Sintered Square and Dutch Woven Mesh - Five Layers
Five-layer sintered mesh is a standard combination of five layers wire meshes with different openings and diameters through sintering (diffusion-bonding) in vacuum, which improves the characteristics of stainless steel woven wire mesh. By bonding the contact points of different wire meshes together, five-layer sintered mesh has become an integrated porous material with enhanced mechanical strength, high permeability and better structural integrity, because the sintering process remains the good filtration rating of the finest mesh layer, also the mechanical strength of the coarser support layers. Besides all of that, heat and pressure are combined to create molecular diffusion-welds at every intersection of the wire mesh where the wires cross over and under one-another, which in turn enhances the temperature and pressure resistance of the sintered mesh. For its distinct features, five-layer sintered mesh is widely used for diffusing, breather vents, filters in many areas such as gas distribution, polyester filtration, water treatment, etc.
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Five-layer sintered mesh front view
Back view of five-layer sintered mesh
Side view of five-layer sintered mesh
Specification
- Material: Stainless steel 316 L, stainless steel 304, 304 L, 316, other materials can be made to order.
- Filtration accuracy: 1 micron to 200 microns.
- Heat resistance: 600 °C.
- Standard thickness: 1.7 mm.
- Standard size: 480 mm × 480 mm, 480 mm × 980 mm, 500 mm × mm, 600 mm × mm, 610 mm × mm, 610 mm × mm, mm × mm, mm × mm, other sizes can be designed as per customers' demand.
- Maximum size: mm × mm.
- Type classification: Sintered dutch woven wire mesh and sintered square woven wire mesh.
Feature
- Steady filter rating under high pressure.
- High mechanical strength.
- Easy to be welded, sheared, punched into various shapes.
- Good capability of corrosion and abrasion resistance.
- Easy to wash, it can be reused for many times.
Five-layer sintered mesh structural drawing, two reinforcing layers and one protective layer contribute stable filtering precision, good strength and easy backwashing.
Five-layer sintered dutch woven wire mesh specification
Code
Nominal filter rating (µm)
Structure
Overall thickness (mm)
Weight / sq.ft (kg)
MIC1L5
1
200 / 400 × / 200 / 12 × 64 / 64 × 12
100 / 400 × / 100 / 12 × 64 / 64 × 12
1.
1.
MIC2L5
2
100 / 325 × / 100 / 12 × 64 / 64 × 12
1.
1.
MIC5L5
5
100 / 200 × / 100 / 12 × 64 / 64 × 12
1.
0.
MIC10L5
10
100 / 165 × / 100 / 12 × 64 / 64 × 12
1.
0.
MIC15L5
15
100 / 165 × / 100 / 12 × 64 / 64 × 12
1.
1.
MIC20L5
20
100 / 165 × 800 / 100 / 12 × 64 / 64 × 12
1.
1.
MIC25L5
25
100 / 165 × 600 / 100 / 12 × 64 / 64 × 12
1.
0.
MIC30L5
30
100 / 400 / 100 / 12 × 64 / 64 × 12
100 / 450 / 100 / 12 × 64 / 64 × 12
1.
1.
MIC40L5
40
100 / 325 / 100 / 12 × 64 / 64 × 12
1.
0.
MIC50L5
50
100 / 250 / 100 / 12 × 64 / 64 × 12
1.
1.
MIC75L5
75
100 / 200 / 100 / 12 × 64 / 64 × 12
1.
0.
MIC100L5
100
100 / 150 / 100 / 12 × 64 / 64 × 12
1.
0.
MIC120L5
120
100 / 120 / 100 / 12 × 64 / 64 × 12
1.
0.
Note: 1. Porosity: 37%. 2. MIC: micron, L: layer.
Filtration property - five-layer sintered mesh
Type
Air permeability L/min.dm2
Rating micron (µm)
Bubble point pressure (Pa) 8%
FP-05
200
2.5 - 7.5
FP-10
250
7.5 - 12.5
FP-15
350
12.5 - 17.5
FP-20
450
17.5 - 22.5
FP-30
550
27.5 - 35
FP-40
650
35 - 45
FP-50
750
45 - 60
860
FP-70
900
60 - 80
690
FP-100
950
80 - 120
630
Note: FP - filtration property, 05 - filter rating is five.
One structural drawing of sintered square woven wire mesh, the protective and reinforcing layers contribute to rigidity.
Specification - five-layer sintered square woven wire mesh
Code
Structure
Thickness (mm)
Weight (kg/m2)
Porosity (%)
FSWM - 1.9
30 / Filter layer / 60 / 20 / 16
1.9
5.3
52
FSWM - 2.5
80 / Filter layer / 30 / 10 / 8.5
2.5
8.8
55
Note
- Filter rating varies from 2 µm to 200 µm, the filtration layer is selected as per customers' need.
