PENNSTATE

Department of Industrial Engineering

BAAM Inc.
Molten Metal Filtration Project Report
Sponsor Company: Hickman, Williams & Company

4/26/2012

Brandon Myers
Andrew Schenone
Mackenzie Barrett
Alex Lukacs
Overview
The objective of the molten metal filtration project is to research, test, and analyze the four
different theories behind the use of extruded and foam ceramic filters for gray and ductile iron.
The results of this project will bring conclusions on which theory(s) explains how the filters
work during the pouring of metal. The results will also allow recommendations to be made for
future tests and analysis to be conducted by another research team.

Four Metal Filtration Theories

There are currently four different theories on how filters work to filter out slag and debris
during the metal pouring process. The first is large particle filtration. This is where large
particles cannot physically fit through the smaller size pores of the filters. All of the tests that
the team conducts will prove this since the theory is intuitively accurate.
The second theory is filter cake. The principle behind this theory is that debris and slag
(both solid and liquid) build up on the feed side of the filter creating a “cake” like effect on the
filter face. This cake narrows the cross sectional area of the filter openings, allowing the filter to
intercept smaller particles than a filter without cake buildup.
The third theory is deep bed filtration which involves particles that are smaller than the
pore openings to adhere on the filter walls. Like the filter cake theory, this decreases the cross
sectional area of the filter openings and prevents smaller particles from passing through.
The fourth and final theory is the tailback theory. This theory focuses on the turbulent
flow of the metal as it flows through the gating up to the filter. As the metal hits the filter it
slows down and “tails back.” This tailback lifts and separates the unwanted slag and particles
away from the filter allowing them to flow to the top of the gating system and be caught in a trap
that is usually created in the gating above the filter. One additional piece of information that
needs to be investigated with this theory is the effects the filter has on the flow after the metal
passes through the filter. After metal passes through the filter the flow becomes laminar but
there are no studies of how long this flow stays laminar. With laminar flow there is less chance
for the metal to oxidize and form more slag.
Through a series of experiments the above mentioned theories will be tested to conclude
which theories are really affecting metal filtration.

Filter Properties Test

The filter pressure tests were conducted to find the failure point of each filter type and
pore dimension for two different tests. Each of the filter types and pore dimensions were tested
five times, giving a total of 20 different data points.
A three point bend test was performed to measure the flexural strength of the filters and a
two point rod test was performed to try to simulate the pressure the filters experience within a
mold during a pour. Both of these tests were performed on a tensile testing machine by a
technician from the ESM department.
 The three point bend test was conducted with a fixture where the filters were placed on
two points that were 1.5 inches apart and a third point that was lowered at a rate of .2 inches per
min onto the filter until failure. The two point rod test was conducted with the filter placed on the
same two points as the three point bend test with a 1.25 inch diameter rod lowered at the same
rate onto the filter until failure.
The results from the pressure tests show the maximum pressure the filters of these pore
sizes, materials, and dimensions can within stand.
Table 1. Results of the pressure tests

3-Point Bend Test 2-point Rod Bend Test

Ceramic Foam Ceramic Foam
2.31 mm 1.70 mm 10ppi 20ppi 2.31 mm 1.70 mm 10ppi 20ppi
200.8 200.8 32.5 49.6 Units= 257.0 264.2 48.5 75.4
263.2 140.2 41.4 47.4 Pounds 186.7 240.0 42.2 46.1
200.0 168.0 24.6 50.1 281.0 214.1 48.8 41.3
145.0 122.9 37.3 49.9 207.7 220.7 45.6 51.4
200.1 137.6 33.4 34.2 240.0 299.9 49.9 60.2
201.8 153.9 33.8 46.2 Mean 234.5 247.8 47.0 54.9
Std.
41.84 30.87 6.25 6.82 Dev. 37.76 35.05 3.12 13.44

Initial Pouring Test

In order to obtain a basic understanding of the function and use of filters, an initial
pouring test was conducted. The purpose of this test was to qualitatively observe the flow of
molten metal through a filter, and also to determine if it would be possible to analyze the amount
of slag caught in a filter after solidification. Additionally, the possibility of using slag-off to
increase the amount of solid slag was tested.

