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Custom square magnesia ceramic foam filter for magnesium alloy casting
MgO ceramic foam filter for molten magnesium filtration
Round 40 PPI MgO foam filter for magnesium casting
Magnesia ceramic foam filter for magnesium alloy filtration

Magnesia Ceramic Foam Filters for Magnesium Alloy Casting

MgO ceramic foam filters are single-use consumables for molten magnesium and magnesium alloys. Their open-cell structure captures oxide films, slag and inclusions, with 10–60 PPI options. Share your alloy, pouring temperature, filter-seat size and target defect for PPI, shape and size review.

Catalogue No. AT-MO-PM1001
Material Mgo
Porosity (PPI) 10 – 60 PPI
Working Temperature up to 1100 °C
Dimensions/Sizes Download PDF
Engineering RFQ Review
Small-Batch Custom Support
Factory-Direct Manufacturing
Drawing & Process Review
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Magnesia ceramic foam filters are rigid, porous components made primarily from magnesium oxide. Their interconnected three-dimensional cells form a tortuous flow path through the filter body. They can be produced in round, square, rectangular or drawing-based shapes to fit different filtration systems.

Magnesia Ceramic Foam Filters Benefits

  • Excellent Chemical Compatibility – Selected for molten magnesium and reactive alloy filtration where MgO material compatibility is required.
  • Uniform Open-Cell Structure – Helps capture oxide films, slag particles, and non-metallic inclusions while maintaining molten metal flow.
  • Stable Flow Support – Helps reduce turbulence and metal bypass when the filter is properly seated in the gating system.
  • Custom Size Review – Round, square, rectangular, and drawing-based filters can be reviewed according to filter cup or holder requirements.
  • PPI Selection Support – 10–60 PPI options are available to balance flow rate and filtration fineness.

 

Properties of MgO Foam Filters

Parameter Alumina (Aluminium Oxide) Silicon Carbide Zirconia (Zirconium Oxide) Magnesia (Magnesium Oxide)
Raw Material Alumina Silicon Carbide Zirconia Magnesia
Color White Black-Gray Yellow Dark Yellow
Pore Density 8-60 ppi 8-60 ppi 8-60 ppi 8-60 ppi
Porosity 80-90% 80-90% 80-90% 80-90%
Refractoriness ≤1100℃ ≤1500℃ ≤1700℃ ≤1000℃
Bending Strength >0.6Mpa >0.8Mpa >1.0Mpa >0.6Mpa
Compressive Strength >0.8Mpa >0.9Mpa >1.2Mpa >0.8Mpa
Bulk Density 0.3-0.45g/cm³ 0.35-0.5g/cm³ 0.9-1.5g/cm³ 0.35-0.5g/cm³
Thermal Shock Resistance 6 times/1100℃ 6 times/1100℃ 6 times/1100℃ 6 times/1100℃
Applications Aluminium alloys and other non-ferrous metal alloys Ductile iron, Malleable cast iron, Gray cast iron, and other cast iron High melting point metal alloys, such as steel, alloy steel, stainless steel, etc. Magnesium and high-activity alloys

How to Choose the Right PPI for MgO Ceramic Foam Filters

PPI Range Best-Fit Casting Situation Engineering Note
10–20 PPI Large castings or higher metal throughput Provides lower flow resistance but captures fewer fine inclusions.
30–40 PPI General magnesium alloy casting Balances filtration efficiency and flow stability for many foundry applications.
50–60 PPI Thin-wall parts or surface-sensitive castings Improves fine particle capture but requires careful flow and gating review.

MgO Ceramic Foam Filters Specifications

Type 1: Magnesia Ceramic Foam Filter Round

Magnesia ceramic foam filter for magnesium casting

Magnesia Ceramic Foam Filter Round
Item NO. Diameter(mm) Thickness(mm) Pore Density PPI Porosity(%)
AT-MO-PM1001 40 11 10/20/30/40/50/60 80~90
AT-MO-PM1002 40 22 10/20/30/40/50/60 80~90
AT-MO-PM1003 50 15 10/20/30/40/50/60 80~90
AT-MO-PM1004 50 22 10/20/30/40/50/60 80~90
AT-MO-PM1005 75 22 10/20/30/40/50/60 80~90
AT-MO-PM1006 80 22 10/20/30/40/50/60 80~90
AT-MO-PM1007 90 22 10/20/30/40/50/60 80~90
AT-MO-PM1008 100 22 10/20/30/40/50/60 80~90
AT-MO-PM1009 120 22 10/20/30/40/50/60 80~90
AT-MO-PM1010 150 25 10/20/30/40/50/60 80~90

