What is Sintered Metal Filter? Complete Guide by Lvyuan

What is Sintered Metal Filter?

What is Sintered Filter Working Principle ?

In other words, because of the stable porous frame, sintered metal filters are some of the better filtration elements available today. available today. In addition, the high temperature, high pressure and corrosion resistance of the metal materials can make iteasily perform the filtration task in a harsher environment. As such, it can easily separate and filter out excess contaminants.

You don't need or want to obtain higher purity gases or liquids for your project, and if you're also looking for

some genuine factory to OEM sintered metal filters for your filtration system, please check here to find the top industrial filter manufacturers.

It may not be a word you come across very often in your everyday communications. 

But nowadays, sintered metal is being used more and more in various industries; the sintered metal has started to become the technology in some manufacturing industries.

 

Then What Exactly is a Sintered Metal ?

In fact, it is an industry of powder metallurgy; in other words, it is the 316L stainless steel powder through the mold. ld

forming, high-temperature sintering into the shape and function of a process that we require.

Then, firstly, sintered. What is sintered?

Sintering is the process of compressing and shaping a compacted mass of material.

by heat or pressure without turning it into a liquid or causing it to melt. Sintering is one of the processes in a manufacturing technology.

with metals, ceramics, plastics and other materials. From Wikipedia

As described in Wikipedia, there are numerous types of materials that can be sintered and the sintered products of different materials. different applications. Then here we would like to give you more information about sintered metal. 

The evolution of sintered metal

Who invents the sintering and when and who started using the sintered products?

Historical evidence shows that the sintering process was developed during the second industrial revolution in the 18th century.

in Sweden and Denmark. Sintered iron was discovered in the course of smelting in coal mines.

But it was not until 1980 that sintered metal was applied to oil filtration. And in 1985, HyPulse® filtration technology was used for the first time.

The second type of continuous filtration process is slurry oil filtration.

So actually you can check as follows: there are 3 main development times. 

 

1.Ancient Origins

Bronze Age:

The first indications of processes similar to sintering originated in the Bronze Age when metal pieces were.

probably made by heating and pressing metal dust.

Iron Age:

It may be that such ironworking techniques as the use of heated and compressed iron ore involved

elements of sintering.

 

2.Industrial Revolution and Early Development

19th Century:

There was growing concern with metalworking methods during the Industrial Revolution. Powder metallurgy,

a process that preceded sintering, started to be developed as a technique for fabricating metal items from powdered materials.

Early 20th Century:

Sintering processes were developed as a result of progress in metallurgical and material sciences.

The use of sintering processes for the production of porous metal filters and bearings increased.

 

3.Modern Era and Technological Advancements

Mid-20th Century:

Sintering technology developed in the mid-twentieth century as a result of technological developments.

in powder metallurgy and materials science. The synthesis of advanced sintered materials for

aerospace, automotive and industrial applications emerged as key areas of interest.

Late 20th and Early 21st Centuries:

In the latter years of the 20th century and the early years of the 21st century, there was significant advancement in the field of sintering technology. The evolution of enhanced sintering methods, such as selective laser sintering (SLS) and binder jetting, led to a substantial expansion in the range of materials that could be processed and the complexity of the resulting structures.

 

Contemporary Applications

Automotive:

Sintered products find application in a variety of automotive components, including gears, bearings, and filters.

The inherent characteristics of sintered products, including strength, durability, and porosity, render them well-suited for high-performance applications.

Aerospace:

The utilisation of sintered materials in aerospace components is primarily driven by their unique combination of low density and high strength.

These materials are utilised in critical components such as turbine blades, fuel nozzles, and heat exchangers.

Medical Devices:

Sintered materials are applied in the manufacturing of implants, prosthetic devices, and dental structures.

These applications are ideal for them because of their biocompatibility and tunable characteristics.

Industrial Applications:

Sintered materials are widely used in many industries such as filtration, electronics, and energy storage.

