Ceramic Foam Filter Alumina CFF for Molten Aluminum
The last thing the metal passes through before it becomes product. Every treatment upstream — degassing, fluxing, settling — leaves some oxide film and inclusions in the melt. A ceramic foam filter in the launder or the mold makes the metal take a tortuous path through thousands of ceramic struts, and the inclusions that touch them stay behind.
Chelora Chemicals is a ceramic foam filter supplier and sourcing partner serving aluminum casthouses and foundries across the United States. We supply alumina filters in standard sizes and PPI grades, with gaskets to match, and dimensional and quality documentation on every consignment.
- Product type
- Ceramic foam filter
- Material
- Alumina-based ceramic
- For metal
- Aluminum and aluminum alloys
- Grading
- Pores per inch (PPI)
- Casthouse sizes
- 7 to 26 inch square
- Casthouse thickness
- 50 mm (2 in)
- Sealing
- Expanding gasket around the plate
- Preheat
- Required before metal flow
- Documentation
- Dimensional & quality certificate
Note: match the PPI to the product, not the price. A finer filter catches more but primes harder and blocks sooner. The grade follows the quality your product needs.
How a foam filter cleans the metal
Depth filtration: the metal winds through the foam, and inclusions stick where they touch.
Why it matters: an inclusion that reaches the casting is a defect. In can stock, foil or aerospace product, one oxide film can be the difference between pass and scrap
What a ceramic foam filter is and does
A ceramic foam filter is an open-cell ceramic plate made by coating a polymer foam with ceramic slurry and firing it, which leaves a rigid, three-dimensional network of interconnected pores. For aluminum the ceramic is alumina-based; silicon carbide filters are used for iron and zirconia for steel.
Filters are graded in pores per inch. Molten metal flowing through the plate has to change direction again and again, so inclusions repeatedly meet the ceramic struts and adhere to them — depth filtration — and as the filter loads, a cake builds that filters finer still. Casthouse plates come in standard squares from 7 to 26 inches, 50 mm thick, seated in a filter box with an expanding gasket so no metal bypasses the plate.
Choosing a filter
- PPI grade. Coarser for general casting and billet, finer for can stock, litho and aerospace.
- Size. Matched to your filter box and metal flow rate.
- Gasket. An expanding gasket that seals against the box and prevents bypass.
- Preheat. The plate must be preheated so metal primes it without freezing.
Handling character
Ceramic foam filters are fragile and must be preheated before metal flow. Details in the Safety section.
| Parameter | Typical value |
|---|---|
| Material | Alumina-based ceramic |
| PPI grade | Per agreed specification |
| Dimensions | Square size and bevel per filter box |
| Thickness | 50 mm casthouse standard |
| Gasket | Expanding gasket, fitted or loose |
| Packaging | Cartoned, cushioned against breakage |
Important: the figures above are indicative of commercial material and are offered for planning only. The batch certificate of analysis is the governing document.
| Property | Value |
|---|---|
| Physical form | Rigid open-cell ceramic plate |
| Material | Alumina-based |
| Grading | Pores per inch (PPI) |
| Mechanism | Depth and cake filtration |
| Sizes | 7 to 26 inch square |
| Thickness | 50 mm (2 in) |
| Other metals | SiC for iron; zirconia for steel |
Sizes and thickness are the common casthouse standards; foundry filters for molds and ladles come in smaller sizes. PPI selection, preheat temperature and flow rates are set by the producer's guidance for the grade. Treat the table as orientation, not as a specification.
Where ceramic foam filters are used
Casthouse launders and foundry molds, wherever inclusions cost product.
DC casthouses
Filter boxes in the launder between furnace and mold, for billet, slab and rolling stock.
- 7 to 26 inch plates
- PPI matched to product
- Gaskets to match
Foundry casting
Smaller filters in the mold gating or ladle to keep oxide out of shaped castings.
- Foundry sizes on request
- Consistent pore structure
- Batch documentation
Sheet & foil stock
Finer grades for can body, lithographic sheet and foil, where single inclusions cause defects.
