COATINGS F I LT R AT I O N FEEDING SYSTEMS M E LT S H O P R E F R A C TO R I E S M E TA L L U R G I C A L A N D P O U R I N G C O N T R O L BINDERS CRUCIBLES

SEDEX
The ceramic foam filter for iron castings
 SEDEX foundry filters
Proven technology a billion times over

Trusted performance
SEDEX foundry filters have been used by the foundry The application of SEDEX foundry filters in the
industry for more than 25 years. During this time, production of the most demanding castings facilitates
the filter and its application have been continuously achieving optimised mechanical and dynamic
improved in co-operation with leading foundry properties of the casting alloy. The use of conventional
engineers around the world. The use of SEDEX gating systems, even with generously dimensioned
foundry filters is a guaranteed way to produce quality, runner bars, is not sufficient to retain enough slag
cost effective castings. Consequently the use of and suspended reaction products to meet the high
SEDEX foundry filters has become state-of-the-art in quality standards of today‘s castings. These demands
many foundries. As the most commonly used foundry can be readily and consistently achieved with the help
filter in the world, SEDEX foundry filter are proven in of SEDEX foundry filters.
its ability to fulfill customer demands.

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Benefits of SEDEX application Application technique

++ Compact, short and direct systems Foseco offers high level customer support. Original layout
++ Less returns ++ Metallurgical investigation of casting defects
++ More free pattern plate area ++ O
 ptimisation of pattern plate layouts including
++ Lower melting costs per poured casting spray mould filling and solidification simulation

++ E ffective retention of non-metallic inclusions ++ Application support in the foundry

including slag and sand
++ Reduced scrap risk
Targeted layout
++ Increased process security
++ Improved physical properties of the casting
++ Improved accuracy of scrap diagnosis

Simulation and
optimisation of the layout

Improved layout

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 SEDEX foundry filters
Highest filtration efficiency and smooth mould filling

High filtration efficiency

The acknowledged effectiveness of SEDEX foundry The inclusion removal mechanism is known as
filters is a result of their foam structure. The deep bed filtration and is only provided by multi-
structure is based on open, interconnected pores dimensional structures like the SEDEX ceramic
providing a plurality of direction and velocity foam filters.
changes in the liquid metal flow. This leads to
intensive contact with the filter surface which The shape of an individual pore is like a penta-
allows small non-metallic particles to be retained gondodecahedron.
within the foam structure. The inlcusions are not
just sieved out on the product entry face.

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The structure of SEDEX filters efficiently retains sand The pictures below have been generated by real time
and slag as well as reaction products from magnesium x-ray investigations and illustrate the metal flow into
treatment. An often underestimated, but nevertheless the mould cavity when different filter types are used.
very important, advantage of ceramic foam filters is
their ability to reduce the turbulence in the molten
metal stream. This helps to ensure an even mould Retention of sand by the
filter structure
filling and protects the metal from re-oxidation.

Retention of silicate slag by

the filter structure

Metal flow into the mould cavity through an Metal flow into the mould cavity through a ceramic
Metal flow into the mould cavity without a filter extruded filter foam filter

Retention of magnesium
sulphide by the filter
structure

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 SEDEX foundry filters
Calculation of choke and filter area

The application of SEDEX foundry filters is performed

in three steps:

Step 1
Calculation of gating systems with filters 22,6 · G
The mould filling speed and filling pattern is
DA=
ρ·t ·ξ ·√H
determined by the dimensions and design of the
gating system. The time to complete the pouring
sequence is determined by the smallest cross-
section in the system. DA Downsprue area [cm2]
22,6 Constant
In the case of conventional gating systems, this G Poured weight [kg]
choke, or controlling section, is the total area of the ρ Density [g/cm³]
ingates. t Pouring time [s]
ξ Friction factor
In gating systems for use with SEDEX foundry filters,
the cross-section of the downsprue becomes the H Effective pouring height [cm]
smallest or controlling section for the system.

In the case of moulding lines where a standardised

downsprue is used, the controlling section must
be placed in the runner bar directly behind the
downsprue.

To ensure an even filling process within the mould

all runner bars should be located in the drag and all
ingates in the cope.