They are widely used in many industries due to their flexibility and ability to perform in different ways.

 

 

A simple definition of sintered metal filter

The metal filter under discussion employs metal powder particles of uniform size, which are formed by stamping. The filter is subjected to a high-temperature sintering process. Sintering is defined as the metallurgical process in which powder-sized bodies of materials are compacted by the application of heat and/or pressure, resulting in the melting of the particles and their subsequent unification.

Metals and alloys undergo a transformation after the stamping process.

Metal forming is achieved through the process of diffusion at temperatures below the melting point of high-temperature furnaces.

The metals and alloys that are currently in common use include aluminium, copper, nickel, bronze, stainless steel, titanium and more.

The powder can be formed through various methods below. These methods include grinding, atomization, and chemical decomposition.

 

What the Sintering Metal Filter Manufacturing Process

Then, so here, we like to check the process detail of  Metal filter manufacturing. if interested, please check below: 

1. What is Sintering, Why Use Sintering?

Sintering can be defined as the process of uniting metal powder particles through the application of elevated temperatures and additional methodologies. In the micron range, the metal powder particles exhibit a lack of physical barriers between them.

This enables precise control over the porosity of the final product.The adoption of lean production systems and manufacturing resources during the manufacturing process is instrumental in ensuring environmental protection.

The open structure of the sintering process gives the metal a stable shape, and the porous cartridge provides the metal with the required strength, resulting in a material with robust filtration performance.

 

2. 3-Main Steps of Sintered Metal Filter Manufacturing

1:  The first step is to get the Power Metal.
Metallic powders can be obtained through various processes, including grinding, atomisation, and chemical decomposition. During the fabrication process, it is possible to mix one metal powder with another to produce an alloy. 
The metal powders can be obtained through grinding, atomization, or chemical decomposition.
The combination of metal powders to form an alloy during the fabrication process is possible, or alternatively, the use of a single powder, preferably of a low titer, is an option. A notable advantage of sintering is that it does not alter the physical characteristics of the metal material. The process is so straightforward that the metal components are not changed.

 

2:  Stamping

The subsequent stage of the process is the casting of the metal powder into a designed mold, with the objective of enabling the shaping of the filter.

The filter assembly is conducted at ambient temperature and under stamping conditions. The force applied during this process is contingent on the type of metal utilised, given that different metals exhibit distinct levels of elasticity.

Subsequent to a high-pressure impact, the metal powder is compressed within the mold to produce a solid filter. 

Following the high-pressure impact procedure, the prepared metal filter can be placed in a high-temperature furnace, for example. 

 

3:  High-temperature Sintering

In the process of sintering, metal particles are bonded together to form a single mass without reaching the melting point of the metal.

The resultant monolith exhibits mechanical robustness, chemical stability, and permeability characteristics that are comparable to those of the metal itself.

The porosity of the filter can be controlled by the process, depending on the flow level of the air or liquid to be filtered.

The designation of the sintered media grade is the mean flow pore, which is also the average pore size of the filter.

Sintered metal media are available in grades ranging from 0.1 to 100, with increasing levels of porosity. The filtration rating in liquid for media grades 0.2 to 20 is between 1.4 and 35 µm absolute. In the context of gas filtration, the range is from 0.1 to 100 µm absolute.

 

 

Why to Use Metal Sintering to Make Filter?

This is a good question: why use metal to make a filter? 

The answer is obvious, and despite numerous reasons, the price is the primary one. 

Why is the cost high? 
Yes, the sintered metal is fully stable and reusable, clean, and can be used many times.

And also, different metals have stable physical and chemical properties and are not easily damaged. 

That is why the sintered filters are increasingly applied in various industries.

What are the Material Choices for Sintered Filters?