- Fine PPI grades
- Two-stage options
- Quality certificate
Aerospace & critical parts
The finest grades for products where inclusion control is a specification requirement.
- Fine PPI grades
- Dimensional certificate
- Traceability per lot
After melt treatment
The final step after degassing and fluxing, not a substitute for them.
- Degassing tablets
- Granulated flux
- Sequence guidance shared
Scheduled supply
Filters are consumed every cast, so steady call-off supply matters more than spot price.
- Annual contracts with call-off
- Price held across the contract
- Second source held in reserve
Delivered to US plants and ports
We ship ceramic foam filters to nominated delivery points across the United States. The regions below are destinations we serve — Chelora Chemicals is a sourcing and supply partner, not a US manufacturer, and does not hold US stock.
Gulf Coast
The largest US chemical cluster, and the usual entry point for bulk consignments.
- Houston & Galveston, TX
- New Orleans & Baton Rouge, LA
- Mobile, AL
Northeast
Container and bulk delivery into the mid-Atlantic and New England manufacturing belt.
- Newark & Elizabeth, NJ
- Philadelphia, PA
- Boston, MA
Southeast
Port-side delivery for the Carolinas, Georgia and Florida processing plants.
- Savannah, GA
- Charleston, SC
- Jacksonville, FL & Norfolk, VA
Midwest & Great Lakes
Inland rail and truck forwarding from the nearest coastal port to the industrial Midwest.
- Chicago, IL
- Detroit, MI
- Cleveland & Columbus, OH
West Coast
Pacific routing for West Coast processors and formulators.
- Los Angeles & Long Beach, CA
- Oakland, CA
- Seattle & Tacoma, WA
Southwest & Mountain
Inland delivery to interior states, forwarded from the Gulf or Pacific gateway.
- Dallas–Fort Worth, TX
- Phoenix, AZ
- Denver, CO
Importing into the United States
A ceramic foam filter is a manufactured article, not a bulk chemical. Articles are generally outside the TSCA section 13 import certification requirement unless an EPA rule specifically requires it, and we confirm the position with your broker before the first shipment. Safety information is supplied to OSHA's Hazard Communication Standard where the producer issues an SDS.
Which party carries that duty follows the Incoterm. On FOB, CFR or CIF terms it is usually the US buyer; on DDP terms it can be the seller or its agent. Safety data sheets and labels are supplied to OSHA's updated Hazard Communication Standard, and the non-dangerous goods transport documentation is prepared before booking.
| Item | How it works |
|---|---|
| Delivery points | Any nominated US plant, terminal or port of discharge |
| Incoterms quoted | FOB · CFR · CIF · DDP |
| Importer of record | Agreed in writing before the first shipment |
| TSCA certification | Section 13 positive certification filed at entry |
| Documentation | Batch COA, SDS, packing list, certificate of origin |
| Pack formats | Cartoned plates, cushioned, on pallets |
Note: regional coverage describes where we deliver, not where we hold inventory. Lead time depends on producer scheduling and ocean transit to your nominated US port — we confirm both in the quotation.
How we supply ceramic foam filters
Chelora Chemicals is a ceramic foam filter supplier and sourcing partner, not a manufacturer. We place your order with a qualified producer whose plates fit your filter box, your metal and your quality requirement.
The first question is the product you cast, because that sets the PPI. A filter fine enough for can stock is overkill for general billet and will prime harder and block sooner; a coarse one in a litho line lets defects through.
The second is the box: plate size, bevel and gasket must match, or metal bypasses the filter entirely. We confirm dimensions against your drawing before the first order.
- PPI matched to your product. Not the finest available, the right one.
- Dimensions confirmed against your filter box. Size, bevel and gasket.
- Consistent pore structure lot to lot. So priming and life stay predictable.
- Packed against breakage. Cushioned cartons on pallets.
- Trial quantities before a contract. Prove priming and life on your own line.
- Batch traceability to the producing plant. Dimensional and quality certificates per lot.
Cartoned and cushioned
Plates packed against breakage, palletized, with full documentation.
Cushioned cartons
Plates individually cushioned and cartoned by size.
Strapped pallets
Cartons palletized and wrapped for container shipment.
