EP3490692A1 - Filtration device for the filtration of a liquid metal or an alloy thereof, and a filtration method using said filtration device - Google Patents
Filtration device for the filtration of a liquid metal or an alloy thereof, and a filtration method using said filtration deviceInfo
- Publication number
- EP3490692A1 EP3490692A1 EP17833157.5A EP17833157A EP3490692A1 EP 3490692 A1 EP3490692 A1 EP 3490692A1 EP 17833157 A EP17833157 A EP 17833157A EP 3490692 A1 EP3490692 A1 EP 3490692A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- filtration device
- fabric
- filtration
- basket
- heat resistant
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D43/00—Mechanical cleaning, e.g. skimming of molten metals
- B22D43/001—Retaining slag during pouring molten metal
- B22D43/004—Retaining slag during pouring molten metal by using filtering means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
- B01D39/086—Filter cloth, i.e. woven, knitted or interlaced material of inorganic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/086—Filters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D43/00—Mechanical cleaning, e.g. skimming of molten metals
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B21/00—Obtaining aluminium
- C22B21/06—Obtaining aluminium refining
- C22B21/066—Treatment of circulating aluminium, e.g. by filtration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/04—Additives and treatments of the filtering material
- B01D2239/0457—Specific fire retardant or heat resistant properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/04—Additives and treatments of the filtering material
- B01D2239/0471—Surface coating material
- B01D2239/0492—Surface coating material on fibres
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Definitions
- the invention relates to new filtration devices for the filtering of a liquid metal (e.g. aluminum) or an alloy thereof, the filtering being carried out in any kind of casting processes using filtration devices, and more particularly in a gravity casting process or in a low pressure casting process.
- a liquid metal e.g. aluminum
- an alloy thereof e.g. aluminum
- Filtration devices are used during casting processes to prevent some debris and/or impurities to enter the cavities. These filtration devices which are subjected to a pressure exerted by a flow of liquid metal or alloy passing there through, may consist of metallic filters (i.e. grids of metal threads), non-metallic filters (i.e. fabrics of heat resistant fibers eventually provided with a protective coating), or ceramic foam filters.
- Each filtration device has a geometric configuration that is matching with a corresponding housing provided at the inlet of a mold cavity.
- filtration devices made of a fabric of metal threads gather at the bottom of the liquid metal or metal alloy (making them hard to recover), and they can partially dissolved into the re-melted metal or metal alloy to contaminate and/or modifying the chemistry of the same.
- ceramic foam filters can partially disintegrate and contaminate the liquid metal or alloy, and/or gather in the bottom of the liquid metal or alloy (making them hard to recover).
- existing filtration devices made of a rigidified fabric of heat resistant fibers gather at the top of the liquid metal or liquid metal alloy (making them easy to recover). An easy and/or rapid recovery of the filtration device is of economical interest.
- Filtering device i.e. fabric filters
- a rigidified fabric made from heat resistant fibers or threads made of heat resistant fibers are of economic interest. Indeed, as the metal chunk (e.g. an aluminum chunk) results from the casting of a metal article into a mold, said chunk contains the fabric filter having filtered the liquid metal poured into the mold. When this chunk is recovered and then re-melted for recycling purposes, contrary to filters made of steel threads which will gather at the bottom of the melting pots, filters made of rigidified heat resistant fibers float on top of the liquid metal or metal alloy to make them very easy to retrieve.
- the metal chunk e.g. an aluminum chunk
- filters made of rigidified heat resistant fibers float on top of the liquid metal or metal alloy to make them very easy to retrieve.
- such fabric can be rigidified by applying thereon a rigidifying material, in order to make it stiff enough to not being deformed by the pressure of a liquid metal passing through its opening, especially liquid aluminum.
- a rigidifying material on the sizing material of the heat resistant fibers reveals to provide serious drawbacks that will discourage a person skilled in the art using filters prepared this way.
- a rigidifying material i.e. a coating
- the coating on the fibers of the resulting fabric shows the drawback of generating a clogging and/or partial obstruction of openings between threads (i.e. reducing the mesh size of the fabric filters).
- the protective/rigidifying coating is often brittle, particles may detach therefrom to contaminate the liquid aluminum, especially when applied on the sizing material of the fibers. Therefore, up to now, attempts for the replacement of such filtration devices by filtration devices made of a fabric of rigidified heat resistant fibers (e.g. of glass fibers or silica fibers) failed to be successful.
- the molded article is removed from the mold and the ceramic foam filter remains trapped within a chunk of the molded article. Said chunk is then removed from the finished article by any appropriate means well known to persons skilled in the art, and re-melted for metal recovery.
- the ceramic foam filters they contain can partially disintegrate and contaminate the liquid metal or metal alloy, and/or gather in the bottom of the liquid metal or metal alloy (making them hard to recover).
- ceramic foam filters show the drawback of having an impact on the temperature of the liquid metal or metal alloy (i.e. the ceramic foam filters have a thermal mass), and eventually affecting the chemistry of the metal or metal alloy which fills the cavity of the mold (i.e. the chemistry of the resulting molded article). Furthermore, because a ceramic foam filter is a monolithic piece of matter, it can be difficult to increase the effective filtration surface of the same.
- the Applicant has further discovered various embodiments which overcome drawbacks associated with said existing filtration devices made of a fabric of rigidified heat resistant fibers and/or threads of heat resistant fibers. More particularly, it is worth mentioning amongst said numerous advantages, that said filtration device according to the invention prevents being deformed by the flow of liquid passing there through, prevents partial obstruction of the meshing, prevents contamination of the filtered liquid metal or liquid metal alloy (e.g. liquid aluminum or aluminum alloy), and/or optionally allows an easy handling by a tool provided with a magnet (especially a robotized arm provided with said tool), while being as efficient as corresponding existing filters, such as filters made of metal threads.
