Filson sintered wire mesh is usually made of multiple layers of metal wire mesh, which is processed through sintering process. The sintered wire mesh is usually made of multilayer wire mesh and processed through the sintering process to form a variety of structures, including plate type, disc type, ink cartridge, etc.
There are many factors that determine the quality of sintered wire mesh, such as material selection, control of production process and inspection of final products. This blog is mainly used to compare the materials to teach you how to choose the most appropriate product, so as to better control its quality and maximize its performance.
Comparison of the Pros and Cons of Different Materials
Sintered metal wire mesh offers a variety of material options, including stainless steel, nickel, Hastelloy, Monel, Inconel, and others. Each material exhibits different characteristics. To make an informed choice for your specific application, it is essential to carefully weigh the pros and cons of sintered wire mesh made from various materials.
Stainless Steel
Filson uses stainless steel 304/316L. One or more layers of stainless steel wire mesh are compressed and sintered, eventually being firmly adhered together without the use of any adhesive. It has excellent filtering properties and robust construction.
Stainless steel sintered wire mesh can withstand high temperature below 480℃, suitable for filtration in high temperature environment without deformation. It is easy to clean and maintain and supports multiple reuse, thus improving cost-effectiveness.
Although the corrosion resistance of stainless steel sintered wire mesh is commendable, it has limited tolerance for certain chemicals. If contact with strong alkali or chlorine-containing substances, such as sodium hypochlorite, may pose a risk of corrosion and cracking.
Nickel
By combining single-layer or multi-layer nickel mesh (nickel 200, nickel 201) together, nickel sintering wire mesh has high mechanical strength, excellent corrosion resistance, eminent thermal conductivity, heat resistance and other properties.
Since it can perform normal filtration at high temperatures of 900°C, nickel sintered wire mesh is very suitable for high-temperature fields like petrochemical industry, metallurgy, and aerospace. In addition, it is able to capture impurities from 1μm to 100μm, showing excellent filtration performance.
Although nickel sintered wire mesh has good overall properties, its relatively high cost makes it less preferred in areas where heat resistance and strength are lower. In this case, other sintered mesh materials can be considered, such as stainless steel.
Hastelloy
Primarily composed of metals including nickel, chromium, molybdenum, iron, and cobalt, Hastelloy C-276 is an alloy with higher strength, superior corrosion resistance and high-temperature resistance than nickel. Its oxidation resistance allows for long-term use without any changes in high-temperature environments.
Different from nickel metal, the machining and molding of Hastelloy are relatively simple and can be operated with conventional methods and equipment. However, it should be noted that it is less easy to weld because of the high nickel content.
The high mechanical strength of Hastelloy sintered wire mesh prevents breakage even in extremely fine mesh configurations, with minimum filtration level of 10μm. It also supports multiple cleaning and reusing without compromising performance.
Monel
Monel, a nickel-based alloy composed primarily of copper, iron, and other metals, boasts a robust structure with greater strength than non-alloyed nickel. Its thermal stability enables it to operate normally without deformation in high-temperature environments up to 480°C.
With good ductility and weldability, Monel sintered wire mesh can be easily processed into various shapes, ranging from standard wire mesh to dutch weave mesh. It is widely used in chemical industry, food&beverage, water treatment, pharmaceutical industry, power generation, nuclear industry and other fields.
The Monel sintered wire mesh exhibits inertness to corrosive chemicals. It maintains good performance in media including hydrofluoric acid, sulfuric acid, and alkalis, etc. However, it may sometimes experience galvanic corrosion.
Inconel
Inconel sintered wire mesh offers a variety of material options, including Inconel 600, Inconel 601, Inconel 625, Inconel 718, etc. Mainly composed of nickel, chromium, iron and other alloy elements, it has excellent oxidation resistance, mechanical strength and weldability.
Sintered Inconel wire mesh is non-magnetic and is suitable for situations where it is not subject to magnetic interference or attraction. It has exceptionally high thermal stability and can withstand temperatures up to 1200°C.
However, it requires precise temperature control and welding technology. When it is permanently exposed to high temperatures or certain chemicals, there is a risk of embrittlement.
Production Technology Control
Temperature
Temperature control during the sintering process plays a decisive role in the quality and performance of product. Firstly, make sure the temperature is controlled close to the melting point of the metal or alloy, not too low or too high, so that the wire mesh can be perfectly combined without deformation.
When come to the cooling phase, you need to slowly lower the temperature to room temperature to prevent thermal shock from damaging the integrity of the sintered mesh.
In short, during the process of making sintered wire mesh, standards must be strictly followed for temperature control to ensure product integrity and high performance.
Technology
When weaving wire mesh, strict control standards should be followed to ensure that the wires are evenly distributed and to avoid inconsistent mesh sizes. When flattening the metal mesh, thickness accuracy and surface smoothness must be maintained. Throughout the sintering process, you need to control factors such as temperature, time, and environmental pressure.
In order to ensure that the various parameters of the product are within the specified range, we constantly monitor process parameters such as temperature, pressure, wire tension, and identify and correct any deviations at any time. The resulting metal mesh forms a strong and complete structure after sintering.
Surface Treatment
The surface treatment technology of sintered wire mesh includes cleaning, coating, polishing, etc. Cleaning is a prerequisite for all operations, including ultrasonic cleaning, solvent cleaning or detergent cleaning to remove surface contaminants and residues.
In order to improve the corrosion resistance or other properties of sintered steel wire mesh, it can be coated with polymers, ceramics, metals, etc. to isolate the direct contact between the metal surface and the environment and reduce corrosion and friction.
The purpose of polishing the surface of the sintered wire mesh is to improve the surface smoothness, eliminate surface defects, achieve ideal appearance and reliable quality, thereby improving the performance and service life of the sintered wire mesh.
Strict Inspection
Raw Material Inspection
Inspection starts with the inspection of raw materials to verify their quality and compliance with the specification. This includes assessing the composition, size, and surface condition of the metal wires used in the grid.
Weaving Inspection
During weaving, check the grid for uniformity, consistency, and any defects such as broken wires or irregular weaving patterns. This ensures that the grid meets the required specifications and standards.
Pressure Leveling Inspection
If flattening is required, check the flat mesh to ensure that the entire surface thickness is uniformly smooth. Identify and address any deviations from the specified tolerances.
Sintering Inspection
After sintering, the sintered wire mesh was thoroughly inspected to verify the correct bonding between the wires to form a uniform porous structure. This includes visual inspection as well as testing of the mechanical strength and dimensional precision.
Inspection of The Final Product
Before packaging and shipment, a final inspection is performed to confirm that the sintered wire mesh meets all quality requirements and customer specifications. Any nonconforming product are identified and isolated for further evaluation or corrective actions.
Conclusion
This blog comprehensively explores the materials, production technology and testing of sintered wire mesh. It provides valuable guides to understanding and rational use of sintered wire mesh to help you make informed decisions that optimize use in a variety of industrial environments.
If you have made it clear which sintered wire mesh you want to buy after reading this blog, or if you still have questions, please Contact Filson as soon as possible. We have experienced sales, professional technical staff and market-competitive products that will definitely satisfy you!
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