 

Type 2: Magnesia Ceramic Foam Filter Square

Round magnesia ceramic foam filter with 40 PPI for steel casting

Magnesia Ceramic Foam Filter Square
Item NO. Length (mm) Width (mm) Thickness (mm) Pore Density PPI Porosity(%)
AT-MO-PM2001 40 40 10 10/20/30/40/50/60 80~90
AT-MO-PM2002 40 40 22 10/20/30/40/50/60 80~90
AT-MO-PM2003 50 50 10 10/20/30/40/50/60 80~90
AT-MO-PM2004 50 50 22 10/20/30/40/50/60 80~90
AT-MO-PM2005 50 50 30 10/20/30/40/50/60 80~90
AT-MO-PM2006 75 50 22 10/20/30/40/50/60 80~90
AT-MO-PM2007 75 75 22 10/20/30/40/50/60 80~90
AT-MO-PM2008 100 100 22 10/20/30/40/50/60 80~90
AT-MO-PM2009 150 100 22 10/20/30/40/50/60 80~90
AT-MO-PM2010 150 150 22 10/20/30/40/50/60 80~90
AT-MO-PM2011 40-300 40-300 10-50 10/20/30/40/50/60 80~90

 

MgO vs Alumina vs Silicon Carbide vs Zirconia Foam Filters

Filter Material Better Used For Not the Best Fit When
MgO ceramic foam filter Magnesium alloy and reactive alloy melt filtration The project is steel, stainless steel, or very high-temperature alloy casting.
Alumina ceramic foam filter Aluminum and selected non-ferrous alloy casting The melt is highly reactive with alumina or requires higher chemical compatibility.
Silicon carbide ceramic foam filter Cast iron and selected high-temperature foundry processes The application requires MgO chemical compatibility for molten magnesium.
Zirconia ceramic foam filter Steel, stainless steel, and higher-temperature alloy casting The project is mainly magnesium alloy filtration and does not need zirconia-grade refractory performance.

MgO Foam Filters Packaging

  • Each filter is individually packed in shock-resistant foam and sealed in moisture-proof bags. Bulk orders are shipped in reinforced wooden crates.

MgO Foam Filters Packaging

Magnesia Ceramic Foam Filter Applications

Magnesia ceramic foam filters support cleaner and more controlled magnesium casting by helping remove oxide films, slag particles and non-metallic inclusions before the melt enters the mold. Their MgO composition, open-cell structure and customizable geometry make them suitable for a range of magnesium foundry processes.

  • Magnesium Alloy Casting Lines

    MgO foam filters can be positioned at the filtration stage before mold filling. When correctly selected and installed, they help improve melt cleanliness, stabilize metal flow and reduce the risk of inclusion-related casting defects.

  • Magnesium Die-Casting Melt Preparation

    The filters can be used during melt preparation or transfer before magnesium alloy enters the die-casting system. This supports cleaner molten metal for producing automotive components, electronic housings and other lightweight magnesium parts.

  • Quality-Sensitive Magnesium Components

    For castings where surface condition, internal cleanliness or downstream machining quality is important, a suitable PPI can help balance fine-inclusion capture with the required pouring rate. Filter area, thickness and gating conditions should be reviewed together.

  • Custom Filter-Cup and Holder Integration

    Round, square, rectangular and drawing-based filters can be reviewed for existing filter cups, holders and gating systems. ADCERAX can evaluate outside dimensions, thickness, seating depth, edge support and sealing conditions to reduce fitting problems and metal bypass.

  • Foundry and OEM Consumable Supply

    Standard or drawing-based MgO filters can support foundries, casting-equipment suppliers and consumable distributors requiring repeat specifications, packaging review and project-based supply.