- a magnet especially a robotized arm provided with said tool
- the Applicant has surprisingly discovered that it was possible to overcome drawbacks associated with filtering devices made of a fabric of metal threads or made of fabric of heat resistant fibers, when using a filtration device made of a fabric or rigidified heat resistant fibers, having a particular structural shape and orientation.
- the Applicant has surprisingly discovered that it was possible to overcome drawbacks associated with ceramic foam filters by replacing them with less expensive filtration devices made of a fabric of metal threads or of a rigidified filter of heat resistant fibers, such as heat resistant fibers selected from the group consisting of glass fibers or silica fibers.
- the filtration device made of a fabric of metal threads e.g. stainless steel threads
- said metal threads may partially dissolved when contacting the liquid metal or metal alloys to be filtered, to thus contaminate the same.
- the liquid metal alloy to be filtered is an aluminum alloy
- said aluminum alloy can be contaminated with iron. Therefore, the use of a filtration device made of metal threads is limited by the possibility of significanlty negatively affecting the chemistry of the filtered liquid metal or alloy.
- Some, but not all, foundries use magnetic placement of filtration devices in openings of mold cavities. This can either be a performed with a magnetic tool used by an operator for manual placement, or a magnetic tool attached to a robot for automated placement. Also, some but not all foundries use X-ray inspection to confirm the filtration devices are properly positioned in the opening of mold cavities. It is to be noted that handling of a filter or filtration device may be difficult to incorporate into an automated and robotized process. Indeed, filters are usually placed across the inlet of the cavity of the mold manually with a tool grasping them.
- the filtration devices are provided with original structural features allowing a better stiffness of the same to further prevent the possibility of being distorted and/or driven under the pressure of a flux of liquid metal or an alloy thereof which is passing there through.
- the invention relates to a filtration device for filtering a liquid metal or an alloy thereof, wherein said filtration device has a lower face, an upper face, a peripheral edge, a main portion, and a peripheral portion surrounding the main portion, the peripheral portion being shaped to form a concave cavity at the upper face and a convex rim at the lower face; and wherein a ridge portion extends the peripheral portion.
- the ridge portion is particularly useful for:
- Filtration device is extending up in contact with the spreader tip (or distribution pin):
- the invention relates to the above- mentioned first preferred aspect, wherein said filtration device is made of a rigidified fabric of heat resistant fibers or made of threads of heat resistant fibers, impregnated with a composition comprising a mixture of a product A and a product B:
- the product A being obtained by polymerisation of saccharide units; and the product B consisting of at least one inorganic colloidal binding agent, said composition being in a thermoset stage.
- said heat resistant fibers being glass fibers, silica fibers or a mixture thereof.
- the invention relates to the above- mentioned first preferred aspect, wherein the main portion is a dome having its summit oriented toward the upper face.
- the invention relates to the above- mentioned first preferred aspect, further provided with an insert made of a magnetisable material for handling of the filtration device with a tool provided with a magnet.
- the invention relates to the above- mentioned first preferred aspect, wherein the heat resistant fibers are glass fibers, silica fibers or a mixture thereof, and wherein the product A is obtained by caramelization of a mixture M comprising sucrose, water, and optionally at least one additive selected from the group consisting of acids, inorganic wetting agents and acid phosphate adhesives.
- the invention relates to the above- mentioned first preferred aspect, wherein the main portion has a frustoconical shape having its summit oriented toward the upper face.
- the invention relates to the above- mentioned first preferred aspect, further provided with an insert made of a magnetisable material for handling of the filtration device with a tool provided with a magnet.
- the invention relates to the above- mentioned first preferred aspect, wherein the heat resistant fibers are glass fibers, silica fibers or a mixture thereof, and wherein the product A is obtained by caramelization of a mixture M comprising sucrose, water, and optionally at least one additive selected from the group consisting of acids, inorganic wetting agents and acid phosphate adhesives.
- the invention relates to a filtration device for filtering a liquid metal or an alloy thereof, said filtration device being of the type having interconnected baskets, said baskets being provided with original structural features allowing a better stiffness of the same to further prevent the possibility of being distorted under the pressure of the flux of liquid metal or an alloy thereof, passing there through. More particularly, said filtration device is made of a first basket and a second basket,
- the first basket has an outer wall and a cavity defined by an inner wall, an end wall and an opening opposite to the end wall,
- the second basket has an outer wall and a cavity defined by an inner wall, an end wall and an opening opposite to the end wall,
- the opened end of the first basket is housed in the cavity of the second basket to define a filtration body having a structural shape and orientation and comprising a cavity, an upper face, a lower face, and a side face, wherein the end wall of the first basket corresponds to the upper face, and the end wall of the second basket corresponds to the lower face,
- the outer wall of the first basket when the outer wall of the first basket is sized to fit against the inner wall of the second basket, the outer wall of the second basket corresponds at least in part to the side face of the filtration body, or when the outer wall of the second basket is sized to fit against the inner wall of the first basket, the outer wall of the first basket corresponds at least in part to the side face of the filtration body;
- outer wall of the first basket has a top portion and side portion joined by a peripheral portion forming a rim; and the outer wall of the second basket has a bottom portion and a side portion joined by a peripheral portion forming a rim.
- the invention relates to the above- mentioned second preferred aspect, wherein the end wall of the first basket corresponds to the lower face of the filtration device, and the end wall of the second basket corresponds to the upper face of the filtration device,
- the invention relates to the above- mentioned second preferred aspect, wherein said filtration device further comprises a filtration pad within the cavity.