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 n Level of metallurgical contamination
n In the case of ductile iron the treatment technique,
ght %Mg alloy addition and the sulphur level before
treatment
ating system
n practice: The selected filter area can either be applied as a
single filter or in the case of a large area, a number
e(s) of smaller filters. In the latter case they should be
2 positioned as close as possible to the mould cavity so
that the maximum amount of inclusion material can
e increase in be collected.
ulence mould Filtration capacity is influenced by many process
s have to be variables, therefore the above values should only be
t, the runner regarded as guidelines.
bars and the
Filter capacity
quired. kg/cm2
Iron Alloy
Calculation of effective pouring height The following relationship between the gating system
NiResist, SiMo, D5
The filter area can either be applied as a single filter.
0.5 - 1.0
components Ductile
has (Inmold)
proven very successful in practice: In the case of larger castings, several filters can be
1.0 - 2.0 Ductile used. The filters should be positioned as close as
downsprue
2.0 - 4.0 Grey/Malleable runner ingate(s) possible to the mould cavity so that the maximum
amount of inclusion material can be removed.
1.0 experience
According to our application : 1.1 we
recommend that for high alloyed ductile iron (e.g.
: 1.2
NiResist or SiMo) a filter area which is 4 times as Filtration capacity is influenced by many process
big as the downsprue area. For ductile iron we
This gating system ratio with a progressive increase in
recommend a ratio of Downsprue:Filter area of 1:3,
variables, therefore the following values should only
cross-section
for grey and malleable encourages
iron we recommend quiet, low turbulence mould
at least be regarded as guidelines.
a·a filling.
a ratio of 1:2. These ratiosThe resulting
ensure that thecross-sectional
pouring areas have to be
H = h - 2·c time is determinedallocated
by the downsprue
according areatoand
thenotpattern layout. The runner Iron alloy Filter capacity kg/cm2
by the filter.
area is divided by the number of runner bars and the
Step 2
ingatefilter
areaarea,
by the number Grey and malleable iron 2.0 - 4.0
Determine the SEDEX type, numberof ingates required.
and porosity. The required filter area will be Ductile and compacted 1.0 - 2.0
influenced by theStep 2
following factors: graphite iron
Determination of the SEDEX filter size, type and porosity Alloyed and inmould 0.5 - 1.0
n The smallest cross-section in the gating system
n The required filter area will be influenced by
Filter capacity (kg/cm²) the treated ductile iron
n Poured weight following factors:
n Level of metallurgical contamination Based on application experience the following ratio of
n In the case of ductile iron the treatment technique, downsprue and filter area is receommended:
ght c ++ The
%Mg alloy addition andsmallest cross-section
the sulphur level before in the gating system
H = h- 2 treatment
ating system ++ Filter capacity (kg/cm²) Grey and malleable iron 1:2
n practice: The selected filter+area can either
+ Poured be applied as a
weight Ductile iron and compacted graphite 1:3
single filter or in the case of a large area, a number Alloyed and inmould treated ductile iron 1:4
e(s) of smaller filters. +In+ the lattertreatment
case they process
should be
2
Metal
positioned as close as possible to the mould cavity so
that the maximum+amount+ Levelofofinclusion
metallurgical
materialcontamination
can These ratios ensure the pouring rate can be maintained
e increase in be collected. during the complete mould filling process. The mould
ulence mould Filtration capacity is influenced by many process filling rate should not be controlled by the filter. This
s have to be variables, therefore the above values should only be
t, the runner regarded as guidelines.
is the function of the downsprue.
bars and the
Filter capacity
quired. H = h kg/cm2
Iron Alloy

0.5 - 1.0 NiResist, SiMo, D5

Ductile (Inmold)
1.0 - 2.0 Ductile
2.0 - 4.0 Grey/Malleable
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 SEDEX foundry filters
Selection of porosity and filter position

In the introductory phase, it is recommended that the

filter area should be generously dimensioned. The
resulting filter sizes can be optimised once sufficient
application experience has been acquired in a given
foundry environment.

Filter porosity is generally determined by the alloy to

be poured.

On ductile iron and special alloy types Ni-resist and

SiMo containing high levels of reaction products and
the coarse 10 ppi SEDEX filter is normally applied.
Process improvements giving a lower level of reaction
products have allowed some foundries to work with
the finer 20 ppi SEDEX filter.