- The porosity takes 20 mesh as criteria.
Application
Typical applications of five-layer sintered mesh include filtration of polymer, food, water, cosmetic, pharmacy, chemicals and hydraulic fuels. It is also used for fluidization of bulk materials in wagons, conveyors, driers, coolers and storage silos.
Products Display
Five-layer sintered mesh rectangular sheets
5-layer sintered mesh round discs
Five-layer sintered mesh filter cartridge
Five-layer sintered mesh filter cartridge front view
Side view of a five-layer sintered mesh filter cartridge
Side view of a five-layer sintered mesh filter cartridge
Five-layer sintered mesh filter cartridge inside
Five-layer sintered mesh filter cartridge packaging
Packed five-layer sintered mesh panels
Round five-layer sintered mesh
Five-layer sintered filter element
Extended five-layer sintered filter element
FAQs
Polymer filtration, petrochemical and refining, pharmaceutical production, natural gas, new energy and other industries, or the treatment of dust particles such as metal powders/vapors, gelled particles, carbon powder, talcum powder, plant spores, bacteria, and other dust particles.
We can design and customize five-layer sintered mesh products according to your specific needs. Just provide us with the following basic information: shape, application, mounting structure, flow rate, pressure drop, working pressure, working temperature, and material, and then our experienced engineers will provide you with suitable solutions for your reference and choice.
It can withstand high temperatures up to 480 °C at room temperature and 600 °C at transient temperature.
Five-layer sintered mesh flow rate characteristics:
Standard materials SS304, SS304L, SS316, SS316L. We can also customize special alloys such as Hastelloy C-276, Monel Alloy 400, Inconel 600, SS904, SS904L, Duplex stainless steel , etc.
It can be cleaned by countercurrent water, filtering, ultrasonic, melting, baking, etc. It is especially suitable for backwashing.
Backwashing of sintered mesh is achieved by pressurising the mesh from within the machine and quickly opening the backwash square valve during the backwash. The backwash generates a high reverse homeopathic pressure differential, which effectively removes contaminants from the element surface.
Sintered mesh is made from multiple layers of metal mesh through a diffusion solid solution sintering process. Its basic process flow is:
- Mesh structure design. The sintered mesh must meet the requirements of the filter system. Therefore, before production, it is necessary to reasonably customize its filter rating, thickness, number of layers, single-layer metal mesh structure, and material to ensure it meets the needs of the existing current filter systems.
- Mesh pre-treatment. Stack single-layer metal mesh.
- Ultrasonic cleaning. Sintered mesh has good backwashing properties. Through ultrasonic cleaning, excess impurities on the surface of the single-layer metal mesh can be removed, making its surface smooth and facilitating subsequent sintering.
- Vacuum sintering. The cleaned stacked sintered mesh is placed in a vacuum sintering furnace for pressing. When the temperature reaches 1,100 °C, a diffusion solid solution process is employed to ensure that the mesh opening channels are not easily deformed and that the surface is smooth, thereby guaranteeing stable filtration precision of the sintered mesh. At the same time, after the pressing and sintering process, the sintered mesh possesses high mechanical strength and overall rigidity;
- Cutting. When the sintering is completed, suitable dimensions are cut out through machining.
From automotive filters to the filters found in medical devices, the proper filtration of various substances helps make the world go round, This leaves engineers responsible for identifying filter media that will deliver the perfect balance of durability, accuracy, and cost-effectiveness.
Failure to implement an adequate filter media can lead to inconsistent pressure loads in your filter system, increase energy costs, and allow unwanted particles to pass through. This is why you must strive to understand the capabilities of woven wire mesh, particularly when used as a mesh filter.
So, what exactly is a wire mesh filter?
W.S. Tyler has been a prominent manufacturer of wire mesh products for over 150 years and is here to help you better understand if it is suitable for your filtration operation.
To that end, this article will cover:
What metal mesh is
What a mesh filter is
The benefits associated with metal mesh filters
How much mesh filters cost
The company is the world’s best industrial filter mesh supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
What Is Wire Mesh?
Woven wire mesh, or simply wire mesh, is a calculated array of individual metallic wires interlocked together, forming pore openings with an exact size. Prior to the centuries-old weaving process used to fabricate the mesh, specifications, such as the mesh count, wire diameter, weave pattern, layer configuration, and alloy, are all predetermined.
Now, wire mesh can be molded and formed without compromising the integrity of the mesh openings. This allows it to deliver desirable filtration for a wide range of industries.