- the invention relates to the above- mentioned second preferred aspect, wherein said filtration device is made of a rigidified fabric of heat resistant fibers or made of threads of heat resistant fibers, impregnated with a composition comprising a mixture of a product A and a product B:
- the product A being obtained by polymerisation of saccharide units; and the product B consisting of at least one inorganic colloidal binding agent, said composition being in a thermoset stage.
- the invention relates to the above- mentioned second preferred aspect, further provided with an insert made of a magnetisable material for handling of the filtration device with a tool provided with a magnet.
- the invention relates to the above- mentioned second preferred aspect, wherein the heat resistant fibers are glass fibers, silica fibers or a mixture thereof, and wherein the product A is obtained by caramelization of a mixture M comprising sucrose, water, and optionally at least one additive selected from the group consisting of acids, inorganic wetting agents and acid phosphate adhesives.
- the invention further relates to a third preferred aspect of the invention, said third embodiment having an innovative «M» shape.
- This particular «M» shaped filtration device can be made of any appropriate material, including the conventional fabric of metal threads for the filtration of liquid metal or an alloy thereof during the casing of an article into a mold. However, it is preferred having this «M» shaped filtration device made of a rigidified fabric of heat resistant fibers.
- the invention relates to the above-mentioned third preferred aspect, wherein said filtration device is a fabric of metal threads or a fabric of rigidified fibers, said filtration device having a shape that is to be housed within a housing of a casting mold provided with at least one filing inlet, wherein the housing is a parallelepiped, and wherein the fabric is defining a «M» shaped filter, said «M» shape filter having a pair of parallel branches which are to be respectively substantially coplanar with a pair of opposite end of the parallelepipedic housing, and an arch portion having a tip which is either to be oriented toward the cavity, or opposite to the cavity.
- the invention relates to the above- mentioned third preferred aspect, wherein the tip of the arch portion is oriented opposite to the cavity.
- the invention relates to the above- mentioned third preferred aspect, wherein the the fabric is made of stainless steel threads woven together.
- the invention relates to the above- mentioned third preferred aspect, wherein the filtration device is made of a rigidified fabric of heat resistant fibers woven together.
- the filtration device is made of a rigidified fabric of heat resistant fibers woven together.
- a «M» shaped filtration device shows the following unexpected benefits: o Improved consistency of casting pour times as a result of weaving of material, in contrast to relative high variation in pour times with conventional Ceramic Foam Filters
- the arch provides additional surface area for metal flow distribution and filtration.
- the invention relates to the above- mentioned third preferred aspect, wherein the rigidified fabric of heat resistant fibers obtained by thermosetting a composition comprising a mixture of a product A and a product B;
- the product A being obtained by polymerisation of saccharide units; and the product B consisting of at least one inorganic colloidal binding agent impregnated in a fabric of heat resistant fibers that is substantially free of one or more sizing agents, said sizing agents consisting of organic polymers.
- the invention relates to the above- mentioned third preferred aspect, wherein the heat resistant fibers are glass fibers, silica fibers or a mixture thereof, and wherein the product A is obtained by caramelization of a mixture M comprising sucrose, water, and optionally at least one additive selected from the group consisting of acids, inorganic wetting agents and acid phosphate adhesives.
- Aforesaid filtration devices can be made of any appropriate material, such as a grid of metal threads according to techniques well known in the art. However, it is preferred that the filtration devices be made of a fabric of heat resistant fibers, and more particularly of a fabric of a rigidified heat resistant material as defined in the international application PCT/CA2015/050047.
- a composition for preparing the rigidified fabric made of heat resistant fibers or threads of heat resistant fibers, preferably of woven threads made of heat resistant fibers comprises a mixture of a product A and a product B: the product A being obtained by polymerisation of carbohydrate units, natural or synthetic, preferably a saccharide, and more preferably a sugar such as glucose, fructose, galactose, sucrose, maltose, lactose, etc.; and the product B consisting of at least one additive such as a binding agent.
- said composition comprises a mixture of a product A and a product B;
- the product A being obtained by caramelization of a mixture M comprising:
- the product B consisting of at least one inorganic colloidal binding agent.
- the product A being obtained by polymerisation of carbohydrate units, natural or synthetic, preferably a saccharide, and more preferably a sugar such as glucose, fructose, galactose, sucrose, maltose, lactose, etc.; and the product B consisting of at least one additive such as a binding agent; said method comprises the steps of:
- the rigidified fabric is made of woven threads made of glass fibers, silica fibers or a mixture thereof.
- the composition for preparing the rigidified fabric made of heat resistant fibers or made of threads of heat resistant fibers, said heat resistant fibers being glass fibers, silica fibers or a mixture thereof comprises a mixture of a product A and a product B; the product A being obtained by caramelization of a mixture M comprising: sucrose, water, and optionally at least one additive selected from the group consisting of acids, inorganic wetting agents and acid phosphate adhesives; and the product B consisting of at least one inorganic colloidal binding agent.
- the rigidified fabric is made of woven threads of glass fibers, silica fibers or a mixture thereof.
- the sucrose may be of any kind commonly used to make a «caramel».
- the sucrose is a food-grade, refined and granulated sucrose (e.g. table sugar).
- the water may consist of any kind of water allowing to make a «caramel», including tap water, distilled water, demineralized water, etc.
- the water is tap water.
- the acid may be phosphoric acid, sulfuric acid, citric acid, acetic acid or a mixture of at least two of them.
- the acid may be phosphoric acid.
- the inorganic wetting agent may be aluminum ammonium sulfate, magnesium sulfate, aluminum sulfate, calcium sulfate or a mixture of at least two of them. More preferably, the inorganic wetting agent may be aluminum ammonium sulfate.
