Investigation of mechanical and thermo-mechanical strength of ceramic foam filters (CFFs)

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During aluminium production, the molten metal will always contain varying amounts of impurities, e.g., non-metallic inclusions, and for high-quality products removing such inclusions is essential. This can be achieved by filtration using ceramic foam filters (CFFs). However, these filters are highly brittle materials subjected to strong mechanical and thermo-mechanical stresses during transport and operation, which occasionally leads to failure of the filter material. In the present study, the compression strength of five different Al2O3-based CFFs was measured at room temperature and elevated temperature (compressed at 730 °C), as well as while submerged in molten aluminium with varying melt compositions (pure aluminium and an aluminium-magnesium alloy). The compression strengths at room temperature were established to be in the range of 1.19–2.09 MPa depending on the filter type tested. In the case of the CFFs compressed at elevated temperature, a reduction in compression strength in the range of 9.2–58.6% was established to exist depending on filter type and heating duration, except in three of the filter/duration-combinations tested. Compression of CFF samples submerged in molten aluminium led to an even further reduction in compression strength in the range of 42.6–69.4% depending on filter type and duration of exposure. With an exposure time of only 5 min, no difference in compression strength was observed between the two aluminium melts.