In this test, two molds were created with four filters each. One mold contained 2.31mm
ceramic filters and the other contained 1.70mm ceramic filters. It was decided that the gating
system be unpressurized, and that the mold be open. This would allow most of the metal to flow
through the filter and out of the mold rather than solidifying in the gating system and filter.

Each filter was placed 4” down from the top of the cope in a horizontal position. A 1.5”
x 1.5” sprue was cut with no taper straight to the filter. A gate of 1.5” wide x 3.5” long and 5º
draft was placed in the cope and ran out of the mold. A top-down and side-view of the molds
can be seen in Figures 1, 2, 3 and 4 below.
 Figure 1. Top-down view of 2.31mm filter sand mold

Figure 2. Top-down view of 1.70 mm filter sand mold.

The sprue mouths were cut by hand and it should be noted that the lower-right sprue in
the 1.70 mm mold collapsed and took the form of an extremely large funnel (sand chunks on the
filter were cleaned prior to pouring).
 Figure 3. Side view of 2.31 mm sand mold out-gates

Figure 4. Side view of 1.70 mm sand mold out-gates

Fifteen pounds of dirty iron was poured through each filter at 2574ºF. Slag-off was
added in the amount of .100 oz to the upper-right filter in Figure 5. It was determined that
adding slag-off did not result in the desired effect and would not be used in future tests. The
molds solidified overnight and were shaken out the next morning. The filters can be seen below
in Figures 5 and 6 in the same orientation that they were in Figures 1 and 2.
Figure 5. 2.31 mm filters after solidification

Figure 6. 1.70 mm filters after solidification

Water Modeling Table Experiment
The objective of the water modeling table was to simulate the flow of molten metal
through a gating system with a filter by using water as an analogous of molten cast iron. The
desired result from the simulation was to observe the presence of any of the four filtration
theories, primarily the theory of tailback. Being able to see any form of the tailback theory will
help in proving that the solid and liquid slag is being removed away from the filter and thus
allowing clean metal to flow through the filter into the casting cavity. Using the water modeling
table as a preliminary simulation of the gating system used for the pouring test with the quartz
glass window allows for the observation of flaws in the system and how the molten metal will
flow through the gating system and filter. In addition to testing the gating system, the water
modeling table is easy to rebuild and run multiple times.
The filter was placed in the middle of the horizontal gate seen below. This will provide
ample space for us to view flow characteristics before and after the filter. The below setup was
placed in the vertical position such that water will flow in from the top-left corner in the image,
descend down a short distance, turns towards the filter, and exit on the right side.

Figure 7. Top down view of clay gating system

Simulations were run for each filter type (extruded and foam) with each pore dimensions
to be able to compare the filter type and the effectiveness of the two types of pore dimensions.
To be able to observe the turbulence from the flow of water by way of the filters, threads were
attached to the clay walls before and after the filters. These threads would allow for the
observation of turbulence before the filter and a laminar flow after the filter. Setting up a
consistent rate of flow was difficult because of the inconsistency of the water pump. A position
for the valve had to be located for the correct flow rate before each day of tests in order to
somewhat consistent flow rate setting.
 Recording the simulation runs was essential to be able to study the flow without having
to run the water modeling table every time an observation was needed. The recordings were done
with a HD high speed Canon camera, tripod, and studio lighting that were rented from the
university media and technology support services.

Water Modeling Table – Results

The first noticeable result was the difference in how the strings were flowing both before
and after the filters. Before the filters the strings were oscillating up and down and were
noticeably turbulent. The strings after the filter were straight and smooth, indicating laminar
flow.
The ceramic filters had a noticeable buildup of particles on the face of the filter. In the
foam filter the particles would enter the middle of the filter and get caught there. Much fewer
particles appeared on the face of the foam filters as compared to the ceramic filters.
At higher flow rates air vortices formed after the holes of the ceramic filters. This may be
due to the pouring speeds being higher than what would appear in a conventional casting.