- the acid phosphate adhesive may be calcium phosphate, magnesium phosphate, aluminum sulfate or a mixture of at least two of them. More preferably the acid phosphate adhesive may be calcium phosphate.
- the at least one inorganic colloidal binding agent may consist of a colloidal silica, a colloidal alumina, a colloidal zirconia or a mixture of at least two of them.
- said at least one inorganic colloidal binding agent is a colloidal silica.
- said at least one inorganic colloidal binding agent may consist of colloidal silica dioxide, such as for example a colloidal silica dioxide which is a colloidal dispersion of submicron-sized silica particles in the form of tiny spheres, in an alkaline aqueous solution.
- the inorganic colloidal binding agent is a colloidal dispersion of submicron-sized silica particles in the form of tiny spheres, in an alkaline aqueous solution and sold under the trademark NALCO 1 144®.
- Said NALCO 1 144® has the following properties:
- the mixture M comprises:
- the composition defined hereinabove wherein phosphoric acid originates from a mixture of 75 wt % H3PO4 and 25 wt % water, the amount of water being part of the total amount of water of the composition, the aluminium ammonium sulfate is AINH ⁇ SO ⁇ hbO, and the calcium phosphate monobasic is Ca(H2P04)2 «2H 2 0.
- said composition comprises from 50 wt. % to 85 wt. % of the product A and from 15 wt. % to 50 wt. % of the product B.
- said composition may comprise about 66 wt. % of the product A and about 34 wt. % of the product B.
- the caramelization is carried out by heating the mixture M at a boiling temperature, preferably between 100°C and 105°C, more preferably between 100°C and 103°C, for a period of time varying from 5 to 10 minutes, more preferably about 5 minutes, and then allowing the resulting product A to cool.
- the at least one inorganic colloidal binding agent is added to the product A by mixing.
- the rigidified fabric is made of threads of heat resistant fibers selected from the group consisting of acids, inorganic wetting agents and acid phosphate adhesives, said threads having a diameter varying from 0.864 mm to 0.533 mm, and the fabric having a meshing varying from 0.94 mm to 0.255 mm, and from 50.9% to 35.9 % of openings with respect to the total surface of the fabric.
- the heat resistant fibers are made of E- Glass, S-Glass or High Silica Glass. More preferably, it is to be noted that glass fibers or threads of glass fibers may originate from a fabric of glass fiber well known to skilled workmen and easily available on the market, said fabric being treated to remove a polymeric sizing (such as starch) that is present on the fibers (especially to protect them during their processing/manipulation).
- a polymeric sizing such as starch
- a method for the preparation of a rigidified fabric made of heat resistant fibers or made of threads of heat resistant fibers comprising the steps of:
- step b) subjecting the fabric impregnated with the composition, as obtained from step a), to a heating treatment at a temperature of about 101 °C to 160°C to place the composition impregnated in said fabric into a softened thermoplastic state, and optionally allowing the fabric so obtained to cool;
- step c) optionally forming the fabric obtained from step b) into a desired shape and optionally allowing the fabric so obtained to cool;
- thermosetting treatment by heating it to a thermosetting temperature to thermoset the thermoplastic composition impregnated in the fabric in order to rigidify the fabric by cross-linking of the heat resistant fibers or the heat resistant fibers of the threads.
- step b) - subjecting the fabric impregnated with the composition, as obtained from step a), to a heating treatment at a temperature of about 101 °C to 160°C to place the composition impregnated said fabric into a softened thermoplastic state, and optionally allowing the fabric so obtained to cool;
- thermoplastic fabric obtained from step b) or c) being thermosettable into a rigid fabric when subjected to a thermosetting treatment at a thermosetting temperature to thermoset the thermoplastic composition impregnated in the fabric in order to rigidify the fabric by cross-linking of the heat resistant fibers or heat resistant fibers of the threads.
- another method for preparing a rigidified fabric made of heat resistant fibers or made of threads of heat resistant fibers comprising the step of subjecting the thermoplastic fabric as defined hereinabove to a thermosetting treatment by heating it to a thermosetting temperature to thus thermoset the thermoplastic composition impregnated in the fabric in order to rigidify the fabric by cross-linking of the heat resistant fibers or the heat resistant fibers of the threads.
- a very referred aspect of the fabric of glass fiber that can be used as a starting material are fabrics made of threads of glass fibers coated with starch. More particularly, said fabric may be selected amongst those listed in the following table: Fiberglass filtration product - with starch coating
- the product 40L mentioned hereinabove is particularly preferred as starting material.
- FIG. 1 a partial view of a network of a fabric of threads of glass fibers, said threads being provided with a sizing material, according to the prior art; a partial view of a network of a fabric of threads of glass fibers, after having removed the sizing material (i.e. devoided of sizing material); a schematic view of a two-rollers impregnator to impregnate a fabric of Figure 2 with a liquid composition; a perspective view of a filtration device according to the invention; a top plan view of the filtration device of Figure 4; a cross sectional view of filtration device of Figure 5, according to line V -
- V a partial schematic illustration of the filtration device of Figures 4 to 6 positioned in a low pressure casting installation, between a seat portion of an upper end of a rising tube and a diffuser positioned at a filling inlet of a mold (according to the invention); a schematic illustration of a low pressure casting installation with the filtration device illustrated in Figures 4 to 7.
- FIG. 14 a partial perspective view of a filtration device where the filtration body comprises the first basket and the second basket, and a filtration pad housed within a cavity of the filtration body;
- Figure 15 a partial schematic illustration of the filtration device of Figure 13 positioned in a low pressure casting installation, between a seat portion of an upper end of a rising tube and a diffuser positioned at a filling inlet of a mold (according to the invention);
- Figure 16 a schematic illustration of a low pressure casting installation with the filtration device illustrated in Figure 13.
