Aluminum Silicate Filter Box with Low Thermal Loss and Stable Flow Control

Applications of Aluminum Silicate Filter Box

• Extrusion Billet Casthouse – Aluminum Silicate Filter Box in Billet Casting

  ✅Key Advantages

  1. Improved Billet Cleanliness
  Aluminum silicate filter boxes combined with ceramic foam filters help reduce non-metallic inclusions reaching the billet mould, supporting scrap reductions in the range of 20–40 % for inclusion-related defects when properly designed and maintained.

  2. Stable Metal Head and Flow Distribution
  A correctly sized aluminum silicate filter box maintains a consistent metal head above the filter plate, improving flow uniformity across the filter and supporting more uniform billet structure.

  3. Lower Heat Loss Between Furnace and Casting Machine
  Thanks to low thermal conductivity, the aluminum silicate filter box limits metal temperature drop across the filtration step, often reducing temperature loss by several degrees compared with traditional dense refractories under similar conditions.

  ✅ Problem Solved

  A mid-size extrusion plant casting 6–8 inch billets experienced frequent surface pick-up and inclusion streaks, leading to scrap rates of 3–4 % on certain alloys. By introducing an aluminum silicate filter box with a properly matched ceramic foam filter in front of the billet mould, inclusion-related scrap was reduced by around 30 %, and the plant was able to run longer casting campaigns before cleaning the mould and launder system.

• Rolling Slab Casting and Sheet /Foil Producers – Aluminum Silicate Filter Box in Slab Lines

  ✅Key Advantages

  1. Enhanced Slab Quality for Downstream Rolling
  When used ahead of rolling slab moulds, the aluminum silicate filter box improves the removal of oxide films and larger inclusions, enabling more stable hot rolling and reducing downstream strip surface conditioning.

  2. Support for High Casting Speeds
  The combination of lightweight aluminum silicate lining and optimized cavity geometry provides stable flow at typical slab casting speeds, minimizing turbulence that could re-entrain inclusions.

  3. Temperature Control for Thin-Gauge Products
  Low thermal conductivity in the aluminum silicate filter box helps keep the metal temperature within a narrow window before entering the mould, which is critical for slab quality destined for thin-gauge foil and can stock.

  ✅ Problem Solved

  A sheet and foil producer targeting can-stock and thin foil products faced periodic strip surface streaks and pinholes traced back to upstream inclusions. After upgrading to an aluminum silicate filter box with optimized metal level control and ceramic foam filter sizing, the plant reported a noticeable drop in inclusion-related rolling issues and fewer coil rejections, supporting their move into more demanding end-use segments.

• Secondary Aluminium and Automotive Foundries – Aluminum Silicate Filter Box in Recycling and Alloy Casting

  ✅  Key Advantages

  1. Better Handling of Variable Scraps
  Secondary aluminium casthouses dealing with mixed scrap streams benefit from aluminum silicate filter boxes that provide a stable chamber for ceramic foam filters, improving inclusion removal even when input cleanliness varies.

  2. Resistance to Chemical Attack and Erosion
  Aluminum silicate ceramic fiber linings show good resistance to molten aluminium and slag when properly specified, extending the time between relinings compared with some conventional linings under similar conditions.

  3. Support for High-Integrity Automotive Castings
  Consistent filtration through an aluminum silicate filter box and foam filter combination helps reduce internal inclusions that can limit the performance of automotive structural and safety-critical parts.

  ✅  Problem Solved

  An automotive foundry casting suspension and safety-relevant components struggled with X-ray failures linked to inclusions. By introducing an aluminum silicate filter box unit on each furnace line feeding the casting machines, together with stricter maintenance of filter plate replacement, the foundry recorded a reduction in internal-defect scrap and gained more predictable quality for high-integrity castings.

Usage Guide – Aluminum Silicate Filter Box

• Installation

  1. Place the aluminum silicate filter box on a level, load-rated foundation aligned with the launder and casting machine.
  2. Check that all lifting lugs, anchor points and expansion gaps between liner and shell (if present) are free from transport damage.
  3. Install the aluminum silicate liner into the steel shell according to the assembly drawing when shipped separately, ensuring all joints are tight and free of loose debris.Alibaba+2zyceram.com+2
  4. Position the ceramic foam filter plate in the filter cavity on the dedicated support ledges, with the correct flow direction marking and recommended sealing gasket.Tap Out Cone+2alalloycasting+2
  5. Seal the inlet and outlet connections with suitable refractory gaskets or fiber paper to avoid metal leakage.

• Preheating and Start-Up

  1. Close the cover or lid and use burners or electric heaters to preheat the aluminum silicate filter box according to a defined temperature ramp, typically bringing the lining above 650–700 °C before introducing molten aluminium.
  2. When preheating through the filter, follow the filter supplier’s recommendations to avoid thermal shock of the ceramic foam filter plate.
  3. Confirm that all drain plugs and safety weirs are in the planned position before filling with metal.