Water Modeling Table – Recommendations

To continue using the water modeling table to get further results the system needs to be
redesigned. A large problem that contributed to air in the system was not having the entire
system’s walls perpendicular to, and pushed against, the glass. The semi-rounded edges of the
current system allowed air to enter and may have created more turbulence. The inlet and outlet
areas also need to be redesigned. Both areas were too large which made it difficult to have the
flow rates stay consistent across the tests. The entire system should be reduced down to 1” from
the current 1.5”. This is closer in size to the window pouring test system and can emulate an
actual mold much better.
The filter should be moved closer to the inlet so the turbulence further downstream from
the filter can be examined. To get a better view of the turbulence, shorter strings should be added
along the length of the gating system. This will better show the turbulence in more areas
throughout the gating system.
Metal strips can be added before and after the filter to examine the pressure of the flow
by measuring the deflection of the metal.

Double Filter Test

This test was conducted to test the theory of filter cake formation, as well as deep bed
filtration. A successful test would result in an observable build up of slag cake on the first filter
with little to no slag caught in the second filter. Additionally, dross particles would be seen
attached to the inside walls of the ceramic filter. This observation would reflect the deep bed
filtration theory.
 It was decided to conduct the double filter test in both the vertical (open) and horizontal
(closed) configurations. The vertical configuration was chosen to allow for complete drainage of
the mold cavity. This would prevent the cast iron from solidifying in the gating system and
therefore would ensure a clear view of the filter surface. The horizontal configuration was
chosen to represent a real-world use of filters. In this orientation, two large cavities “pigs”
would be filled. This closed mold configuration would allow the entire gating system to fill with
metal and solidify. The metal immediately before the filters could then be cut (cross-sectioned)
in order to visually inspect the cake formation, if any. In both orientations, all four filter types
will be tested. (Ceramic and foam, 1.70mm, 2.31mm and 10 ppi, 20 ppi respectively).

Double Filter Test – Vertical Orientation

In Figure 8 below, the pattern plate of the vertical orientation setup is shown. If an
observable cake of slag builds up on the first filter but not the second, this proves 1. that a filter
cake does exist, and 2. it is contributing to the other filtering effects significantly.

Figure 8. Pattern plate setup of Double Filter Test

The results of the double filter vertical mold pours are shown below in Figures 9 through
12. In each image, the filter on the left was the first filter that the metal passed through and the
feed sides are facing up.
 Figure 9. 10 ppi Foam

Slag

Figure 10. 20 ppi Foam

Figure 11. 2.31 mm Ceramic

 Figure 12. 1.70 mm Ceramic
Before each pour, slag was added to the ladle. The addition of slag was thought to
increase the chances of a cake building up and to make this phenomenon more visible. It is
apparent from the images above that the foam filters caught a much larger volume of slag than
did the ceramic filters. This may be due to inconsistent slag levels in the ladle during each pour.
When comparing the foam and ceramic filters, there appears to be no visible slag cake
present on the foam filters. Instead, the slag is concentrated throughout the entire thickness of
the filter. This adhering of slag to the foam filters’ walls is more consistent with the deep bed
theory of filtration. Additionally, the ceramic filters experienced very minimal slag cake. There
is visible cake on the flat surfaces of the filter, however this cake does not overlap the actual
pores. The filter cake theory is suggested to work via a slag cake that builds up on itself and
overlaps the pores of the filter. Therefore, the results obtained from the ceramic filters in this
experiment do not support the theory. Lastly, there was no evidence of deep bed filtration in the
ceramic filters. These filters were cracked open and the inside walls of the pores did not show
any signs of attached slag.

Double Filter Test – Horizontal Orientation

In Figure 13 and 14 below, the pattern plate of the horizontal orientation setup is shown.

Figure 13. Cope side

 Figure 14. Drag side

Like the vertical orientated double filter test, four molds were made to accommodate the
four combinations of filter types and sizes.
These tests were inconclusive due to the unsuccessfully filling of the molds. The pigs
were too large and as the molten metal flowed into them, the buoyant force overpowered the
mold weights and slightly lifted the cope from the drag. This resulted in the molten metal
leaking from the mold and the pour had to be stopped. Figure 15 illustrates how the double filter
horizontal mold test failed.

