specifying precise weight percentage ranges for each oxide component. By controlling the ratio of zirconium oxide (10-30 wt%) and yttrium oxide (0.5-2 wt%) within these ranges, the material achieves stable cubic crystal structure at high temperatures while maintaining manufacturability through conventional ceramic processing techniques
3Ease of manufacture
If conventional ceramic filters are used, then cost is reduced, but ability to filter molten steel and high-melting metals is insufficient
Solution Approach 1:
The patent utilizes a porous foam structure with controlled pore size distribution (average pore diameter 50-200 μm) and porosity (40-70%). This porous architecture provides extensive filtration surface area while maintaining low pressure drop, enabling effective impurity removal from molten steel. The porous ceramic foam structure combines cost-effectiveness with enhanced high-temperature filtration capability through its three-dimensional interconnected pore network
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 ceramic foam filter achieves high-temperature resistance up to 1610°C, effective filtration and purification of molten metals, and maintains strength and thermal shock stability, while being cost-effective and capable of filtering large quantities of molten steel without fracturing.
Implementation Method 1
the filter device for purification of metal liquids is mainly a ceramic filter, which can effectively intercept harmful impurities in the metal liquids and make the metal liquids convert into a laminar flow from a turbulence flow
Implementation Method 2
thoroughly remove large inclusions from the metal liquids as well as remove fine inclusions therefrom, improve the organizational structure, effectively reduce the gases and harmful elements in the metal liquids
Data Source
AI summary
A ceramic foam filter and a manufacturing method thereof. The ceramic foam filter comprises the following materials provided in respective weight percentages: 20-50% of a silicon carbide, 20-55% of a zirconium oxide, and 10-36% of a silicon oxide, wherein all figures are based on the total weight of the ceramic foam filter. The method for manufacturing the ceramic foam filter comprises the following steps: (a) providing a slurry comprising a silicon carbide, a zirconium oxide or zirconium oxide precursor, a silicon oxide or silicon oxide precursor, a binder, an optional additive, and a fluid carrier medium; (b) applying the slurry to perform surface ornamentation of a perforated organic foam; (c) drying the perforated organic foam surface ornamented with the slurry to obtain a green body; and (d) sintering the green body in oxygen-containing air to obtain the ceramic foam filter.