Usage and Preheating Guide for MgO Foam Filters

Proper installation and preheating help reduce filter cracking, metal bypass, and unstable flow during pouring. MgO foam filters should be handled as brittle refractory consumables and inspected before use.

  • Installation

    Place the filter flat inside the gating cup, filter seat, or holder. The edge should contact the refractory surface evenly to reduce metal bypass. Do not force the filter into an undersized seat, and avoid point pressure on corners or thin sections.

    For custom holders, check the drawing tolerance, seating depth, and metal stream direction before production.

  • Preheating

    Preheating should be adjusted according to filter size, alloy type, and foundry procedure. Uniform preheating is recommended to reduce thermal shock at the beginning of pouring. Avoid localized flame heating, because uneven heating can create micro-cracks in the ceramic foam structure.

  • During Pouring

    Maintain a stable pouring rate and avoid sudden impact on the filter surface. If inclusions remain after filtration, review the selected PPI, filter thickness, flow rate, and gating design together instead of increasing PPI alone.

  • Cleaning / Maintenance

    1. Single-use recommended: Do not reuse filters exposed to metal infiltration, erosion, or slag adhesion.
    2. After casting, allow the filter to cool gradually with the mould to avoid thermal shock breakage.
    3. Once metal residue solidifies, dispose of the filter safely according to local refractory waste regulations.
    4. Inspect unused filters before each pour — replace any with visible cracks or corner damage.

  • After Use

    MgO ceramic foam filters are normally treated as single-use foundry consumables after molten metal exposure. Reuse is not recommended because metal infiltration, erosion, and slag adhesion can reduce structural stability and filtration consistency.

Magnesia Ceramic Foam Filters FAQ

  1. Q: What are magnesia ceramic foam filters used for?
    A: Magnesia ceramic foam filters are mainly used in magnesium alloy casting to improve melt cleanliness before the metal enters the mold cavity. Their open-cell MgO structure helps trap oxide films, slag particles, and non-metallic inclusions while supporting smoother molten metal flow through the gating system. They are commonly used in foundry filtration systems, gating cups, filter holders, and reactive alloy casting processes where chemical compatibility with active magnesium melts is important.
  2. Q: What pore size (PPI) should I choose for my casting process?

    A: The suitable PPI depends on the casting size, required filtration fineness, pouring rate, and gating design. A 10–20 PPI filter is usually selected for larger castings or higher metal flow where lower flow resistance is important. A 30–40 PPI filter provides a balanced option for many magnesium alloy casting applications. A 50–60 PPI filter offers finer inclusion capture for thin-walled parts or surface-sensitive castings, but the flow condition and filter size should be reviewed carefully.

  3. Q: Can magnesia ceramic foam filters be reused?
    A: No. Magnesia ceramic foam filters are normally used as single-use foundry consumables after molten metal exposure. Reuse is not recommended because metal infiltration, slag adhesion, erosion, and thermal stress can reduce the structural integrity and filtration consistency of the filter.
  4. Q: What dimensions or shapes can Mgo foam filters be customized?
    A: ADCERAX supports square, round, rectangular, and contour-shaped MgO ceramic foam filters. Custom dimensions can be reviewed according to customer drawings, sample references, filter holder dimensions, gating system layout, and casting process requirements. For quotation, buyers should provide the required shape, diameter or length and width, thickness, PPI, quantity, and any drawing or filter seat details.
  5. Q: How should I preheat magnesia filters before pouring?
    A: Magnesia ceramic foam filters should be preheated before pouring to help reduce thermal shock cracking and support stable metal flow. The preheating method, temperature, and holding time should be adjusted according to the filter size, alloy type, foundry procedure, and casting condition. Avoid uneven or localized heating, because sharp temperature differences may create cracks in the ceramic foam structure.
  6. Q: Can these filters be used for aluminum alloy casting?
    A: MgO ceramic foam filters are mainly selected for molten magnesium and selected reactive alloy filtration. For aluminum alloy casting, alumina ceramic foam filters are usually more suitable and should be reviewed according to the alloy type, pouring condition, and filtration requirement. If the project involves steel, stainless steel, or higher-temperature alloy casting, zirconia ceramic foam filters should usually be reviewed instead.
  7. Q: Why should I use MgO ceramic foam filters instead of alumina or silica filters?
    A: MgO ceramic foam filters are selected when chemical compatibility with active magnesium melts is important. In certain magnesium alloy casting processes, alumina or silica filters may not be the best fit because the filter material must be reviewed against the melt chemistry and casting condition. For magnesium alloy filtration, MgO filters help provide a more suitable ceramic filtration medium for capturing oxide films, slag particles, and non-metallic inclusions before the melt enters the mold.
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Customize Magnesia Ceramic Foam Filters

