Division 01 — Metallurgical / Ferrous
Ferrous Metal Treatment
Ferrous metal treatment is the foundry chemistry used to cast and finish iron-based metals — grey iron, ductile iron, and steel. It covers the mould and core coatings, moulding materials, feeding and surface treatments, patching compounds, and parting agents applied during casting to control metal quality, surface finish, and dimensional accuracy.
CFC Egypt manufactures a complete range of ferrous treatment products from our Sadat City plant. Every product is engineered for the thermal and chemical demands of iron and steel casting: refractory coatings rated to withstand pouring temperatures, binder systems that build moulds capable of holding dimensional tolerances, and feeding compounds that eliminate shrinkage defects by keeping risers liquid through solidification. Whether you run a green-sand grey-iron foundry or a steel investment-casting operation, we supply the chemistry for the full casting cycle.
01
What It Covers
Ferrous metal treatment spans five interconnected chemistry groups, each addressing a specific stage of the casting process — from mould preparation before the pour to release and repair afterwards.
01
High-Performance Core & Mould Coatings
Refractory coatings — zircon-, magnesia-, and graphite-based — applied to moulds and cores before the pour. They form a barrier that gives a clean casting surface, prevents burn-on and veining defects, and improves dimensional accuracy by eliminating sand erosion at the metal–mould interface.
02
High-Performance Moulding Materials
Binders, catalyst/hardener sets, and sand treatment additives that build strong, dimensionally stable moulds and cores. The right binder chemistry is the foundation of casting accuracy — it determines green strength, stripping time, hot strength, and the ease with which the mould collapses after solidification for clean shakeout.
03
Feeding & Surface Treatment
Exothermic and insulating feeding compounds, riser sleeves, and melt surface treatments that regulate solidification. By keeping risers liquid longer than the casting body, feeding systems compensate for the volumetric shrinkage that occurs as molten iron contracts, eliminating internal voids and shrinkage porosity in critical sections.
04
Patching Materials
Refractory patching and repair compounds for ladles, furnaces, and mould surfaces. Maintaining the integrity of metal-handling equipment is critical to process safety and metal quality — patching materials provide rapid, high-temperature repairs that restore service life without extended shutdowns.
05
Release & Parting Agents
Agents applied to patterns, core boxes, and permanent moulds to ensure clean release of the casting and protect tooling from thermal cycling and adhesion. Consistent parting agent application reduces mould damage, extends pattern life, and prevents surface tearing on the casting face.
02
Where It's Used
Iron and steel castings are structural components in many of the world's most demanding applications. Ferrous foundry chemistry is used wherever dimensional precision, mechanical integrity, and surface quality cannot be compromised.
Automotive Castings
Engine blocks, cylinder heads, exhaust manifolds, brake discs, and differential housings are among the highest-volume ferrous castings globally. Tight dimensional tolerances and clean, defect-free surfaces are non-negotiable for engine and drivetrain components, making high-performance mould coatings and precise feeding systems central to every automotive foundry's operation.
Agricultural & Construction Machinery
Counterweights, gearbox housings, hydraulic valve bodies, and track links are produced in grey and ductile iron for their combination of strength, wear resistance, and castability. These high-section-weight castings demand robust binder systems, adequate feeding, and refractory coatings that protect the mould surface through long solidification cycles.
Pipe, Valves & Fittings
Ductile iron pressure pipes, gate valves, flanges, and bends for water and gas distribution networks are produced by centrifugal casting or sand casting. Centrifugal pipe production uses specialist spinning coatings that must distribute evenly at speed and provide a smooth bore surface; sand-cast valves require high-quality refractory coatings to meet pressure-class surface finish standards.
Pumps, Compressors & Valves
Cast iron and steel pump casings, impellers, and valve bodies handling corrosive or high-pressure fluids require clean internal bore surfaces, accurate wall thicknesses, and freedom from porosity. Zircon mould coatings and controlled feeding are the primary tools for achieving the internal surface quality and soundness that pressure vessel certification demands.