Gaskets fitted or loose
Expanding gaskets fitted to the plate or supplied separately.
Small trial lots
Small lots to prove priming and life on your line.
Incoterms to suit you
Quoted on the Incoterm your purchasing team works to.
Scheduled deliveries
Annual volume released against your casting schedule.
A ceramic article in a molten metal stream
A ceramic foam filter is a ceramic article, not a reactive chemical, so the hazards are handling and process hazards: ceramic dust from cutting or breakage, a hot, metal-laden spent filter after the cast, and moisture in the plate or box meeting molten metal. The summary below is orientation only; follow the producer's documentation and your own casthouse safety program.
Classified hazards
DustCeramic dust from cutting or breakage: avoid inhalation; use dust control.HeatSpent filters are hot and metal-laden: handle with heat-resistant PPE.H₂ODamp plates or boxes in contact with molten aluminum: steam eruption risk.PreheatPreheat per producer guidance before metal flow.SDSGasket materials carry their own safety information.
Preheat is a quality step and a safety step. A cold plate can freeze the first metal and fail to prime, and a damp one can cause steam eruption. Preheat the plate and filter box to the temperature the producer specifies, check the gasket has sealed, and only then start metal flow.
Storage
Store cartons indoors in a dry area, off the floor, and stacked no higher than the carton marking allows. Keep plates dry and in their packaging until use. Handle cartons carefully; foam ceramics crack under impact.
Handling
Unpack immediately before use and inspect each plate for cracks or damage. Seat the plate and gasket in a clean, dry filter box and preheat to the producer's guidance. After the cast, remove the spent filter with heat-resistant PPE. Control dust when cutting or breaking plates.
Transport
Ceramic foam filters ship as non-dangerous goods. The packaging requirement is protection against breakage, not hazard. We confirm packaging and documentation for your destination before booking.
Every batch, documented
We verify documentation before dispatch so there are no surprises at your incoming-goods bench.
Specification agreed
PPI grade, plate size, bevel and gasket confirmed against your filter box and product before order placement.
Producer quality checks
The producing plant checks dimensions and pore structure on each lot before release.
Documentation review
Dimensional and quality certificates checked by our desk before the shipment is booked.
Traceable dispatch
Each shipment is traceable to its producing lot, with full chain-of-custody records on request.
Why finer is not always better
It is tempting to assume the finest filter is the safest choice. It is not. A finer PPI grade has smaller pores and more strut surface, so it captures smaller inclusions — but it also needs more metal head to prime, carries less flow for its size, and blocks sooner as the cake builds.
That is why casthouses grade filters to the product. Coarser grades suit general billet and extrusion stock; finer grades go into can body, lithographic sheet and foil; the finest into aerospace and other critical product. Some lines run two filters in series, a coarse one to take the bulk load and a fine one to polish.
And no filter replaces melt treatment. Degassing removes hydrogen, which a filter cannot touch, and fluxing removes the bulk of the oxide. The filter is the last line of defense, and it works best when the lines before it have done their job.
We do not publish operating process parameters here; this is background only. Full technical documentation accompanies every shipment, and any process-specific detail you need is best confirmed directly with our technical desk.
| Product family | Molten metal filter |
|---|---|
| Material | Alumina-based ceramic |
| Grading | Pores per inch (PPI) |
| Casthouse sizes | 7 to 26 inch square, 50 mm thick |
| Mechanism | Depth and cake filtration |
| Before use | Preheat; check gasket seal |
Related foundry & melt-treatment products
Melt-treatment products that work upstream of the filter, supplied from the same desk.
Ceramic foam filters, answered
What is a ceramic foam filter?
What are ceramic foam filters for aluminum made of?
What does PPI mean?
What sizes are available?
How does a ceramic foam filter work?
Do ceramic foam filters need preheating?
Why is the gasket important?
Is a finer filter always better?
Does a filter replace degassing and fluxing?
Do you manufacture ceramic foam filters?
Get a quote on ceramic foam filters
Send your filter box drawing or plate size, the PPI you run today, your alloy and product, and monthly usage. We will confirm dimensions, match the grade and quote trial quantities.