- Figure 17 a schematic perspective view of a two-part mold
- Figure 18 a schematic perspective view of one part of the two-part mold
- Figure 19 a perspective view of a ceramic foam filter according to the prior art
- Figure 20 a cross sectional perspective view according to XII IV-XII IV of the part of mold of figure 18 with a ceramic foam filter positioned in the housing (prior art);
- Figure 21 a rigidified fabric filtration device having a «M» shape
- Figure 22 a schematic perspective view of one part of the two-part mold with the
- a composition was prepared as follows:
- a mixture M was prepared by admixing the following ingredients together in a stainless steel container. More particularly, the ingredients of the mixture consist of:
- sucrose Food graded table sucrose ⁇ i.e. table sugar) sold by Lantic Inc. under the trade name Lantic (hereinafter called sucrose in the present example).
- Tap water as available from the Applicant's laboratory facilities located in the city of Sherbrooke, Quebec, Canada.
- Laboratory grade phosphoric acid 75% wt. (i.e. a mixture of 75 wt % H3PO4 and 25 wt % water).
- the resulting homogeneized mixture was subjected to heating until a temperature of 100°C to 103°C was reached for at least 5 minutes, to thereby form a caramel defining said product A. Said product A was thereafter allowed to cool at room temperature.
- a product B which is a colloidal dispersion of submicron-sized silica particles in the form of tiny spheres, in an alkaline aqueous solution and sold under the trademark NALCO 1144®, said NALCO 1144® having the following properties:
- a fabric 107 (see Figure 2) of glass fibers that is substantially free of a sizing material consisting of starch was prepared.
- a fabric 104 of glass fibers consisting of E- Glass threads 108 coated with a layer 1 10 of starch (as a sizing agent) was subjected to a heat treatment in an oven at 450°C for about 2 minutes, to burnout said starch (in the presence of oxygen) and thereby remove the sizing agent.
- Figure 1 represents the fabric 104 with the threads 108 coated with the layer 1 10 of starch
- the Figure 2 represents the fabric 107 with the threads 108.
- Fabrics 104 and 107 are provided with openings 112. More particularly, the fabric 104 is of the type 40L as defined hereinabove.
- a rigidified, thermoplastic fabric of glass fibers was prepared according to a method wherein a fabric of glass fibers as obtained from example 2 was impregnated with the composition as defined in example 1 , to thus obtain a fabric impregnated with said composition.
- the fabric was successively passed in the a reservoir containing said composition and then between a pair of opposite rubber-rolls of a two- rollers impregnator, as schematically illustrated in the enclosed Figure 3. Said two-rollers impregnator is well known to skilled workman and does not need to be explained in details.
- a composition 101 was contained in a reservoir 103 located above a pair of rubber-rolls 105.
- the fabric 107 was passed successively across the composition 101 and then between the pair of opposite rubber-rolls 105, which are pressed one against the other, to push an amount of the composition within the openings of the fabric 107.
- the impregnated fabric so obtained was then subjected to a heating treatment in a continuous oven at a temperature of about 160°C for about 2 minutes to place the composition impregnated therein into a softened thermoplastic state.
- thermosettable fabric so obtained i.e. impregnated with the composition transformed into a thermoplastic state
- the thermosettable fabric so obtained was ready to be used for further treatments such as an optional forming the thermoplastic fabric into a desired size and/or shape, and then a thermosetting treatment to thermoset the composition and provide a rigidified fabric by cross-linking of the heat resistant glass fibers. If not used immediately, the fabric may be allowed to cool at room temperature.
- the rigidified fabric so obtained can be used as a filter for liquid metal as such liquid aluminum or aluminum alloy.
- This rigidified fabric which originates from a 40L type fabric of glass fiber as defined hereinabove, is provided with openings of 0.0255cm 2 .
- this filter showed to be as efficient as those of the prior art without the drawbacks.
- thermoplastic fabric obtained from example 3 cooled at room temperature, was cut into a piece of 3 inches x 3 inches and then placed in a hot mold consisting of a pair of opposite mold halves, to thereby soften and mold the piece of fabric into a desired shape by compression-moulding. Then, the shaped fabric was allowed to cool.
- the shaped fabric so obtained was ready to be used for further treatments such as a thermosetting treatment to thermoset the composition and provide a rigidified fabric by cross-linking of the heat resistant glass fibers.
- the shaped fabric obtained from example 5 was subjected to a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidify the fabric by cross-linking of the glass fibers of the threads.
- the shaped rigidified fabric so obtained can be used as a filter for liquid metal as such liquid aluminum or aluminum alloy, especially in a low pressure casting process.
- This shaped rigidified fabric which originates from a 40L type fabric of glass fiber as defined hereinabove, is provided with openings of 0.0255cm 2 .
- this filter showed to be as efficient as those of the prior art made of metallic threads, without the drawbacks.
- the fabric obtained from example 3 was cut into a piece of 3 inches x 3 inches, and while being still in a softened thermoplastic state, placed in a cold mold consisting of a pair of opposite mold halves, to thereby obtain a fabric into a desired shape by compression-moulding.
- the shaped fabric so obtained was subjected to a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidify the fabric by cross-linking of the glass fibers.
- the shaped rigidified fabric so obtained can be used as a filter for liquid metal as such liquid aluminum or aluminum alloy, especially in a low pressure casting process.
- this filter showed to be as efficient as those of the prior art made of metallic threads, without the drawbacks.
- the fabric obtained from example 3 had cooled at room temperature, said fabric may be reheated to the softened thermoplastic state by any appropriate means.
- a rigidified fabric of glass fibers F was prepared according to a method wherein a fabric 107 of threads 108 of glass fibers 1 10 (see Figure 9 and 10) as obtained from example 2 was impregnated according to example 3 with the composition 101 defined in example 1 , to thus obtain a fabric impregnated with said composition.