As the technology of powder metallurgy moves on, there are more options of raw materials for the production. materials for filters made of sintered metals

There are many other metals and alloys that one can select from in order to fulfill special demands of higher temperature and pressure, corrosion resistance, etc. Main metal materials such as: 

Stainless Steel Filter: 316L, 304L, 310, 347, and 430
Bronze
Inconel® 600, 625, and 690
Nickel 200 and Monel® 400 (70 Ni-30 Cu)
Titanium
Alloys 
A variety of sintered stainless steel filters are available, including cartridges, plates and tubes, manufactured from stainless steel.
The 304 and 316 stainless steel grades are particularly noteworthy for their high filtration efficiency, extended operational lifespan, and broad applicability in diverse fields, including liquid and gas filtration. These materials are resistant to corrosion and can withstand temperatures in excess of 1000°C.
The use of these materials is set to increase in the future.

 

The following are the benefits of the Sintered Metal Filter

1. Corrosion resistance
Almost all the metals are inherently anticorrosive, like sulfides, hydrides, oxidation, and so on.

2. Better separation of the contaminants
The ability to fine-tune the porosity of the cartridge to the fluid ensures that you get the best.  filtration you desire and obtain a fluid free of contaminants. Also, the filter does not corrode; the reaction of the filter does not lead to the appearance of impurities in the fluid.

3. High Thermal Shock
In the manufacturing process, heat is produced, and the physical characteristics of these metals assist in reducing the thermal shock of the filter since it is very large. Therefore, you can use these filters in a vast number of applications based on the thermal classification of the application. 

High thermal shock also provides good fluid filtration without having to worry about the heat of the application.

4. Reasonable Pressure Drop
A sintered metal filter can ensure fluid pressure in your application, so it will last longer. maximum operation.
Even a small pressure loss is dangerous for your application.

5. Heat and Pressure Endurance
This filter can be used in applications where the temperature and pressure are high without any problem. worrying about your filter element.

Employing sintered metal filters during the synthesis of chemical reactions and gas treatment plants is that you get the best filtration results in case you use the right plants.

6. Durable and Difficult to Fracture
The other advantage of using a sintered metal filter is that it is normally very strong and resistant to fracture.

In the course of the manufacturing process, the joining of metals takes place at temperatures that are well below the melting point.

The end product is a sintered metal filter with high mechanical strength to endure different harsh environments.

For instance, you can employ it in applications that involve friction, but you are not likely to break.

7.  Fine Tolerances
This means that your sintered metal filter can filter your fluid without reacting with it because of the fine tolerances.

After filtration is done, the sintered metal filter will maintain its physical characteristics of the filtration material.

Nevertheless, it would be wise to ensure that the metal you use for your filter will not interact with the fluid you are filtering.

8. Geometric Possibilities: A Spectrum
Sintered cartridges give you the opportunity to make use of a large number of geometric possibilities. You can achieve

This while adding the powder into the dye during the production of the product.

The mold is the one that should design your filter.

Thus, you are allowed to run the design as you wish, at your discretion.

 

For instance, if a small filter is required for a specific application, the design can be readily modified to create a smaller sintered metal filter. Furthermore, should the application in question possess a distinctive appearance, the design of the mold can be readily modified during the manufacturing process.

 

How do Sintered Metal Filters Work?

This problem can also be said to be the working principle of sintered metal filters. 
It is a commonly held belief that this question is very difficult to answer, and while this may be the case, it is not. It is possible that those who read this explanation may find themselves in a state of surprise; however, it is also possible that this will not be the case.

Sintered metal filters are indeed highly useful filters. The collection of contaminants occurs on the surface of the fluid; when the fluid is forced through the metal filter, the large particles and contaminants are left on one side of the cartridge. However, when selecting a proper filtration level for your fluid, it is essential to ensure that it can meet all the required filtration criteria.

 

These Requirements Include

 1. Contaminant retention backwash capability 
 2. Pressure Drop

In the context of pressure drop, it is imperative to consider a range of parameters.

These factors include:

The viscosity of the fluid, its velocity when passing through the filter element, and the characteristics of the contaminant. 

