May, 10

STELEX* ZR
Ceramic Foam Filters For Steel Castings
Product STELEX ZR is a ceramic foam filter for steel casting applications. STELEX ZR
Description filters are produced from partially stabilized zirconia, a highly stable refractory
material offering the best combination of thermal shock resistance, resistance to
chemical attack, hot strength and creep resistance. STELEX ZR filters are
intended for use in all grades of steel at pouring temperatures up to 3050°F.

STELEX ZR filters smooth metal flow in the mold when used in a conventional
gating system. They also remove non-metallic inclusions such as furnace and
ladle slag, furnace and ladle refractory materials, molding sand, products of
deoxidation, and products of reoxidation.

The requirements for filtration are derived from the need to improve quality,
productivity, and profitability. Proper filter use reduces internal re-work costs in
welding and cleaning, reduces the rate of casting returns, improves mach
inability, improves machine tool life, and increases casting yield. Filtration is
among the most cost-effective and flexible means of addressing the need for
Clean Metal and Metallurgical Consistency.

Product Length/ Frontal

Filter Size Product Packaging Thickness
Range Width Area
(mm) Code (pcs/ctn) (in)
(in) (in2)
50 Diax20/10 PPI 504550 240 1.94 +/- .06 2.95 0.75
50 Diax25/10 PPI 274210 240 1.94 +/- .06 2.95 1.00
60 Diax20/10 PPI 563100 117 2.34 +/- .06 4.30 0.75
60 Diax25/10 PPI 256050 117 2.34 +/- .06 4.30 1.00
75 Diax25/10 PPI 335040 117 2.93 +/- .06 6.94 1.00
90 Diax25/10PPI 316190 117 3.51 +/- .08 9.86 1.00
100 Diax25/10 PPI 141000 54 3.92 +/- .06 12.06 1.00
125 Diax30/10 PPI 427500 40 4.92 +/- .06 19.00 1.20
150 Diax30/10 PPI 333730 16 5.90 +/- .06 27.33 1.20
175 Diax35/10 PPI 108170 14 6.89 +/- .06 37.28 1.38
200 Diax35/10 PPI 107820 9 7.87 +/- .06 48.69 1.38
50x50x20/10 PPI 307600 240 1.96 +/- .06 3.85 0.75
55x55x25/10 PPI 261550 240 2.14 +/- .06 4.59 1.00
75x75x25/10 PPI 160950 117 2.93 +/- .06 8.59 1.00
100x100x25/10 PPI 304600 54 3.92 +/- .06 15.37 1.00
125x125x30/10 PPI 160300 40 4.92 +/- .08 24.21 1.20
150x150x30/10 PPI 548550 16 5.90 +/- .08 34.81 1.20
200x200x35/10 PPI 364480 9 7.87 +/- .06 48.69 1.38

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA

Product The following guidelines are intended to provide a baseline of information for
Application initial product evaluations.

POURING TEMPERATURE
To ensure consistency in priming and metal flow, metal should be poured at a
minimum of 125°F above its liquidus temperature. Typical minimum pouring
temperatures are 2880°F for carbon steel and 2770°F for stainless steel.

SUPERHEAT
To minimize the risk of mis-run when using filters in conventional runner systems,
it is desirable to superheat all grades of steel. The degree of superheat is
affected by the casting design and section thickness, and by the level of elements
that cause oxide-rich films to form on the surface of the molten steel, such as
aluminum and chromium. As a rule of thumb, pouring temperatures should be
increased by 50°F above the normal pouring temperatures. Also, every
reasonable precaution should be taken to minimize variations in pouring
temperatures.

The performance of STELEX ZR filters varies significantly by pouring

temperature, pouring rate, head of metal, residual elements, metal chemistry, and
placement in the mold. Users are strongly encouraged to conduct experiments to
determine the obtainable flow rate and flow capacity for each filter size.

DETERMINATION OF FILTER SIZE

Refer to Tables 1 & 2 in determining the proper filter size, inlet surface area, flow
rate, and flow capacity. Filter selection is a simple three-step process.

Step 1
Flow rate requirements: When determining the minimum filter area which will
maintain a proper mold filling rate, multiply the gating system choke area by 4.5.
Using the usable Frontal Area column from Table 1, choose the STELEX ZR
filters or filters which provides the required filter area.

Filter Area (inches2) ≥ 4.5 x Choke Area (inches2)

Step 2
Flow capacity requirements: Using the appropriate Capacity Range column of
Table 2, determine the filter or filters which will pass a sufficient amount of steel
for the application.