- a composition 101 was contained in a reservoir 103 located above a pair of rubber-rolls 105.
- the fabric 107 was passed successively across the composition 101 and then between the pair of opposite rubber-rolls 105, which are pressed one against the other, to push an amount of the composition within the openings existing between fibers of the threads 108 forming the fabric 107.
- the pressure against the fabric 107 was stopped, an amount of the composition 101 pushed within the openings of the threads 108 was retained within said threads (e.g. by capillary suction) thereby leaving surfaces of the fabric substantially depleted of excess amount of the composition, and another amount of the composition not retained within the fabric, was adhered to the rubber-rolls and returned to the reservoir 103.
- the impregnated fabric so obtained was then subjected to a heating treatment in a continuous oven at a temperature of about 160°C for about 2 minutes to place the composition impregnated therein into a softened thermoplastic state.
- the fabric F so obtained i.e. impregnated with the composition transformed into a thermoplastic state
- was ready to be used for further treatments such as an optional forming the thermoplastic fabric into a desired size and/or shape, and then a thermosetting treatment to thermoset the composition and provide a rigidified fabric by cross-linking of the heat resistant glass fibers of the threads. If not used immediately, the fabric may be allowed to cool at room temperature.
- the shaped fabric so obtained was ready to be used for further treatments such as a thermosetting treatment to thermoset the composition and provide a rigidified fabric by cross-linking of the heat resistant glass fibers of the threads of glass fibers.
- the fabric F obtained from example 8 was cut into a piece of 3 inches x 3 inch, and while being still in a softened thermoplastic state, placed in a cold mold consisting of a pair of opposite mold halves, to form a filtration device 201a (see figures 4 and 5) having a particular structural shape and orientation, by compression-moulding. Compression moulding is carried out at about 150°C.
- the filtration device 201 a was subjected to a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidity the fabric by cross-linking of the glass fibers.
- a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidity the fabric by cross-linking of the glass fibers.
- the fabric obtained from example 8 had cooled at room temperature, said fabric may be reheated to the softened thermoplastic state by any appropriate means for moulding, and then subjected to the thermosetting treatment.
- This filtration device 201a made of said rigidified fabric, which originates from a 40L type fabric of glass fiber as defined hereinabove, is provided with openings of 0.0255cm 2 .
- the filtration device 201a can be used in a low pressure casting installation 202a comprising:
- a mold 205a preferably made from a pair of opposite parts 205'a and 205'a, the part 205"a being mobile to allow an easy removal of the molded article, said mold 205a being provided with a filing inlet 207a, a cavity 209a and a diffuser 211a mounted across the filling inlet 207a;
- the resulting article After cooling of the liquid aluminum alloy contained in the cavity 209a to form the molded article, and removal of the same form the cavity 209a, the resulting article is provided with the filtration device trapped in a protrusion.
- the air initially contained in the cavity 209a is evacuated via openings 227a.
- the diffuser 211 a applies a slight pressure against the main portion 257a of the filtration device 201a, in order to help maintaining the filtration device 201a in place during the priming of the same. Indeed, it is well known that the during the priming phase of a filter, the pressure applied by the liquid starting to flow there through is greater and then said pressure falls when the flow of liquid is established.
- the filtration device 201a is made of at least one ply of a fabric of rigidified heat resistant fibers.
- This filtration device 201a comprises a lower face 251a, an upper face 253a, a peripheral edge 255a, a main portion 257a, and a peripheral portion 259a surrounding the main portion.
- the main portion 257a and a part of the peripheral portion 259a are to be positioned across the upper opening 221a.
- the peripheral portion 259a forms a concave cavity 261a at the upper face 253a and a convex rim at the lower face 251a, said convex rim 261 a being oriented downwardly, the upper face of the main portion 257a is positioned against the diffuser 211a, and the peripheral portion 259a being in part positioned against the seat portion 223a.
- the filtration device 201 a is further provided with a ridge portion 275a. This ridge portion 275a further reinforce the stiffness of the resulting filtration device to minimize the risk of having the filtration device 201a deformed under the pressure of a liquid metal or alloy passing there through.
- this ridge portion which can extend horizontally as illustrated or at an angle, is designed to rest on a corresponding portion of the seat portion 223a.
- This ridge portion 275a contributes to make easier the correct centering of the filtration device in the mold and/or rising tube.
- a stainless steel 229a staple can be provided at the center of the main portion 257a.
- This staple 229a allows the handling of the filtration device 201a with a tool provided with a magnet, for an easy positioning of the peripheral portion 259a and ridge portion 275a against a corresponding seat portion 223a (especially with a magnetic tool and more preferably with a magnetic tool operated by a robot). Also, the presence of the stapple 229a allows to confirm the proper positioning of the filtration device 201a against the seat portion 223a (e.g with X-rays devices).
- the particular structure and orientation of the filtration device 201 a in the low pressure casting installation 202a allows to efficiently filter the liquid aluminum alloy before filling of the cavity 209a. More particularly, said filtration device 201a showed to be as efficient as those of the prior art made of metallic threads, without the drawbacks.
- the first basket 451a has an outer wall 453a and a cavity 455a defined by an inner wall 457a, an end wall 459a and an opening opposite 461a to the end wall 459a.
- the second basket 471a has an outer wall 473a and a cavity 475a defined by an inner wall 477a, an end wall 479a and an opening opposite to the end wall 479a.
- the opened end of the first basket 451a is housed within the cavity 475a of the second basket 471 a to define a filtration device 401 a having a structural shape and orientation and being provided with a cavity 493a, an upper face 495a, a lower face 497a, and a side face 499a.
