Welcome to the AdTech Case Study Center. Here, we demonstrate how our high-end molten metal filtration and degassing technologies solve real-world production challenges for global aluminum foundries.

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1. Molten Aluminum Degassing Unit | Online Degassing Solution

Target Product: Online Degassing Unit, Degassing Rotor

• Time: October 2023

• Location: Mexico (Automotive Component Manufacturer).

• The Challenge: The client was producing high-performance aluminum alloy wheels but faced a high scrap rate (over 8%) due to pinhole porosity and high hydrogen content. Their existing degassing equipment was inefficient, leading to inconsistent metal quality between batches.

• AdTech’s Solution: We implemented the AdTech Online Degassing Unit with a dual-rotor configuration. We optimized the argon flow rate and utilized our high-strength, anti-oxidation graphite rotors. The system was integrated with a PLC control to ensure precise gas-to-metal contact time.

• The Result: The hydrogen content was successfully reduced to below 0.12ml/100g Al. The scrap rate dropped from 8.5% to 1.2%, saving the client approximately $15,000 in monthly material loss.

Learn more about AdTech Degassing Units

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2. Plate-Type Filtering Unit | High-Purity Alloy Filtration

Target Product: Plate-Type Filtering Unit, Filter Box

• Time: February 2024

• Location: Turkey (Aluminum Foil & Packaging Plant)

• The Challenge: A foil producer reported “dark spots” and pinholes in ultra-thin (6-micron) foil production. These defects were caused by microscopic non-metallic inclusions that standard filtration methods failed to capture.

• AdTech’s Solution: AdTech provided a Multi-stage Plate-Type Filtering Unit. By combining a 30ppi CFF with a secondary fine-mesh plate filter, we created a deep-bed filtration effect. We also redesigned the lining using high-silicon molten material to prevent secondary pollution.

• The Result: The purity of the molten aluminum reached aerospace standards. The pinhole count per square meter of foil was reduced by 70%, enabling the client to enter the high-end pharmaceutical packaging market.

Learn more about AdTech Plate-Type Filtering Unit

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3. Ceramic Foam Filter (CFF) | Daily Casting Quality Optimization

Target Product: Ceramic Foam Filter, Alumina Filter

• Time: June 2024

• Location: Vietnam (Aluminum Extrusion Billet Producer)

• The Challenge: The client faced inconsistent flow rates during the casting of 6xxx series billets, leading to surface turbulence and oxide skin entrapment in the final logs.

• AdTech’s Solution: We supplied our High-Purity Alumina Ceramic Foam Filters (Pural) with specialized beveled edges and sealing gaskets. We guided the client on the correct pre-heating temperature (above 200°C) and placement within the filter box to ensure a steady “laminar flow.”

• The Result: The extrusion speed of the billets increased by 15% because the internal metal structure was more uniform. The surface finish of the extruded profiles met the “Architectural Grade” requirements on the first pass.

Learn more about AdTech Ceramic Foam Filter

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4. Boron Nitride Coating | Tooling Protection & Release

Target Product: Boron Nitride (BN) Coating, Nano Coating

• Time: August 2023

• Location: Thailand (Die-Casting Factory)

• The Challenge: Molten aluminum was frequently sticking to the launders and ceramic transition plates, leading to frequent downtime for manual cleaning and rapid degradation of the refractory materials.

• AdTech’s Solution: We introduced AdTech Nano-grade Boron Nitride Coating. This high-temperature lubricant provides a non-wetting surface. We trained their staff on the “thin-layer multi-spray” technique to ensure maximum adhesion to the refractory substrate.

• The Result: The cleaning frequency was reduced from once every shift to once every three days. The lifespan of the transition plates and launders was extended by 40%, significantly lowering maintenance costs.

Learn more about AdTech Boron Nitride Coating

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5. Refining Flux | Impurity & Dross Management

Target Product: Refining Flux, Drossing Flux, Covering Flux

• Time: April 2024

• Location: Brazil (Recycled Aluminum Smelter)

• The Challenge: Using secondary aluminum scrap resulted in high dross formation and significant metal loss (burning loss). The smoke produced during their old refining process also violated local environmental regulations.

• AdTech’s Solution: AdTech customized a Sodium-free, Environmentally Friendly Refining Flux. This flux has a low melting point and high surface activity, allowing it to efficiently separate the aluminum from the dross (making the dross “dry”).

• The Result: The metal recovery rate increased by 1.8%. More importantly, the dross was dry and powdery, containing very little metallic aluminum. The factory successfully passed the environmental emission audit.

Learn more about AdTech Refining Flux