ADCERAX provides custom-engineered magnesia ceramic foam filters to meet different casting processes, alloy types, and furnace configurations. Each filter can be tailored in geometry, pore structure, and mechanical performance to ensure perfect integration with your gating system.

1. Dimensions & Geometry

  • Outer / Inner Size Range: 30 mm – 200 mm standard; larger or irregular sizes available on request.
  • Thickness Options: 25 mm, 40 mm, 50 mm, and custom thicknesses for specific mold depths.
  • Shape Selections: Square, round, rectangular, or non-standard contours (e.g., trapezoidal or oval openings).
  • Tolerance: Precision controlled within ± 0.5 mm for both length and thickness.

2. Filtration Structure

  • Pore Density (PPI): 10 PPI – 60 PPI; coarse pores for high flow casting, fine pores for premium surface finish.
  • Porosity Uniformity: ≥ 80 % open-cell network, ensuring smooth metal flow and low turbulence.
  • Flow-rate Adjustment: Tailored pore size distribution to balance permeability and filtration accuracy.

3. Surface & Edge Finish

  • Edge Styles: Bevelled, straight-cut, or polished edges for easy seating and minimal metal bypass.
  • Surface Condition: Raw (as-cast) or finely ground surfaces to reduce turbulence initiation points.
  • Coating / Impregnation Options: Optional protective or wetting-control layers for high-reactivity melts.

4. Structural & Mechanical Tuning

  • Density Control: Adjusted ceramic foam density (0.35 – 0.55 g/cm³) to match alloy viscosity.
  • Reinforcement Option: High-strength backbone for multi-pouring or extended use.
  • Thermal Shock Rating: ≥ 6 cycles @ 1100 °C, tested under standard foundry pouring conditions.

5. Compatibility & Integration

  • Designed to fit standard filter cups, metal frames, or ceramic holder systems.
  • Optional transition adapters are available for integration with existing alumina filter setups.
  • Technical drawing support is available for OEM mould layout matching.
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Magnesia ceramic foam filters are rigid, porous components made primarily from magnesium oxide. Their interconnected three-dimensional cells form a tortuous flow path through the filter body. They can be produced in round, square, rectangular or drawing-based shapes to fit different filtration systems.

Magnesia Ceramic Foam Filters Benefits

  • Excellent Chemical Compatibility – Selected for molten magnesium and reactive alloy filtration where MgO material compatibility is required.
  • Uniform Open-Cell Structure – Helps capture oxide films, slag particles, and non-metallic inclusions while maintaining molten metal flow.
  • Stable Flow Support – Helps reduce turbulence and metal bypass when the filter is properly seated in the gating system.
  • Custom Size Review – Round, square, rectangular, and drawing-based filters can be reviewed according to filter cup or holder requirements.
  • PPI Selection Support – 10–60 PPI options are available to balance flow rate and filtration fineness.

 

Properties of MgO Foam Filters

Parameter Alumina (Aluminium Oxide) Silicon Carbide Zirconia (Zirconium Oxide) Magnesia (Magnesium Oxide)
Raw Material Alumina Silicon Carbide Zirconia Magnesia
Color White Black-Gray Yellow Dark Yellow
Pore Density 8-60 ppi 8-60 ppi 8-60 ppi 8-60 ppi
Porosity 80-90% 80-90% 80-90% 80-90%
Refractoriness ≤1100℃ ≤1500℃ ≤1700℃ ≤1000℃
Bending Strength >0.6Mpa >0.8Mpa >1.0Mpa >0.6Mpa
Compressive Strength >0.8Mpa >0.9Mpa >1.2Mpa >0.8Mpa
Bulk Density 0.3-0.45g/cm³ 0.35-0.5g/cm³ 0.9-1.5g/cm³ 0.35-0.5g/cm³
Thermal Shock Resistance 6 times/1100℃ 6 times/1100℃ 6 times/1100℃ 6 times/1100℃
Applications Aluminium alloys and other non-ferrous metal alloys Ductile iron, Malleable cast iron, Gray cast iron, and other cast iron High melting point metal alloys, such as steel, alloy steel, stainless steel, etc. Magnesium and high-activity alloys

