Disclosed is a flow-controllable tundish structure capable of filtering inclusions in molten steel. The tundish structure comprises a tundish (1), the tundish being divided into three separated cavities which comprise an impact zone cavity (1a) in the middle and pouring zone cavities (1b) at two sides thereof. A long nozzle (2) for pouring is vertically arranged in the center of the impact zone cavity, and molten steel flows down out of the long nozzle for pouring and is injected into the impact zone cavity; and a turbulence suppressor (3) directly facing the long nozzle for pouring is arranged on the cavity bottom under the long nozzle for pouring, and the molten steel flowing down out of the long nozzle for pouring impacts on the turbulence suppressor and is then buffered and mixed. Filter assemblies (A) are respectively arranged between the impact zone cavity and the pouring zone cavities at the two sides, and the buffered and mixed molten steel in the impact zone cavity is filtered by the filter assemblies and is then delivered into the pouring zone cavities at the two sides. Discharge ports (4) are respectively arranged in the bottom of the pouring zone cavities, and the molten steel filtered by the filter assemblies flows into the pouring zone cavities and then flows out from the discharge ports. The flow-controllable tundish structure has the advantages of a simple structure, easy building and lower cost, and has a good liquid steel purification effect.

Systems and methods are disclosed that overcome problems with conventional filters for high temperature casting materials. According to embodiments, uniform, engineered filters enable consistent and repeatable metal flow rates without becoming a secondary source of contamination. Proven Additive Manufacturing (AM) methods generate engineered filters that achieve consistent filtration efficiency and predictable metal flow into a casting mold. Through this application of AM for ceramics, the resulting filter incorporates features that can be adjusted on-demand to address the needs of specific alloys and geometries applied in the production of castings. According to an embodiment, the method includes generating, using an additive manufacturing apparatus, a plurality of layers, wherein each layer includes individual ceramic ligaments arranged in a grid pattern having a two-dimensional rotational orientation. The method further includes stacking the layers along a thickness direction to form the filter.

A molten metal filter box. The filter box includes a filter housing provided in a flow path for molten metal. A horizontal partition is disposed within the filter housing and has at least one filter receiving passage. A filter medium in the shape of a substantially flat plate is positioned within the filter receiving passage and below an inflow path of the molten metal. The filter medium includes a hole. A filter handling tool is disposed within the hole. The filter handling tool can optionally include a handle secured to the molten metal filter box to suspend the filter medium. Advantageously, the filter medium can be removed by grasping the filter handling tool and removing the filter medium.

An apparatus for countergravity casting a metallic material, comprises: a crucible for holding melted metallic material; a casting chamber for containing a mold; a fill tube capable of extending into the crucible to communicate melted metallic material to the casting chamber; a gas source coupled a headspace of the melting vessel to allow the gas source to pressurize said headspace to establish a pressure differential to force the melted metallic material upwardly through said fill tube into said mold; and means for gettering sulfur.

Apparatus and a method for filtering molten metal, in particular aluminium, including a container (1) with a removable lid (20) provided on top of the container to keep the container sealed (air tight) during operation, the container (1) being provided with an inlet chamber (2) having an inlet opening (5) receiving metal from a metal supply launder (10) and outlet chamber (3) with outlet opening (6) connected to a launder segment (10). The container further being provided with partition wall (8) between the inlet chamber (2) and outlet chamber (3) and with ceramic foam filter (17) mounted in the outlet chamber. The inlet chamber (2) and outlet chamber (3) are provided side by side within the container (1) and being split by the partition wall (8) extending from the bottom of the container and upwardly to a preset level of the container interior height. The container (1) is connected in parallel with the metal supply launder (10) via stubs (5, 6) that communicates with the inlet (5) and outlet (6) openings respectively, the launder (10) being provided with a dam (14) or valve device downstream the outlet (6) of the container (1) and another dam or valve device (13) between the said launder stubs (5 and 6). Inside the container (1) there is further arranged a second outlet chamber (4) with a filter (17) that when in use, communicates with the first outlet chamber (3) via a space above a partition wall (8) extending from the bottom of the container and upwardly to a preset level of the container interior height, where the second outlet chamber (4) has one outlet (7) provided by a stub (7) connected to a launder segment (10) being in connection with metal supply launder (10). The second outlet chamber (4) is used for increasing the filter capacity when producing metal with a high cleanliness.

A filter for filtering a liquid metal and to be received in a mold housing defined by internal side and face walls. The filter has a top wall and side walls extending downwardly from the top wall, the side walls being joined together at respective corners. The side walls extend downwardly towards distal end portions. The corners of the filter have a stiffness or rigidity that is higher that the remainder of the filter for increasing the strength of the overall filter and for helping the filter to maintain its shape and integrity throughout casting. The shape of the side walls allows an easy and consistent placement of the filter in the mold housing and ensures that the filter is maintained in place.

An apparatus for countergravity casting a metallic material, comprises: a crucible for holding melted metallic material; a casting chamber for containing a mold; a fill tube capable of extending into the crucible to communicate melted metallic material to the casting chamber; a gas source coupled a headspace of the melting vessel to allow the gas source to pressurize said headspace to establish a pressure differential to force the melted metallic material upwardly through said fill tube into said mold; and means for gettering sulfur.

An apparatus and method for filtering molten metal (M), such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle (12) for the molten metal (M). A vibrator vibrates at least one of the filter, the receptacle (12) or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

An apparatus and method for filtering molten metal, such as aluminum or an aluminum alloy includes at least one ceramic foam filter or any other type of filtration media such as porous tube or alumina balls disposed in a receptacle for the molten metal. A vibrator vibrates at least one of the filter, the receptacle or the metal and may be used to induce priming, filtering and/or drainage of the filter. The vibrator may be retrofitted to an existing filter system and may be adjustable in frequency and amplitude. The vibration may be continuous over a given period or produced in a single shock.

Described are high pressure filter housings and apparatuses that are useful to contain a fluid under high pressure, with example housings including first and second pieces having complimentary tapered joint surfaces that can form a fluid-tight seal without a gasket located between the surfaces, and methods of making and using the high pressure filter apparatuses.