The contaminant characteristics that must be considered include its shape, density, and size. 

In instances where the contaminant is solid, uniform in shape, and capable of forming a compact cake, the implementation of surface filtration becomes a viable option.

 

The Efficiency of Sintered Metal Filtration Depends on

1. the pressure rises to the value of the increased pressure and then decreases to the absolute pressure is reached. 

2. the steady stream of the liquid. 

End conditions can be obtained by thickening contaminants that rise to the level that the fluid pressure is reduced. 

This pressure declines gradually until the maximum drop for a given viscosity and flow rate characteristic is achieved.

Another important issue is the backwashing of the filter, where the gas is pressurized to the screen and rapidly

turning the backwash discharge valve as the backwash is in progress.

 

A high reverse instantaneous pressure differential is created. The filtration process also serves to remove contaminants from the filter element surface. The flow of clean fluid in the reverse direction through the filter element assists in the removal of contaminants and leads out of the filter.

The observed increase in pressure drop rate is indicative of a gradual and uniform increase in contaminant size. In order to ensure the reproducibility of outcomes, it is imperative to regulate the pressure drop across the filter element. 
Fluid temperature fluctuations have been observed to influence viscosity, with the term itself being derived from the Latin word viscum, meaning mud. In such instances, the pressure drop across the filter element is known to enhance, rather than to realise the filtration effect. 
It is therefore essential to ensure that the filter's operating temperature is maintained during the filtration process, in conjunction with the temperature and pressure of the fluid. It is imperative to adhere to the appropriate backwashing method when cleaning the filter.

 

 

Main 6-Kinds of The working principle of metal filtration

I hope it will be useful for you to learn more for how sintered metal Filter can be useful for filtration of liquid, gas and voice.

1.) Liquid & Gas filtration/separation

Sintered metal filters can either eliminate or minimize particulate contamination in a gas or liquid stream.

Suspended particles could be sediment, metal chips, salt, etc., and therefore particulate matter can be but is not limited to.

algae, bacteria, fungi spores, and other undesirable chemical/biological pollutants. Metal filter pore sizes

can make it range from 0.2 µm to 250 µm. 

 

2.) Sparger

The following are some of the applications of sparging:

Soda carbonisation

Beer carbonisation

Oxygen stripping of edible oils

Sparging is defined as the process of injecting a gas into a liquid. The application of this process can be categorised into two distinct methods: The removal of undesirable dissolved gases, a process also referred to as oxygen stripping or dissolved volatile liquid extraction. It can also be used to inject a gas into a liquid (carbonization).

The traditional method of sparging yielded bubbles with a diameter of 6 mm, whereas PM filter sparging facilitated the formation of bubbles with an even smaller diameter.The diameter of the bubbles, and consequently the surface area, is a crucial factor in determining the efficiency of sparging. The application of this process can be enhanced by reducing the duration of the process.

3.) Breather Vents

Sintered metal filters are utilised as breather vents in various systems, including cylinders, gearboxes, manifolds, and hydraulic systems. The function of breather vents is twofold: firstly, they enable pressure balance and facilitate the exchange of air and/or gas in and out of a system; secondly, they prevent the ingress of particulate matter into the system.

Sintered bronze filter discs are of particular utility in electric motors, where they serve to protect the motor from dust, moisture, and other contaminants. At the same time, these filters permit air interaction, a process which is necessary for the stability of the internal climate of the motor and its proper functioning and longevity. 
Metal filters can be backwashed to remove particulate matter, thereby extending their lifespan as a breather vent when compared with other filter media.

 

4.) Sensor Protection

Sintered metal filters can also function as a protective cover for electronic components, such as thermometers, sensors, and components of medical equipment, as well as other critical products. These filters can protect against water, liquids, sediments, dust, and pressure variations. 

