An investigation was performed to measure the efficiency of solid alumina inclusion removal by filtration during casting. A mold design was developed using modeling software to produce two castings that fill simultaneously, one with a filter and the other without a filter. The design avoided vortex formation and thus air entrainment, which helped to avoid reoxidation inside the mold cavity. Samples from these castings were analyzed utilizing an SEM/EDS system with automated feature analysis (AFA) to measure the efficiency of inclusion removal using a 20 ppi zirconia foam filter. This study also documents the occurrence of inclusion flotation and agglomeration in the ladle which, in turn, affects the removal efficiency of these inclusions by filtration in the mold