How to Choose the Right PPI for MgO Ceramic Foam Filters

PPI Range Best-Fit Casting Situation Engineering Note
10–20 PPI Large castings or higher metal throughput Provides lower flow resistance but captures fewer fine inclusions.
30–40 PPI General magnesium alloy casting Balances filtration efficiency and flow stability for many foundry applications.
50–60 PPI Thin-wall parts or surface-sensitive castings Improves fine particle capture but requires careful flow and gating review.

MgO Ceramic Foam Filters Specifications

Type 1: Magnesia Ceramic Foam Filter Round

Magnesia ceramic foam filter for magnesium casting

Magnesia Ceramic Foam Filter Round
Item NO. Diameter(mm) Thickness(mm) Pore Density PPI Porosity(%)
AT-MO-PM1001 40 11 10/20/30/40/50/60 80~90
AT-MO-PM1002 40 22 10/20/30/40/50/60 80~90
AT-MO-PM1003 50 15 10/20/30/40/50/60 80~90
AT-MO-PM1004 50 22 10/20/30/40/50/60 80~90
AT-MO-PM1005 75 22 10/20/30/40/50/60 80~90
AT-MO-PM1006 80 22 10/20/30/40/50/60 80~90
AT-MO-PM1007 90 22 10/20/30/40/50/60 80~90
AT-MO-PM1008 100 22 10/20/30/40/50/60 80~90
AT-MO-PM1009 120 22 10/20/30/40/50/60 80~90
AT-MO-PM1010 150 25 10/20/30/40/50/60 80~90

 

Type 2: Magnesia Ceramic Foam Filter Square

Round magnesia ceramic foam filter with 40 PPI for steel casting

Magnesia Ceramic Foam Filter Square
Item NO. Length (mm) Width (mm) Thickness (mm) Pore Density PPI Porosity(%)
AT-MO-PM2001 40 40 10 10/20/30/40/50/60 80~90
AT-MO-PM2002 40 40 22 10/20/30/40/50/60 80~90
AT-MO-PM2003 50 50 10 10/20/30/40/50/60 80~90
AT-MO-PM2004 50 50 22 10/20/30/40/50/60 80~90
AT-MO-PM2005 50 50 30 10/20/30/40/50/60 80~90
AT-MO-PM2006 75 50 22 10/20/30/40/50/60 80~90
AT-MO-PM2007 75 75 22 10/20/30/40/50/60 80~90
AT-MO-PM2008 100 100 22 10/20/30/40/50/60 80~90
AT-MO-PM2009 150 100 22 10/20/30/40/50/60 80~90
AT-MO-PM2010 150 150 22 10/20/30/40/50/60 80~90
AT-MO-PM2011 40-300 40-300 10-50 10/20/30/40/50/60 80~90

 

MgO vs Alumina vs Silicon Carbide vs Zirconia Foam Filters

Filter Material Better Used For Not the Best Fit When
MgO ceramic foam filter Magnesium alloy and reactive alloy melt filtration The project is steel, stainless steel, or very high-temperature alloy casting.
Alumina ceramic foam filter Aluminum and selected non-ferrous alloy casting The melt is highly reactive with alumina or requires higher chemical compatibility.
Silicon carbide ceramic foam filter Cast iron and selected high-temperature foundry processes The application requires MgO chemical compatibility for molten magnesium.
Zirconia ceramic foam filter Steel, stainless steel, and higher-temperature alloy casting The project is mainly magnesium alloy filtration and does not need zirconia-grade refractory performance.

MgO Foam Filters Packaging

  • Each filter is individually packed in shock-resistant foam and sealed in moisture-proof bags. Bulk orders are shipped in reinforced wooden crates.

MgO Foam Filters Packaging

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