Precision Sintered Powder Filter for Micro-Particle Removal

- Stainless steel (304L/316L): corrosion resistance covering PH2-12, temperature resistance 500 ℃, suitable for petrochemical, food processing and other scenes

- Titanium and titanium alloys: corrosion resistance to aqua regia and seawater, temperature resistance to 600°C in dry state, preferred in pharmaceutical and seawater desalination fields

- Nickel-based alloys (Inconel, Hastelloy): high temperature resistance to 980 ℃, chlorine corrosion resistance, dedicated to high temperature catalytic reaction systems

- Copper-based alloys: porosity 35-45%, thermal conductivity of 380W/(m-K), suitable for explosion-proof environments.

- Special materials: Monel alloy (Ni-Cu), ferro-aluminum alloy, etc. to meet the needs of special working conditions.

Filtration precision: 0.22-200μm (PTFE up to 0.3μm)

Permeability: gas 1300m³/(h-kPa) liquid 0.02-20L/cm²-min-Pa

Temperature resistance: -196℃~900℃ (nickel-based alloy)

Mechanical Strength: Compressive Strength 0.8-3MPa Burst Pressure 8MPa

Regeneration capacity: ultrasonic cleaning efficiency>95% High temperature burning regeneration>50 times

Through gradient sintering technology to realize the precise distribution of pores (pore size 0.22-200μm), porosity range 28-50%:

- Tubular cartridge: outer diameter Φ5-200mm (can be customized to Φ1000mm), length 1-15m welded molding, axial flow channel design to reduce pressure drop

- Composite structure: five-layer sintered mesh (protective layer + precision control layer + dispersion layer + double-layer reinforcement layer) to achieve compressive strength ≥ 8MPa

1. Petrochemical industry
- PTA mother liquor recovery: 316L material filter element intercepts ≥0.5μm catalyst particles.
- Crude oil pre-filtration: Monel alloy is resistant to hydrogen sulfide corrosion.

2. Pharmaceutical field
- Aseptic air purification: Titanium filter element is FDA approved, with a surface roughness Ra≤0.8μm.
- Terminal filtration of pharmaceutical solution: 0.22μm precision PTFE cartridge realizes bacterial retention rate >99.99%.

3. Electronics industry
- Ultrapure water preparation: gradient pore titanium cartridge removes ≥0.1μm particles.
- High-purity gas filtration: the nickel-based alloy cartridge is resistant to corrosion of electronic special gas.

4. Food and Beverage
- Beer clarification: five-layer sintered mesh to achieve turbidity <0.5EBC
- Fruit juice filtration: 316L cartridge passes 3A sanitary certification.

1. Raw material
- The metal powder is selected from 316L stainless steel, titanium alloy or copper-based alloy with 20-100 mesh (particle size of about 150-840μm), and the particle size distribution is optimized by ball mill or screening machine.
- Add 5-10% volatile agent (e.g. paraffin) or molding agent (e.g. polymer binder), mix in the mixing equipment for 1-3 hours to achieve uniform dispersion and ensure the stability of the pore structure.
- Special process requirements: gradient cartridge needs to be layered with coarse particles (≤100 mesh), medium particles (200-300 mesh), fine particles (≥300 mesh) powder, which is stacked layer by layer to form 1-3mm raw embryo sheet through casting machine.

2. Molding process
- Cold isostatic pressing molding: the mixed powder is pressed into the high-speed steel mold under 500MPa pressure to form a hollow cylindrical/tubular structure with a compactness of more than 92%.
- Gradient structure manufacturing: 3D printing technology or casting method is used to realize the gradient change of porosity (e.g. 30% outer layer → 50% inner layer), which improves the dirt holding capacity by 30%.
- Drying treatment is required after molding, and the temperature is controlled at 80-120°C to remove volatile agents and prevent the billet from cracking.

3. Sintering process
- Vacuum sintering furnace for high temperature treatment: stainless steel cartridge 800-900 ℃, titanium alloy 1250 ℃, nickel-based alloys 1350 ℃, sintering time 2-6 hours.
- Key control points: oxygen content <50ppm (argon protection), temperature uniformity ± 5 ℃, cooling rate <5 ℃ / min. - Special structural treatment: multi-layer composite cartridges need to be coiled and welded, with low-precision security cartridges (e.g. 0.5μm) embedded inside to form a double protection.

4. Post-treatment process
- Mechanical processing: laser cut the end face to Ra≤0.8μm, welded M20/DOE standard interface, precision error＜0.05mm.
- Surface treatment: Electrochemical polishing to enhance corrosion resistance, or spray PTFE coating to enhance hydrophobicity.
- Performance testing: ISO 2941 permeability test, ASTM F838 bacterial retention verification, burst pressure ≥ 8MPa test.

1. Material performance breakthrough
- Resistant to extreme environment: 316L stainless steel is resistant to 500℃ high temperature/PH2-12 corrosion, titanium alloy is resistant to aqua regia/seawater erosion (600℃ dry state).
- Excellent mechanical strength: compressive strength of 0.8-3MPa, nickel-based alloy burst pressure up to 8MPa, alternating load withstand > 10,000 cycles.
- Outstanding regeneration ability: ultrasonic cleaning efficiency>95%, high temperature burning regeneration>50 times, life expectancy is 3-5 times longer than traditional cartridges.

2. Structural innovation advantages
- Gradient pore design: the outer layer has 5μm precision to intercept large particles, the middle layer has 2μm control precision, and the inner layer has 0.22μm to realize terminal filtration, with a pressure drop of 0.08ΔP.
- Composite function integration: five-layer sintered mesh structure (protective layer + precision layer + dispersion layer + double-layer reinforcement layer) improves the dirt holding capacity to 3-5 times.
- Intelligent pore size adjustment: Memory alloy cartridge can realize ±5μm dynamic pore size adjustment to adapt to flow fluctuation.

3. Improvement of process economy
- Raw material utilization rate＞98%, energy saving 40% than traditional casting process.
- Rapid prototyping technology shortens the production cycle by 50%, and 3D printing realizes single-piece customization of complex structures.
- Modular design supports online replacement, reducing maintenance costs by 60%.

1. Petrochemical field
- PTA mother liquor recovery: 316L filter element intercepts ≥0.5μm catalyst and is resistant to 20MPa high pressure.
- Crude oil desulfurization: gradient nickel-based cartridge is resistant to H₂S corrosion, with a precision of 1μm.

2. Biopharmaceutical
- Aseptic air filtration: titanium cartridge passed FDA certification, surface roughness Ra≤0.8μm.
- Vaccine terminal filtration: 0.22μm precision PTFE composite cartridge with bacterial retention rate >99.99%.

3. High-end manufacturing
- Semiconductor ultrapure water: gradient titanium cartridge removes ≥0.1μm particles, resistivity>18MΩ-cm.
- Aviation hydraulic system: multi-layer sintered mesh cartridge is resistant to -196℃ liquid nitrogen environment.