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SEDEX* ULTRA
THE CERAMIC FOAM FILTER FOR IRON CASTINGS

++ Highest filtration efficiency

++ Improved Yield
++ Consistent flow rates
 SEDEX ULTRA
A new generation of filters for Iron Castings

SEDEX ULTRA ceramic foam filters represent the latest

development in the filtration of Ductile, Grey and
Malleable Iron castings. Using a unique production
process, the edges of the filter are closed on all 4 sides,
resulting in improved edge definition.
In addition, SEDEX ULTRA filters use an optimised
ceramic composition, which allows filter weight to be
reduced, resulting in a consistently more open pore
structure. This enables SEDEX ULTRA to deliver the
highest levels of filtration efficiency as foundries can
use finer pore filters, whilst maintaining their pouring
times and metal flow rates. In some cases, foundries
have been able to reduce the size of filter employed,
whilst maintaining the same pouring time, with the
added advantage of reducing the weight of liquid
metal contained within the filter core print – improving
casting yield.
Key benefits of SEDEX ULTRA filters include:
++ Cleaner Castings and Reduced scrap
- Use of finer filters to increase inclusion
capture and improve flow modification
- More open structure allows casting pouring
times to be maintained
++ Improved Casting Yield
- F ilters can be downsized, reducing the
weight of the gating system and improving
casting yield
 onsistent Flow Rates
++ C
-M ore open pore structure ensures more
consistent pouring times in many applications

The closed edges of the SEDEX ULTRA filter also give

improved handling characteristics, particularly with
automated placement systems and reduce the chance
of metal bypass as the filters seal in the core print
more effectively.

SEDEX ULTRA
filter placed
in the gating
system of a
A range of
DISAMATIC
SEDEX ULTRA
casting
filters

2
SEDEX ULTRA filters
Cleaner castings and increased yield

Calculation of the gating system Application example of SEDEX ULTRA

In gating systems using SEDEX ULTRA filter, the In this example of a ductile Iron flywheel, we can see
smallest cross-section or choke area should be at how the application of SEDEX ULTRA enables the use
the base of the downsprue. of a smaller filter area, providing improved casting
yield.
The calculation of this choke area (CA) is based on
the “general downsprue formula” as shown below: The top image shows the initial conventional
unfiltered gating system, with a total poured weight
of 25 kg – pouring time 15.5 secs.
In the first optimisation, a conventional SEDEX filter Initial gating system
50x50x15mm/20ppi was applied, reducing scrap
rate and at the same time reducing poured weight
CA = downsprue [cm2] to 23.7 kg – pouring time 10.5 secs.
22.6 = constant
W = poured weight [kg] In the second optimisation, the gating system is modi-
= friction factor fied to accept a SEDEX ULTRA 20 40x40x15. Poured
= density [g/cm3] weight is further reduced to 23.5 kg – a metal saving
t = required pouring time [s] of 0.2 kg per casting compared with the standard
filtered gating system. Pouring time was again
H = effective pouring height [cm]
maintained at 10.5 secs.
1st Optimisation
- Conventional
Based on the higher flow rate capacity of the ULTRA The last modification alone results in a returns SEDEX Application
product, depending upon application, the filter area saving of 10,000 kg per annum. Together with the 50x50x15mm/20ppi

may be reduced by up to 20% and a finer filter can pouring time reduction and returns saving from
be employed. The following capacity guidelines can the initial modification, this results in a significant
be used: commercial improvement for the foundry.

Filter capacity kg/cm2 Iron alloy

0.5 - 1.2 NiResist, SiMo, GJS (Inmold)
1.0 - 2.4 GJS / GJV
2.0 - 4.8 GJL / GJM

SEDEX ULTRA
filter sitting in the 2nd Optimisation
coresetter print of SEDEX ULTRA 20
a DISA 40x40x15

3
 Quality Assured
Higher quality and lower costs

Quality management
The Foseco quality management system is certified Important product attributes monitored in this
against DIN ISO 9001, VDA 6.1 and ISO 14001. All way include:
relevant product quality features of SEDEX ULTRA ++ Filter dimensions
filters are controlled and recorded according to these ++ Filter weight
quality standards. ++ Cold compression strength
++ Porosity Filter
++ Thermal shock resistance (impingement test) measurement

Next to filtration effectiveness, thermal shock and

erosion resistance to the liquid iron are the most
important product attributes. These properties are
evaluated regularly using liquid cast iron. A special test
procedure, the impingement test, has been specifically
developed for this purpose. Extensive use of this test
has enabled Foseco to continually improve the quality
and consistency of the SEDEX iron filter.

It ensures that the filters are tested under the most

severe conditions possible, in terms of ferrostatic Room
pressure and filter support. This test represents the most temperature
Impingement
testing unit
relevant quality measure for our customers. strength
measurement

*FOSECO, the Logo and SEDEX are trade marks of the Vesuvius Group, registered in certain countries, used under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval Foseco International Limited
system of any nature or transmitted in any form or by any means, including photocopying and recording, without the written permission of the copyright holder or as expressly permitted by law. Applications for Drayton Manor Business Park,
permission shall be made to the publisher at the address mentioned.
Tamworth, Staffordshire, England B78 3TL
05/2015 · re 500 e

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