Figure 15. Leaking of the double filter horizontal mold.

Double Filter Test – Results and Recommendations
Based on the results from the double filter vertical mold test, it is hypothesized that 1.
Filter cake is minimally present on ceramic filters and non-existent in foam filters and 2. Deep
bed filtration is prevalent in foam filters but non-existent in ceramic filters.
Due to the low number of trials, it was impossible to definitively confirm or deny the
existence of filter cake or deep bed filtration. For this reason, it is recommended that multiple
trials be conducted in the future.
The horizontal molds should be constructed with larger flasks to accommodate the
oversized pigs. This will prevent the cope and drag from separating and leaking molten metal.
It is also suggested to create identically gated molds both with and without filters. The
molds without filters will serve as a control. After solidification, these molds can be analyzed
with an electron microscope. This will allow for the counting of inclusions in the solidified pigs.
Currently, the design of the molds is such that the metal flows directly on top of
(vertical), or parallel to the ground (horizontal) and into the filter. It is suggested that the design
is altered to allow the metal flow to enter the filter against gravity (from the bottom of the filter).
This gating design would prevent slag from simply falling onto the filter once the system drains.

Quartz Glass Window Pouring Tests

The purpose of the quartz glass window experiment was to be able to observe the tailback
theory and the flow of molten metal through a filter in a green sand mold. Additionally, the
effects the filter has on the metal’s turbulence as it flows through the gating are to be observed.
A pattern plate and custom vertical parting line cope and drag system was designed and
fabricated. The final pattern plate can be seen below in Figure 16 and 17. This pattern is slightly
different from the original design. The original system called for the metal to empty into two pig
molds under the window mold. However this meant that no base board under the mold could be
used, which caused the mold to crack when moved. The redesign has the metal exit out the side
of the mold into a pig allowing the use of a base board. Figure 18 shows the positioning of the
window mold and the pig mold. This configuration allowed for 50 lbs. of metal to be poured
through the mold. A pouring sleeve was used to allow metal to be quickly thrown into the mold
and to keep the sand from blowing out of the mold. Unfortunately with this new configuration
the pig mold could not be examined for slag after it solidified as the molten iron came into
contact with air as it exited the window mold. Additionally, a high speed camera was used to
record metal passing through the filter. Four different filters were used for this test two ceramic
filters (1.70 and 2.31 mm) and two foam filters (10 and 20 ppi).
 Sprue Cup

Filter

Exit
Glass

Figure 16. Front of Pattern Plate

Sprue Cup

Viewing Window

Figure 17. Back of Pattern Plate

 Exit
Window Mold

Pig Mold

Figure 18. Mold

Configuration

Quartz Glass Window – Results

From the quartz glass window experiment the theory of tailback was observed. These are
best seen in the foam 10 ppi and the ceramic 2.13 mm filters. In both videos a piece of solid slag
floats in and then is pushed back as the molten metal rushes back away from the filter. Figure 19
below shows the piece of slag from the 10 ppi foam filter right before it is pushed away from the
filter by the molten metal that is tailing back.
Slag

Figure 19. Tailback Effect (Foam 10 ppi)

 While tailback can be seen before the casting cavity is completely filled it cannot be
determined if this phenomena continues to occur once the system is completely filled.
Additional tests should be conducted to determine if tailback continues to occur once the system
is filled.
Additionally this experiment allowed for the observation of how molten metal exits the
filter. It should be noted that after contacting the filter it takes one to two seconds for the filter to
prime and for metal to actual start flowing out the other side. While the videos portray metal
flowing through the filters better, Figure 20 below shows molten metal as it exits a 1.70 mm
ceramic filter while Figure 21 shows the 20 ppi foam filter. From the test it was observed that
both ceramic filters seem to project the molten metal out the other side as it is forced through the
filter. However, for both of the foam filters it appears as if the metal falls out and downward
(drops) as it exits the filter. This would suggest that ceramic filters allow more surface area of
the metal to come into contact with the surround air as it exits the filter before the system is
completely filled.

