STELEX PrO – T H E F O A M F I LT E R F O R S T E E L

F O R T H E P R O D U C T I O N O F C L E A N F I LT E R E D C A S T I N G S
S T E L E X* P r O
A N E W G E N E R AT I O N F O R T H E F I LT R AT I O N O F S T E E L

Calculation of gating systems The filter area must be sufficiently large to

The choke of a STELEX PrO gating system prevent early blockage during pouring, and
is usually the downsprue diameter. the surface area should be at least 4.5
The calculation of this choke area is based times that of the choke. The filter must be
on the ”general ingate formula” well supported around all edges of the exit
face. For this purpose almost 45% of the
22.6 x G In-line
DA = exit area should be used for support. gating system
ξx xtx H with STELEX
DA = downsprue area (cm2) filter print 7
22.6 = constant for acceleration More information about filter types,
G = poured weight (kg)
ξ = friction factor
filtration capacities and packaging is
= density (kg/dm3) available from your local Foseco company.
t = required pouring time (s)
H = effective pressure or pouring height (cm)

Additional support is available from our

Our recommendations for the gating system technical experts who can offer advice on
cross sections are: application rules and gating system design. In-line
downsprue = 1.0 gating system
with two
runners cross section = 1.1 no. 6 prints
ingates cross section = 1.2.

Range of
STELEX filter prints

KALPUR ST
direct pour unit,
side feeder

Consistent ”Priming”
.................................................

Reduction of temperature
related inclusions
...................................................

KALPUR ST
direct pour unit, Higher filtration capacity
.....................................................
top feeder

Excellent flow rate characteristics

........................................................

Foseco Foundry International · PO Box 5516 · Tamworth, Staffordshire · England B78 3XQ · Phone: +44 (0)1827 262021 · Fax: (0)1827 283725
www.foseco.com · Please contact your local Foseco Company · *FOSECO, the Logo, STELEX and KALPUR are Trade Marks of the Foseco Group of Companies, used under licence. All
rights reserved. No part of this publication may be reproduced, stored in a retrieval 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. All statement, information and data contained herein are published as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical
experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights,
04/2007 · re 300 e

(3) that no further safety measures are required to meet local legislation. The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller
are based on their respective conditions of sale available on request. ©Foseco International Limited 04/07

L O W W E I G H T, H I G H P E R F O R M A N C E , C O S T E F F E C T I V E . . .
 S T E L E X P r O – F I LT R AT I O N O F S T E E L C A S T I N G S
F O R T H E P R O D U C T I O N O F C L E A N F I LT E R E D C A S T I N G S A N D T H E M I N I M I S AT I O N O F T U R B U L E N C E
STELEX PrO (Priming Optimised) are the
new generation of ceramic foam filters,
specifically developed for carbon and low
alloy steels. With this new ceramic structure
the priming limitations, inherent with
zirconia based ceramic filters are eliminated.
STELEX PrO foundry filters create filter-
clean castings and minimise turbulent metal
flow during mould filling. Performance and
lightness are not incompatible, on the
contrary these are the basis for the particular
attributes which makes this filter so special
compared to the currently used zircon oxide
filters for cast steel.
STELEX PrO foundry filters have
the following features:
Low weight
Low heat capacity
Low firing shrinkage of 4 -5 %
Slag resistance
Thermal shock resistance
Low levels of internal stress
Exceptionally high creep resistance
High levels of hot strength
2 3
The particular benefits of STELEX
PrO foundry filters are:
Consistent ”Priming” even when
pouring temperatures are low such
that pouring temperatures normal for
conventional gating systems are
possible
Reduction of temperature related
inclusions
Higher filtration capacity
Excellent flow rate characteristics
compared to zircon ceramics
Flexible filter positioning - the filter
can be placed horizontally and vertically
and is ideally placed at the ingate
The use of finer porosity filters is
possible
When used in the KALPUR direct pour
system the filter will float to the
feeder surface after pouring, reducing
the risk of secondary shrinkage and
maximising feeding efficiency
No difficulties during remelting of
returns containing STELEX PrO filter
material
Lower costs for energy
Lower costs for refractory materials
Application
The new STELEX PrO filter has been
specifically developed for application to
carbon, low alloy and manganese steels.
However, STELEX PrO is not
recommended for application to
alloys with a carbon content below
0.15%, or to high alloy steels such
as stainless steel.
When applied in a running system STELEX
PrO filters remove inclusions from the metal
stream, control the metal flow rate and
reduce turbulence. The flow control and
turbulence reduction reduce the risk of
erosion and reoxidation defects and are
especially important when pouring cast Range of
steels. STELEX Pro
filters
Incorporation of STELEX PrO in the
gating systems
STELEX PrO filters can be incorporated in
the runner bar, or, if used for ”Direct-pour”
placed within a KALPUR direct pour
Two filters
system. placed in filter
print 6, close
The superior priming properties of STELEX
to the ingates
PrO means that the filter can be placed at
the ingate rather than at the base of the
downsprue. This position ensures filtration
of any inclusions generated in the running
system and optimal turbulence control
before the metal enters the mould cavity.
KALPUR ST
Foseco’s filter prints for round and
side-feeder
square filters are specifically designed
to ensure correct placement of STELEX
PrO in the gating system.
When used in a KALPUR system, the
unit can be used for both side and top
feeding.
For large castings where the filter can
not be positioned on the parting line, KALPUR ST
top-feeder
specially developed ceramic hollow-
ware filter prints are available to locate
and support the STELEX PrO filter.
 S T E L E X P r O – F I LT R AT I O N O F S T E E L C A S T I N G S
F O R T H E P R O D U C T I O N O F C L E A N F I LT E R E D C A S T I N G S A N D T H E M I N I M I S AT I O N O F T U R B U L E N C E
STELEX PrO (Priming Optimised) are the
new generation of ceramic foam filters,
specifically developed for carbon and low
alloy steels. With this new ceramic structure
the priming limitations, inherent with
zirconia based ceramic filters are eliminated.
STELEX PrO foundry filters create filter-
clean castings and minimise turbulent metal
flow during mould filling. Performance and
lightness are not incompatible, on the
contrary these are the basis for the particular
attributes which makes this filter so special
compared to the currently used zircon oxide
filters for cast steel.
STELEX PrO foundry filters have
the following features:
Low weight
Low heat capacity
Low firing shrinkage of 4 -5 %
Slag resistance
Thermal shock resistance
Low levels of internal stress
Exceptionally high creep resistance
High levels of hot strength
2 3
The particular benefits of STELEX
PrO foundry filters are:
Consistent ”Priming” even when
pouring temperatures are low such
that pouring temperatures normal for
conventional gating systems are
possible
Reduction of temperature related
inclusions
Higher filtration capacity
Excellent flow rate characteristics
compared to zircon ceramics
Flexible filter positioning - the filter
can be placed horizontally and vertically
and is ideally placed at the ingate
The use of finer porosity filters is
possible
When used in the KALPUR direct pour
system the filter will float to the
feeder surface after pouring, reducing
the risk of secondary shrinkage and
maximising feeding efficiency
No difficulties during remelting of
returns containing STELEX PrO filter
material
Lower costs for energy
Lower costs for refractory materials
Application
The new STELEX PrO filter has been
specifically developed for application to
carbon, low alloy and manganese steels.
However, STELEX PrO is not
recommended for application to
alloys with a carbon content below
0.15%, or to high alloy steels such
as stainless steel.
When applied in a running system STELEX
PrO filters remove inclusions from the metal
stream, control the metal flow rate and
reduce turbulence. The flow control and
turbulence reduction reduce the risk of
erosion and reoxidation defects and are
especially important when pouring cast Range of
steels. STELEX Pro
filters
Incorporation of STELEX PrO in the
gating systems
STELEX PrO filters can be incorporated in
the runner bar, or, if used for ”Direct-pour”
placed within a KALPUR direct pour
Two filters
system. placed in filter
print 6, close
The superior priming properties of STELEX
to the ingates
PrO means that the filter can be placed at
the ingate rather than at the base of the
downsprue. This position ensures filtration
of any inclusions generated in the running
system and optimal turbulence control
before the metal enters the mould cavity.
KALPUR ST
Foseco’s filter prints for round and
side-feeder
square filters are specifically designed
to ensure correct placement of STELEX
PrO in the gating system.
When used in a KALPUR system, the
unit can be used for both side and top
feeding.
For large castings where the filter can
not be positioned on the parting line, KALPUR ST
top-feeder
specially developed ceramic hollow-
ware filter prints are available to locate
and support the STELEX PrO filter.
STELEX PrO – T H E F O A M F I LT E R F O R S T E E L