Step 3
After determining the recommended filter size based on the flow rate and flow
capacity requirements (Steps 1 & 2), the larger of the two filters would be used.
The user needs to confirm that the ladle used in pouring is capable of supplying
the desired amount of metal to the mold, specified in the Nominal Flow Rate
column of Table 2. If a bottom-pour ladle is utilized for pouring, take special
consideration in determining filter size. The ladle must be capable of delivering
sufficient metal at the beginning and end of the pour.

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA

Product Table 2: Flow Capacity and Flow Rate Capacity values for STELEX ZR ceramic
Application Con’t foam filters
Maximum Filtration Capacity (Lbs)
High Level of Low Level of Maximum
Deoxidation Products Deoxidation Products Flow Rate
Filter Size Carbon Stainless Carbon Stainless (lbs/sec)
(mm) Steel Steel Steel Steel
50 Diax20/10 PPI 65 85 98 127 8.4
50 Diax25/10 PPI 65 85 98 127 8.4
60 Diax20/10 PPI 94 122 141 183 13.0
60 Diax25/10 PPI 94 122 141 183 13.0
75 Diax25/10 PPI 147 191 220 286 23.0
90 Diax25/10 PPI 212 275 317 412 34.0
100 Diax25/10 PPI 261 339 391 508 46.0
125 Diax30/10 PPI 407 529 611 794 62.0
150 Diax30/10 PPI 586 762 879 1143 85.0
175 Diax35/10 PPI 798 884 1040 1562 111.0
200 Diax35/10 PPI 1043 1156 1360 2040 142.0
50x50x20/10 PPI 83 108 125 162 13.0
55x55x25/10 PPI 100 131 151 196 13.0
75x75x25/10 PPI 187 243 280 364 23.0
100x100x25/10 PPI 332 431 498 647 42.0
125x125x30/10 PPI 519 674 778 1011 63.0
150x150x30/10 PPI 747 970 1120 1456 87.0
200x200x35/10 PPI 1328 1724 1992 2588 155.0
** Flow Rate and capacity data was generated using Foseco’s METHODCALC* for steel filter application
software. The calculations for round filters assume a direct impingement application, 12-inch effective head
height, the filter as the choke, and a 2830oF pouring temperature from a lip pour ladle. The calculations for
square filters assume a FP1 filter print, 12-inch effective head height, the filter as the choke, and a 2830oF
pouring temperature from a lip pour ladle.

GATING DESIGN AND FILTER PLACEMENT

Optimal results are achieved using unpressurized gating systems. The choke
should be at or near the sprue.
STELEX ZR filters must be adequately supported to maintain integrity and to
prevent metal bypass. There are five basic filter positions, which are suitable for
the vast majority of steel filter application requirements. Please reference the
STELEX ZR Filter Print Data Sheet for more details on filter print design.
STELEX ZR filters prime more consistently when the filters are applied in a
horizontal position, at the base of the sprue. It is best to use the fewest number
of filters possible to ensure problem free priming and flow---a larger, single filter is
preferable to several smaller filters.
When pouring directly onto the face of the filter, take every precaution to minimize
the height from which metal is poured. Maintain the highest level of temperature
control possible to maintain superheat when pouring to minimize mis-runs. The
gating system should be designed to assure rapid filling and be more than
capable of accommodating the maximum delivery rate from the ladle. Assure full
metal delivery from the ladle to keep the sprue full during pouring to prevent
intermittent flow. Minimize the level of deoxidizers--particularly Al, Ti, and Zr--
used in maintaining a “clean” heat. Cleaner metal increases the filtration capacity
of steel filters and minimizes filtration costs.

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA

 CAUTION
FOSECO products are made from quality materials and are designed to serve with maximum efficiency and minimum risk. However, as with many substances used
in industry, health hazards may be present in the use of FOSECO products and, therefore, it is extremely important that the user familiarize himself with the warning
and handling instructions on the label and on the Occupational Safety and Health Data Sheet. Contact a FOSECO representative if further information is needed or
if the product is to be used in an unusual application.
Every effort is made to ensure the fitness of FOSECO products for their stated purpose, however, because FOSECO has no control over the use of its products, no
warranty can be made in regard to results attending their use or to possible adverse metallurgical consequences and side effects. You should read carefully the
Terms and Conditions of Sale which accompany the sale of any FOSECO product which you use.

* Trademark of the Foseco Foundry Division of the Vesuvius Group, used under license.

FOSECO, 20200 Sheldon Road, Brook Park, Ohio 44142-1360 USA

Telephone: 440-826-4548, Facsimile: 440-826-3434

Foseco is a division of Vesuvius USA Corporation, Illinois, USA