Figure 20. Ceramic 1.70mm

Figure 21. Foam 20 ppi

However, it cannot be determined from these experiments how turbulent the metal flow is
after the system becomes completely filled with metal. Additional test will be needed to
understand what happens once the system is full.
Quartz Glass Window – Recommendations
It is the group’s belief that further studies using the quartz glass window could prove
useful in helping to understand how filters work and their effects on the flow of metal. The
following is a list of recommendations that could aid in the experiments and give suggestions for
additional experiments.

 Use a filtered camera lens

 Adjust slag levels to maximize results
 Put solid particle of slag in gating system both before and after filter to see the flow of
metal as it is poured
 Decrease the depth of the gating system to a half inch so that slag is closer to the glass
 Build a longer out gate and place smaller pieces of glass along gate to see turbulence
o Will need to design a way to actually see the turbulence of the metal
 Have the filter placed horizontally and pour metal onto filter to see how it exits the filter
o Place mold at different heights and watch how the metal free falls out of the filter
 Conduct tests with the filter in different positions,
o Find 3 or 4 commonly used filter positions
o May find that certain filters work better for certain positions

Final Recommendations
After conducting the experiments described above, the team believes that additional
knowledge can be obtained by further experimentation through the water modeling table and the
use of quartz glass windows to observe metal flow. In addition to the recommendations made
for the individual experiments described in this report, the team also suggests the following:
 Limit the scope of the research
o Focus on water modeling table or quartz glass window molds
 Supply the next team with:
o Larger flasks in order to make larger molds
o Extra pouring ladle
 One team member should be a mechanical engineer who has studied fluid mechanics
 Use electron microscope to quantify slag/inclusion levels in solidified castings
 Verify the chemical composition of the cast iron used
 If possible, conduct the pouring experiments at a foundry
 Appendix
Instruction Set

Water Modeling Table Instructions

Primary Tools used
 Tape measure- taking measurements
 Hair dryer-help in molding once clay is one the water modeling table
 Sand mold utensils-used to sculpt the gating system
 Toothpicks-guides for the corners and sides of gating system
 Oven-to warm clay to working temperature

Creating the Base

 Plywood panels were cut and shaped to create a support for the clay mold
 2”x4”s were cut to create support around the plywood panels and to create an anchor
around the table
 Extra Styrofoam was used as a spacer to add more support to the plywood
 The plywood does swell after getting wet, causing the clay to slightly lift

Creating the pattern

 A 4” section of wood, 1.5”x1.5”, was cut and attached to a large 2”x4” to create a
pressing pattern of the system
 Large chunks of clay were heated in the oven at its lowest setting to reach working
temperature
 The pliable clay was pushed and sculpted into the plywood base to create an outline of
the idea of the gating system, inlet, and outlet
 The pattern was pushed into the clay to create the pattern in the clay
 By hand, the inlet (sprue) and the outlet were formed to desired shape and size
 A hair dryer was used to heat the clay up to be molded by hand and with the utensils
 With the sand mold utensils an area was dug up in the gating system for where the filters
were to be placed
 ¼” weather stripping was placed along the length of the walls. (weather stripping works
very well as a seal, but might need to replace due to it losing its elasticity)

Running the system

 The glass was placed down onto the top of the table
 The clamps were placed mainly in the areas where the water is flowing and 3 smaller
clamps were placed towards the bottom of the table (weather stripping might need to be
placed on the bottom edges of the table to stop leakage)
  The hoses were connected to the inlet from the pump and another from the outlet to the
return inlet of the tank
 The flow knob was doubled checked to be closed
 The pump was plugged in and turned on
 The flow knob was slowly opened until water started flowing
 The speed was slowly increased until water filled the system
 Areas where a leak occurred were marked off with tape on the glass
 The glass was removed after the system was off and drained
 Areas were built up with more clay using the hair dryer or more weather stripping was
added
 The system was ran again to make sure there are few leaks
 The table was propped up during all the test runs, but down during molding
 Another hose was attached to the bottom of the table, with the other end in the access
hole in the top of the tank. This was to allow any water that leaked out of the system and
into the open cavity to reenter the tank