 

5.) Flow Control ( Throttling / Dampening )

A single special sintered filter is capable of managing flow in an air, gas, vacuum, and fluid flow system. The uniform pore size of the filter ensures consistent flow rate control, thereby preventing damage to valves, sensors, and other components downstream. The application of flow control encompasses various domains, including pneumatic timers, the regulation of gas supplies, and the implementation of time delays. 

 

6.) Air Exhaust Silencers

Sintered filters have the capacity to be welded or sinter-bonded to any required fitting, thereby serving as an exhaust silencer. The functionality of the filter encompasses the ability to safeguard both solenoids and manifolds within the system from the infiltration of contaminants. Additionally, it has been demonstrated to attenuate the acoustic intensity of exhaust emissions. 
Furthermore, these filters have been shown to reduce the rate of air exhausting from the system, thereby minimising contaminant wafting. These filters are also notable for their environmental friendliness.

 

 

For what is Sintered Filters applied to?

In relation to the aforementioned query, a pertinent question to pose is: What are the applications of sintered metal filters?

Given the complexity of the production process, it is reasonable to inquire about the potential applications of sintered metal filter cartridges.

However, it is evident that these filters find application in various industries.

The following are some of the more prominent applications:

1. Chemical processing

Sintered metal filters are utilised extensively in the chemical, solvent and gas processing industries, as well as in the nuclear industry. The corrosion-resisting capability, high working temperatures, and chemical attack resistance of sintered metal filters make them a preferred choice in the chemical processing field.

2. Petroleum refining

In the context of petroleum refining, the utilisation of optimal filtration mechanisms is paramount for the separation of diverse fuels.
The selection of metal filters is dependent on the degree level, with the objective being the filtration of the specific fuel from the feedstock. 
The employment of sintered metal filters is instrumental in achieving this objective.
This is due to the fact that metal filters do not form a chemical compound with the fuel as paper filters do.
Consequently, the fuel will be devoid of any contaminants, as it will have undergone filtration.
A further advantage of metal filters is their ability to withstand temperatures in excess of 700 degrees, a requirement common to petroleum processing industries.

3. Power generation

The generation of hydroelectric power is contingent upon the continuous operation of a turbine. 
However, the environment surrounding the turbine frequently necessitates filtration to ensure a body of water is available through which the turbine will not be contaminated by any debris.
The presence of impurities within the turbine can lead to its overloading, resulting in the cessation of its rotational movement and, consequently, the interruption of electricity generation. The utilisation of sintered metal filters is instrumental in ensuring the efficacy and efficiency of power generation.
These filters are utilised to filter water from the turbine in order to generate electricity.
The durability of the turbine is enhanced by the resilience of these filters to wear and tear from contact with water.

4. Natural gas production

Gas production represents a significant area of application for sintered metal filters, and will be the focus of the following discussion.
Sintered metal filters are of significance in the production of gas due to their ability to interact with the gas, and their versatility in a range of conditions.

5. Food and beverage

Within the domain of food and beverage processing, metal filters play a pivotal role in the extraction of nutrients and juices from food materials.
These filters are utilised to screen out nutrients and juices during food processing, thereby preventing their loss during the manufacturing process.
A notable advantage of these filters is their versatility, as they are not affected by particular foodstuffs or beverages.
It is imperative to ensure that the quality of the production process is maintained when utilising these filters.

 

What kind of Sintered Metal Filters Lvyuan Can Supply ?

Lvyuan: Your all-in-one sintered filter solution

Lvyuan specializes in the manufacturing of sintered metal filters, stainless steel filter housings, PE filters, and other filter cartridges.
The company has obtained CE, ROHS, SGS, and other certifications, indicating its commitment to quality and safety standards. In addition to its core product line, Lvyuan offers OEM and ODM services, catering to the specific needs of its clients.The company's products find application in diverse fields, including food and beverage, machinery manufacturing, petrochemical, biopharmaceutical, medical and health, electronic and electrical liquid filtration, and air filtration. Lvyuan's client base spans over 85 countries, with a presence in multiple industries, totaling more than 1,000 customers.