- the filtration device 401a is optionally further provided with a filtration pad 500a housed within said cavity 493a.
- the end wall 459a of the first basket 451a corresponds to the lower face 493a of the filtration body 401a
- the end wall 479a of the second basket 471a corresponds to the upper face 495a of the filtration body 401a
- the outer wall 453a of the first basket 451a is sized to be friction fit against the inner wall 477a of the second basket 471a
- the outer wall 453a of the second basket 471a corresponds at least in part to the side face 499a of the filtration body 491 a (i.e. the filtration device 401 a).
- the outer wall 479a of the second basket 471 a can be sized to be friction fit against the inner wall 457a of the first basket 451a, the outer wall 473a of the first basket 471a corresponds at least in part to the side face 499a of the filtration body 491 a (i.e. the filtration device 401 a).
- upper face 495a of the filtration device 401a has a main portion 492a and the lower face 497a of the filtration device 401a has a peripheral portion 494a, said main portion 495a being for positioning against a diffuser 411a positioned across a filling inlet 407a of a mold of the low pressure casting installation 402a; and said peripheral portion 494a is for positioning across an upper opening 421 a of a rising tube 413a of a low pressure casting installation 402a, said peripheral portion 494a being oriented for positioning against a seat portion 423a of the rising tube 413a surrounding the upper opening 421 a.
- the first basket and the second basket are each provided with a structural feature that allow to further prevent the filtration device 401a to be deformed by the pressure of a flow of liquid metal or alloy passing there through. More particularly, the first basket 451a has a bottom portion and side portion joined by a peripheral portion 452a forming a rim 454a; and the outer wall of the second basket 471a has a top portion and a side portion joined by a peripheral portion 472a forming a rim 474a.
- the filtration device 401a so obtained which is still in a thermoplastic stage, was ready for further treatments such as a thermosetting treatment to thermoset the composition and provide the filtration device 401a made of a rigidified fabric by cross-linking of the heat resistant glass fibers which forming the threads of the fabric.
- a thermosetting treatment to thermoset the composition and provide the filtration device 401a made of a rigidified fabric by cross-linking of the heat resistant glass fibers which forming the threads of the fabric.
- the thermoset filtration device 401a is prepared by submitting the thermoplastic filtration device to a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidify the fabric by cross-linking of the glass fibers forming the threads of the fabric.
- the filtration device 401a is ready for use for filtering a liquid metal as such liquid aluminum or aluminum alloy, especially in a low pressure casting process.
- this filtration device 401a was made of said rigidified fabric, which originates from a 40L type fabric of glass fiber as defined hereinabove, is provided with openings of 0.0255cm 2 .
- this filtration device 401a showed to be as efficient as those of the prior art made of metallic threads, without the drawbacks.
- the filtration device 401a can be used in a low pressure casting installation 402a comprising:
- a mold 405a preferably made from a pair of opposite parts 405'a and 405'a, the part 405"a being mobile to allow an easy removal of the molded article, said mold 405a being provided with a filing inlet 407a, a cavity 409a and a diffuser 411a mounted across the filling inlet 407a;
- the resulting article After cooling of the liquid aluminum alloy contained in the cavity 409a to form the molded article, and removal of the same form the cavity 409a, the resulting article is provided with the filtration device trapped in a protrusion.
- the air initially contained in the cavity 409a is evacuated via openings 427a.
- the diffuser 411a applies a slight pressure against the main portion 457a in order to help maintaining the filtration device 401a in place during the priming of the same. Indeed, it is well known the during the priming phase of a filtration device, the pressure applied by the liquid starting to flow through said filtration device is greater, and then said pressure falls when the flow of liquid is established. As mentioned above, when used for the filtration of liquid aluminum, this filtration device 401a showed to be as efficient as those of the prior art made of metallic threads, without the drawbacks.
- the fabric obtained from example 3 was cut into a piece of 5 inches x 21 ⁇ 2 inches, and while being still in a softened thermoplastic state, placed in a cold mold consisting of a pair of opposite mold halves, to thereby obtain a fabric into a desired shape by compression-moulding.
- the fabric so obtained was «M» shaped.
- the «M» shaped fabric so obtained was subjected to a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidify the fabric by cross-linking of the glass fibers.
- the shaped rigidified fabric so obtained can be used as a filter for liquid metal as such liquid aluminum or aluminum alloy, especially in a gravity casting process.
- the fabric obtained from example 3 was cut into a piece of 5 inches x 21 ⁇ 2 inches, and while being still in a softened thermoplastic state, placed in a hot mold consisting of a pair of opposite mold halves, to thereby obtain a fabric into a «M» shape by compression-molding.
- the shaped fabric so obtained was «M» shaped.
- the «M» shaped fabric was subjected to a thermosetting treatment in an oven at 450°C for 2 minutes, in order to rigidify the fabric by cross-linking of the glass fibers.
- the «M» shaped rigidified fabric 643 (see Figure 21) so obtained can be used as a filter for liquid metal as such liquid aluminum or aluminum alloy, especially in a gravity casting process.
- This example illustrates the casting of an article made of aluminum in a two- part mold 621.
- This two-part mold 621 comprises a part 623 and a part 625 (see Figures 17 and 18) which are each provided with a cavity defining when both parts are pressed one against the other, a mold cavity 629, a cavity filing inlet 631 , a mold conduit 633 and a mold housing 635.
- the mold conduit 633 has an opening 637 and an opening 639, the opening 639 being in fluid communication with the mold cavity 629.
- the part 625 is further provided with an opening 626 allowing the air contained within the mold cavity 629 to escape during the filling of said mold cavity 629 with liquid aluminum.
- a ceramic foam filter 641 which was commonly used in prior art molding process.