Getting the flow rate

Materials needed:

 2 buckets of at least 5 gallons (garbage cans were used)

 Stop watch
 Scale

Method

 The scale was zeroed using the weight of one of the buckets
 The outlet hose was disconnected from the inlet of the tank and placed into one of the
buckets
 The system was turned on and allowed to fill up
 At this point the hose is moved into the other bucket and a time is started
 After a specified amount of time the hose is removed from the bucket and the time is
stopped
 The system is then turned off
 The position of the valve during the flow test was taken by marking on a piece of tape on
the valve handle and valve with a ruler so that same positioning of the valve is consistent
 The bucket is weighted while full of water
 The weight divided by the time is used to calculate the lb/s
 Notice: the flow rate did change if the hose from the pump was filled before the pump
was on and the valve was open rather than being empty
 Empty buckets after each test back into the access opening in the top of the tank to avoid
heavy lifting and the loss of water in the tank.
Double Filter Experiment Instructions
Vertical Mold

Part 1.

Part 2. is the space for the filter and should be as close to the actual filter dimensions as possible
with the addition of draft.
 Part 3.

Part 4.

 Each part was hot glued to the pattern plate. This technique is fast, easy, and somewhat
reliable. Occasionally, a part will separate from the pattern and will have to be re-glued.
Drilling through the pattern plate and screwing the parts down is the most sturdy, but
most time consuming method.
 Begin by making the drag which should be a pure block of sand (pattern is on cope side).
 Instead of using a standard metal bottom plate, use a piece of plywood that is slightly
wider and longer than the bottom of the mold.
 After the cope is made, remove the jacket and place another piece of plywood on top of
the cope. (Same sized plywood that was used as the bottom plate).
 Clamp the plywood to the mold using one clamp on each longer side of the mold.
 Cut out sprue cup and exit hole.
 Place the mold on a wooden table with a hole in the center. Ensure that the exit hole of
the mold is centered over the hole in the table.
 Place a large ladle underneath the table in order to catch the metal.
  Metal should be poured at ~2600 degrees Fahrenheit from the furnace, into the mold.
 Once the ladle is full, two people lift the table with mold on top away from the furnace.
Two other people will pick up the large ladle and empty the metal back into the furnace
for the next pour.
o Watch the supplied video for the double filter experiments to see this process
in action

Horizontal Mold

6
 Part 5. Gates to pigs

Part 6. Pigs

 This mold is made and poured like a typical horizontal mold.

 If using this design, add more than one 20 lb. mold weight to each mold, otherwise the
cope will be lifted from the drag (buoyant force due to large pigs) and molten metal will
leak out.

Do not hesitate to contact Andrew Schenone for more specific or detailed information
regarding the double filter experiments.

Phone: 516-524-6232
E-mail: schenone45@gmail.com
Quartz Glass Window Mold Instructions
 Assemble cope, drag and pattern plate. Make sure that the detachable sides of the cope
and drag are located on the same side.
 Mold drag, there will be about two inches of sand over the window opening, dig this out.
 Place the sideboard (the one with the hole cut in it) on the mold and flip the mold over.
 Mold cope.
 Remove pattern plate, set cope down so that the casting cavity faces you. Insert filter
filling sides with sand to hold it in place.
 Insert quartz glass. Flip drag upside down and attach to cope.
 Place mold with window side down on sideboard on 2x4 stacked two high.
 Remove the four wing nuts on the sides. Push bolts into sand and remove the cope and
drag. Remove bolts from sand.
 Place other side board on top and clamp the two boards, do not over tighten or you will
break the mold. Make sure side boards are not below bottom of mold.
 Place bottom board on mold and flip up to the correct position.
 Transport to molding area using the orange lift.
 Move mold from the orange lift onto metal baseboards that are stacked to a correct height
so that it lines up with the pig mold.

Do not hesitate to contact Brandon Myers for more specific or detailed information
regarding the quartz glass window experiments.

Phone: 610-781-8665
E-mail: pittsteelers3608@yahoo.com