• Operation

  1. Maintain a stable metal head above the ceramic foam filter in the aluminum silicate filter box to keep flow velocity within the recommended range.
  2. Avoid sudden large changes in metal throughput that could cause turbulence, air entrainment or erosion of the liner.
  3. Monitor metal temperature at the inlet and outlet; a small temperature drop across the aluminum silicate filter box is expected due to its insulating properties.
  4. Replace the ceramic foam filter plate according to casting tonnage or time-based schedules defined for each alloy and cleanliness level.

• Shut-Down, Cleaning and Storage

  1. When stopping casting, lower the metal head in a controlled way and drain the aluminum silicate filter box if required by local practice.
  2. After cooling to a safe temperature, remove residual solid metal from the outlet region and around the filter cavity using non-metallic tools to avoid damaging the liner.
  3. Inspect the aluminum silicate liner for cracks, spalls or heavy buildup; repair small defects with compatible refractory patch material.
  4. If the aluminum silicate filter box is stored for a prolonged period, keep it dry and protected from mechanical impact.

• Common Misuse and Corrective Actions

  1. Misuse: Filling the Aluminum Silicate Filter Box from Ambient Temperature with Hot Metal
  Issue: Excessive thermal shock to the aluminum silicate liner and the ceramic foam filter plate.
  Fix: Implement a controlled preheating schedule and verify the lining temperature before first metal contact.

  2. Misuse: Oversized Flow Rate Through a Single Aluminum Silicate Filter Box
  Issue: High velocity through the filter, turbulence in the cavity and reduced filtration efficiency.
  Fix: Recalculate metal throughput per filter area, adjust head height or add additional filter capacity.

  3. Misuse: Operating With Heavy Metal Buildup on the Liner
  Issue: Reduced effective volume, disturbed flow and higher risk of refractory inclusions breaking free.
  Fix: Include regular cleaning of the aluminum silicate filter box in maintenance schedules and remove buildup with proper tools and procedures.

FAQ – Aluminum Silicate Filter Box

1. Q: What temperature range can an aluminum silicate filter box handle?
   A: The aluminum silicate ceramic fiber liner in an aluminum silicate filter box typically supports continuous operation around 1000–1100 °C, which is suitable for most molten aluminium filtration duties.
2. Q: How does an aluminum silicate filter box improve metal cleanliness?
   A: The aluminum silicate filter box controls the flow path through the ceramic foam filter, increasing contact time between molten aluminium and the filter channels so inclusions can be captured and retained, often reducing inclusion-related defects when correctly sized and maintained.
3. Q: Is an aluminum silicate filter box only used with ceramic foam filters?
   A: Aluminum silicate filter boxes are primarily designed for ceramic foam filters, but they can also be configured for other filter media or multi-stage filtration systems depending on the casthouse design.
4. Q: What is the difference between an aluminum silicate filter box and a dense castable filter well?
   A: An aluminum silicate filter box uses a lightweight ceramic fiber liner with low thermal conductivity and good thermal shock resistance, while a dense castable filter well is heavier, stores more heat and may be more sensitive to thermal cycling in some operating modes.
5. Q: Can the dimensions of an aluminum silicate filter box be customized?
   A: Yes, aluminum silicate filter boxes are usually custom-built, with internal cavity size, inlet and outlet geometry and steel shell dimensions specified according to the customer’s launder layout, filter plate size and casting equipment.
6. Q: How long does an aluminum silicate filter box typically last in service?
   A: Service life of an aluminum silicate filter box depends on alloy type, metal cleanliness, thermal cycling and mechanical handling; under typical casthouse conditions, the liner is designed for repeated casting campaigns and is replaced when erosion, cracking or buildup reaches defined limits.

Aluminum Silicate Filter Box Reviews

• ⭐️⭐️⭐️⭐️⭐️
  After switching to an aluminum silicate filter box and matching ceramic foam filters, we saw a clear improvement in billet surface cleanliness and a reduction in inclusion-related scrap on our 6000 series alloys.
  -- Mark Jensen, Casting Process Engineer, EuroCast Billet Plant
• ⭐️⭐️⭐️⭐️⭐️
  The aluminium silicate ceramic filter box design integrated smoothly into our slab casting line. Metal temperature is more stable across the filtration step, and our rolling team has reported fewer strip surface issues linked to upstream inclusions.
  -- Laura Martínez, Operations Manager, Atlantic Aluminum Rolling Mill
• ⭐️⭐️⭐️⭐️⭐️
  Working with the ADCERAX factory on a custom aluminium silicate ceramic fibre filter box allowed us to adapt the inlet and outlet to our existing launders. The fit to our process was accurate and helped stabilize casting of critical automotive parts.
  -- Daniel Hughes, Technical Director, Northlake Alloy Foundry
• ⭐️⭐️⭐️⭐️⭐️
  ADCERAX supplied several aluminum silicate filter boxes as part of a wider casthouse upgrade. Dimensional consistency and liner quality have been good, and the units have performed as expected under continuous casting conditions.
  -- Soo-jin Kim, Procurement Manager, Hanseong Casthouse Equipment