- Said ceramic foam filter 641 was a monolithic parallelepiped and occupied the entirety of the capacity defined by the housing 635.
- said ceramic foam filter 641 was replaced by a «M» shape filter 643 as obtained from example 13. More particularly, the «M» shape filter 643 was of such size to have its volume is completely housed within the mold housing 635, with parallel branches 636 substantially coplanar with opposite wall 635a of the housing 635 and the tip of the arch 638 of the «M» oriented opposite to the mold cavity 629.
- liquid aluminum was poured in the opening 637 to flow through the conduit 633, the «M» shape filter positioned in the housing 635, and cavity filing inlet and the cavity 629 itself. More particularly, this process of pouring liquid aluminum into the mold is called gravity casting process.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Textile Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Filtering Materials (AREA)
- Filtration Of Liquid (AREA)
- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
- Manufacture And Refinement Of Metals (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/224,028 US10434569B2 (en) | 2014-01-23 | 2016-07-29 | Filtration device for the filtration of a liquid metal or an alloy thereof, and a filtration method using said filtration device |
PCT/CA2017/050908 WO2018018156A1 (en) | 2016-07-29 | 2017-07-28 | Filtration device for the filtration of a liquid metal or an alloy thereof, and a filtration method using said filtration device |
Publications (2)
Publication Number | Publication Date |
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EP3490692A1 true EP3490692A1 (en) | 2019-06-05 |
EP3490692A4 EP3490692A4 (en) | 2019-07-17 |
Family
ID=61015232
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP17833157.5A Withdrawn EP3490692A4 (en) | 2016-07-29 | 2017-07-28 | Filtration device for the filtration of a liquid metal or an alloy thereof, and a filtration method using said filtration device |
Country Status (8)
Country | Link |
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EP (1) | EP3490692A4 (en) |
JP (1) | JP2019529113A (en) |
KR (1) | KR20190031507A (en) |
CN (1) | CN109562310A (en) |
BR (1) | BR112019001620A2 (en) |
CA (1) | CA3030877A1 (en) |
MX (1) | MX2019001227A (en) |
WO (1) | WO2018018156A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA3091403A1 (en) | 2018-02-23 | 2019-08-29 | Pyrotek High Temperature Industrial Products Inc. | Coating composition and method of making same |
CN110303142B (en) * | 2019-08-13 | 2021-08-27 | 巢湖宜安云海科技有限公司 | Magnesium alloy casting gate device |
CN110586919B (en) * | 2019-09-12 | 2021-10-15 | 陕西专壹知识产权运营有限公司 | Suction pump type slag removing method for molten aluminum |
CN112059165B (en) * | 2020-08-31 | 2021-09-28 | 安徽省含山县威建铸造厂(普通合伙) | Preparation method of molten steel filter screen for casting |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4154289A (en) * | 1976-04-06 | 1979-05-15 | Marie-Therese Simian | Gating system |
FR2684563B1 (en) * | 1991-12-04 | 1994-05-27 | Daussan & Co | FILTER FOR LIQUID METAL CONSISTING OF PLATES WITH HOLES IN REFRACTORY MATERIAL. |
US6254810B1 (en) * | 1998-02-09 | 2001-07-03 | Cerminco Inc. | Method for coating profecting and rigidifying a fabric made of heat-resistant fibers |
DE19859031C5 (en) * | 1998-12-21 | 2012-08-02 | ASTI Gießereigeräte GmbH | Arrangement of a cast filter, casting filter and its use |
GB0613001D0 (en) * | 2006-06-30 | 2006-08-09 | Juma Kassim A | A filter |
US8939193B2 (en) * | 2006-08-23 | 2015-01-27 | Peio Todorov Stoyanov | Method and apparatus for filtered and controlled flow metal molding |
CN103736970B (en) * | 2013-11-27 | 2016-06-15 | 江苏凯特汽车部件有限公司 | Bowl-shape drainage screen is used in aluminum alloy wheel of vehicle casting |
SI3102732T1 (en) * | 2014-01-23 | 2019-12-31 | Les Produits Industriels De Haute Temperature Pyrotek Inc. | A composition, a method for preparing said composition, a method for preparing a rigidified fabric, the rigidified fabric so obtained, a filtration device, methods for the manufacture of the filtration device, installation, process and use of said filtration device for the filtration of a liquid metal or an alloy thereof |
CN204262287U (en) * | 2014-07-29 | 2015-04-15 | 海福和博克公司 | Casting filter |
-
2017
- 2017-07-28 BR BR112019001620A patent/BR112019001620A2/en not_active Application Discontinuation
- 2017-07-28 KR KR1020197004309A patent/KR20190031507A/en unknown
- 2017-07-28 JP JP2019504777A patent/JP2019529113A/en active Pending
- 2017-07-28 WO PCT/CA2017/050908 patent/WO2018018156A1/en active Search and Examination
- 2017-07-28 MX MX2019001227A patent/MX2019001227A/en unknown
- 2017-07-28 CA CA3030877A patent/CA3030877A1/en not_active Abandoned
- 2017-07-28 EP EP17833157.5A patent/EP3490692A4/en not_active Withdrawn
- 2017-07-28 CN CN201780046951.4A patent/CN109562310A/en active Pending
Also Published As
Publication number | Publication date |
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KR20190031507A (en) | 2019-03-26 |
CN109562310A (en) | 2019-04-02 |
EP3490692A4 (en) | 2019-07-17 |
MX2019001227A (en) | 2019-06-03 |
WO2018018156A1 (en) | 2018-02-01 |
JP2019529113A (en) | 2019-10-17 |
CA3030877A1 (en) | 2018-02-01 |
BR112019001620A2 (en) | 2019-06-11 |
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