Grey iron which contains lower levels of reaction

products is normally filtered using 20 ppi SEDEX filter.
30 ppi products may be applied if the molten metal is clean
and fluid.

Malleable iron with the lowest level of metallurgical

contamination and high pouring temperatures has
good pouring characteristics. Consequently, the fine
30 ppi SEDEX filter can be applied.

The extra fine 40 ppi porosity is used mainly for grey

iron castings produced on vertically parted moulding
lines.

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 vertically
Step 3 Specially designed filter prints are also available for
Selection of the appropriate SEDEX filter print use with vertically parted moulds such as DISAMATIC
Filtration effectiveness is greatly dependent upon moulding machines. There are two types of different
the correct application of the filter. To assist application options:
foundries in this operation Foseco has developed
a range of filter prints. It is strongly recommended 1. Positioning of the filter by hand in a pouring bush
that foundries take advantage of their availability. vertically
2. Positioning of the filter lower in the mould; this
The use of the SEDEX filter prints will help to requires the availability of a coresetter to mechanically
ensure correct position, entry face area and exit place the filter in the open mould half in the short
face support for the selected filter type. In many time available and with the necessary accuracy
cases the position of the filter and suitable filter
print is defined by the layout of the pattern plate. vertically

horizontally

inclined

horizontally

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 SEDEX foundry filters
Application in vertically parted moulds

Advantages of using SEDEX filters in vertically

parted moulds: Moulds can be divided into three basic categories:
++ Simplified gating systems 1. Single cavity
++ Improved mould filling 2. Two or more cavities at the same level
3. Two or more levels of cavities
++ Reduced metal filling velocity
++ Reduced turbulence and erosion As well as these three types of moulds, the position
of the ingate(s) must be taken into account. The
++ Fewer surface and gas defects lower the cavity in the mould, the smaller the
ingates should be in order to ensure even filling of
++ Improved machinability the complete spray. To assist in achieving this, the
position of the controlling section or choke also
In the case of vertically parted moulds there are needs to be considered. Each of the three cavity
some additional aspects which need to be taken into types can be ingated in one of three ways, giving a
consideration when calculating and designing the total of nine gating system variations.
gating system.

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a] Bottom gated:
A downsprue controlled system can be applied, the In all cases the choke section must be located behind
cross-section of runner(s) and ingate(s) can each be the filter. This will ensure the filter is fully primed
Gating system
increased by 10%. with liquid metal for the whole pouring operation. with filter
It is important that the filter is located in a correctly
b] Side gated: designed and dimensioned filter print. The filter print
The controlling section should be located just in front must ensure that the filter is secured in place and
of the ingate(s). The latter section can be increased cannot move or fall out as the mould is blown out
by 10%. or moved. It is essential that the print provides the Turbulent
mould
required exit face support during pouring. filling,
c] Top gated: the metal
impacts
When gating through a feeder or KALPUR unit the The introduction of additional resistance to a gating directly
controlling section must be positioned at the ingate(s). system for vertical parted moulding lines (such as an against the
mould cod
Any runner or downsprue sections should be larger inclined downsprue or sprue cross over) reduces the
than the ingate(s). velocity and makes the mould filling more even. An
example is shown on the right. Specific application
issues can be addressed by contacting one of our
product managers.
Gating
system
with
inclined
downsprue,
cross over
and filter

More even
and less
turbulent
mould filling

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 SEDEX quality is assured

Quality management Important product attributes monitored in this way

The Foseco quality management system is certified include:
against DIN ISO 9001 and ISO 14001. All relevant
product quality features of SEDEX filters are ++ Filter dimensions
controlled and recorded according to these quality ++ Bulk density
standards. Dimensional
++ Cold compression strength inspection

++ Porosity
++ Thermal shock resistance (impingement test)

Thermal shock and erosion resistance to the liquid

metal stream are important product attributes.
These properties are evaluated regularly using liquid
cast iron. The impingement test has been specifically
developed for this purpose. Extensive use of this test
IMAGE to be
has enabled Foseco to continuously improve the replaced
quality and consistency of the SEDEX filter. Testing
cold
compression

Impingement
testing unit

FOSECO. YOUR PARTNER TO BUILD ON. Foseco International Limited

Drayton Manor Business Park,
10/2018 · re 500 e

Tamworth, Staffordshire,
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