F O R T H E P R O D U C T I O N O F C L E A N F I LT E R E D C A S T I N G S
S T E L E X* P r O
A N E W G E N E R AT I O N F O R T H E F I LT R AT I O N O F S T E E L

Calculation of gating systems The filter area must be sufficiently large to

The choke of a STELEX PrO gating system prevent early blockage during pouring, and
is usually the downsprue diameter. the surface area should be at least 4.5
The calculation of this choke area is based times that of the choke. The filter must be
on the ”general ingate formula” well supported around all edges of the exit
face. For this purpose almost 45% of the
22.6 x G In-line
DA = exit area should be used for support. gating system
ξx xtx H with STELEX
DA = downsprue area (cm2) filter print 7
22.6 = constant for acceleration More information about filter types,
G = poured weight (kg)
ξ = friction factor
filtration capacities and packaging is
= density (kg/dm3) available from your local Foseco company.
t = required pouring time (s)
H = effective pressure or pouring height (cm)

Additional support is available from our

Our recommendations for the gating system technical experts who can offer advice on
cross sections are: application rules and gating system design. In-line
downsprue = 1.0 gating system
with two
runners cross section = 1.1 no. 6 prints
ingates cross section = 1.2.

Range of
STELEX filter prints

KALPUR ST
direct pour unit,
side feeder

Consistent ”Priming”
.................................................

Reduction of temperature
related inclusions
...................................................

KALPUR ST
direct pour unit, Higher filtration capacity
.....................................................
top feeder

Excellent flow rate characteristics

........................................................

Foseco Foundry International · PO Box 5516 · Tamworth, Staffordshire · England B78 3XQ · Phone: +44 (0)1827 262021 · Fax: (0)1827 283725
www.foseco.com · Please contact your local Foseco Company · *FOSECO, the Logo, STELEX and KALPUR are Trade Marks of the Foseco Group of Companies, used under licence. All
rights reserved. No part of this publication may be reproduced, stored in a retrieval 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. All statement, information and data contained herein are published as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical
experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights,
04/2007 · re 300 e

(3) that no further safety measures are required to meet local legislation. The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller
are based on their respective conditions of sale available on request. ©Foseco International Limited 04/07

L O W W E I G H T, H I G H P E R F O R M A N C E , C O S T E F F E C T I V E . . .