What Is a Wire Mesh Filter?
Filters are known to be porous materials designed to remove impurities and miscellaneous particles from liquids and gases. In the world of filtration, there are various materials used as filter media, such as metal fiber felt and wedge wire.
Wire mesh filters are a network of metallic wires that forms a pliable filter cloth with precise, rigid pore openings that engineers can customize to accommodate most filter systems. Additionally, because metal mesh filters are one of the most durable filter media available, they can be used in applications, such as sanitary pipe systems, to remove contaminants or in applications, such as nutsche filters, to extract a filter cake.
If you are interested in learning how woven wire mesh compares to other filtration solutions, you may find value in the following articles:
- Metal Fiber Felt vs Woven Wire Mesh Filters (Benefits, Drawbacks, and Cost)
- Comparing Filter Media: Woven Wire VS Wedge Wire
Why Use Wire Mesh?
There are many benefits associated with wire mesh filters. This includes the filter's accuracy, flow rate, durability, and ability to be cleaned.
Let's look into how wire mesh can deliver the listed benefits.
Flow Rate
One of the most significant advantages wire mesh has over most filter media used today is its ability to deliver an adequate flow rate. This is achievable as the wire diameter and mesh opening can be customized to perfectly match the contaminants you are filtering out, providing you with an enhanced level of filtration surface area.
This is especially true when a three-dimensional metal mesh filter is used. This is because three-dimensional mesh filters offset two layers of filter cloth, doubling the achievable flow rate.
Durability
While alloys such as Alloy 310, Inconel 600, Super duplex, Duplex, Hastelloy C22, and Titanium can be used to construct wire mesh filters, 300 series stainless steel is predominantly used. This helps create a filter that can withstand a wide range of impurities, pressure variations, and extreme temperatures without hindering the filter's accuracy.
In addition, stainless steel is a very pliable material, allowing the filter to be formed to fit your filter system and hold its shape after several uses.
Accuracy
The weaving process used to construct wire mesh filters is heavily monitored from start to finish. As a result, the pore openings of the filter are exact and uniform throughout the filter.
These precise pore opinings ensure that the end product, whether a filtered substance or a filter cake, is consistent and complies with industry standards.
Cleanability
As wire mesh features accurate pore openings, blinding and plugging are significantly reduced. This, combined with the enhanced flow rate, means system operators can clean the metal filter mesh easily.
These two properties allow the wire mesh filter to be backflushed and purged of any unwanted debris with minimal pressure.
What Limitations Are Associated With Wire Mesh Filters?
The most notable limitation associated with wire mesh filters is the limitation as to how much wire mesh can be drawn when being formed into a filter. In fact, there is a ratio that must be followed to ensure the mesh is not drawn deeper than its diameter, damaging the mesh.
So, for example, a direct fuel injection automotive filter with a 5-inch diameter can only have a depth of five inches or less.
It's also important to know that a wide variety of wire mesh weave patterns can't be woven past 5 microns. This can be problematic when working with various gases, as gaseous particles can typically pass through 5-micron screens.
How Much Does a Wire Mesh Filter Cost?
From extruder screen packs to sanitary pipe sock screen gaskets, the price of a wire mesh filter is dependent on the parameters of the filter. This includes the layer configuration, mesh specifications, and amount of fabrication needed to form the desired size and shape of the filter.
Additionally, the quantity of filters being acquired plays a major role in the overall price of a wire mesh filter. This is because most wire mesh filters are made to order, which requires several hours to set up the tooling needed to construct any particular filter.
A good rule of thumb to follow when designing wire mesh filters is higher purchase volumes reduce the overall cost.
Read the following article to learn more about the factors surrounding the cost of a wire mesh filter:
- How Much Do Fabricated Wire Mesh Components Cost?
Square Mesh vs Filter Cloth: What Is Right for Me?
Wire mesh filters are a network of metallic wires interlocked together to form precise pore openings that can be used to decontaminate a substance or extract a filter cake. The cleanability, accuracy, flow rate, and durability that wire mesh offers make it stand out when compared to other filter media, such as metal fiber felt and wedge wire.
As you continue to pursue wire mesh filters, it's essential that you understand the two forms wire mesh is available in: square mesh and filter cloth. Knowing the differences between the two mesh variants will help to ensure you achieve efficient filtration.
With over 150 years of wire mesh experience, W.S. Tyler strives to ensure you understand everything you need to know about mesh filters.
Review the following article to gain insight into how square mesh and filter cloth differ:
Want more information on Sintered Metal Fiber? Feel free to contact us.
- Square Wire Mesh vs. MINIMESH® Filter Cloth: Which Is Best for Me?