Division 01 — Metallurgical / Ferrous / Core & Mould Coatings

High-Performance Core & Mould Coatings

Refractory mould and core coatings — zircon-, magnesia-, graphite-, and alumino-silicate-based — applied to sand mould and core surfaces before pouring to prevent burn-on, veining, and metal penetration and to produce a clean, dimensionally accurate casting surface.

The quality of a ferrous casting is determined at the mould surface. When liquid iron or steel contacts an unprotected sand mould at temperatures from 1350 to 1600 °C, the results are predictable and costly: sand grains fuse to the casting face, veining cracks form across the mould surface as the sand expands thermally, and metal penetrates the pore spaces between grains. CFC Egypt's EGYCOAT series addresses each of these failure modes with refractory chemistries matched to the metal being cast. Graphite-based GR grades provide an effective, cost-efficient barrier for grey and ductile iron in green-sand and no-bake moulds. Zircon-based ZR grades deliver the chemical stability and surface smoothness required for steel and high-quality ductile iron at the highest pouring temperatures. Magnesia-based MG grades are specified for high-manganese steels where silica refractories would react with the metal. All EGYCOAT products are manufactured at our Sadat City plant and are available in brush, flow-coat, and dipping grades.

Demande de devis Ferrous metal treatment

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Ce qu'il couvre

The EGYCOAT range spans four refractory chemistries, each engineered for a specific metal type, moulding system, or application method. Selecting the right chemistry and grade is the primary factor in casting surface quality.

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Graphite & Carbon Coatings (GR Series)

Carbon-based coatings for grey iron and ductile iron in green-sand, resin no-bake, and shell moulds. Graphite's non-wetting behaviour against molten iron gives strong burn-on resistance; a reducing atmosphere at the mould surface suppresses iron oxide formation. The GR series covers brush, flow-coat, and spray grades for all standard grey and ductile iron foundry operations.

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Zircon Coatings (ZR Series)

Zircon silicate (ZrSiO4) coatings for steel castings and premium ductile iron. Zircon combines high refractoriness (stable to above 1650 °C), low thermal expansion (resisting crack formation), and excellent surface smoothness. The ZR series is the primary coating system for all carbon and low-alloy steel foundries, producing a clean casting surface that minimises post-cast fettling.

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Magnesia Coatings (MG Series)

Magnesia (MgO) coatings for high-manganese steels, chromium steels, and other alloys where the silica present in zircon would react with the metal and cause inclusions. Magnesia is chemically basic and inert against these reactive alloys, providing a stable refractory barrier without silica-related chemistry. The MG series is the standard specification for Hadfield (austenitic manganese) steel foundries.

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Dipping Coatings (370 Series)

Ready-to-dip refractory coatings formulated for automated core production where cores are immersed in a coating tank and conveyed to a drying oven. The EGYCOAT 370 series is engineered for consistent coverage, controlled drainage to avoid coating pooling at core extremities, and rapid drying to keep pace with mechanised core making lines. Suitable for cores used in grey iron and ductile iron production.

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Domaines d'utilisation

Mould and core coatings are applied wherever iron and steel are cast in sand moulds. The specific grade selected depends on the alloy, the moulding system, the casting weight, and the surface finish requirement.

Pièces moulées pour l'automobile

Engine blocks, cylinder heads, exhaust manifolds, and brake discs are produced in grey iron and ductile iron at high volumes. Cores for water jackets and oil galleries require a dipping coating that provides a smooth bore finish, resists gas defects, and collapses cleanly for shakeout without damaging the casting. GR series and dipping grades are the standard in automotive grey iron foundries.

Steel Castings

Steel foundries producing pump casings, valve bodies, wear parts, and structural components require zircon coatings that withstand steel pouring temperatures above 1550 °C. The ZR series delivers the high-temperature stability and low surface roughness needed to meet international casting surface standards and minimise post-cast grinding and fettling costs.

Ductile Iron Pipe & Fittings

Sand-cast ductile iron valves, flanges, and bends for water and gas distribution require coatings that give a clean external surface and a smooth bore, reducing hydraulic roughness and facilitating pipe lining. Centrifugal pipe production uses specialised spinning coatings that distribute evenly at high rotation speed and form a smooth, even bore surface.

Heavy Engineering & Wear Parts

Large section castings — mill liners, crusher jaws, excavator teeth, and counterweights — require coatings that remain intact through long solidification cycles without cracking or washing. High-manganese steel wear parts need the chemical resistance of MG series magnesia coatings to prevent silica-inclusion defects that would weaken the casting under impact service.

Pumps, Valves & Pressure Parts

Pressure-rated castings require defect-free surfaces both externally and at core-formed internal bores. Sand inclusion defects — caused by inadequate coating coverage — are a direct cause of rejection under hydrostatic test. Zircon coatings on the cores and mould faces prevent sand erosion and metal penetration, giving clean surfaces that pass visual and pressure inspection without repair.

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CFC Mould & Core Coating Products

A selection from the EGYCOAT range — graphite GR grades for cast iron, zircon ZR grades for steel, magnesia MG grades for special steels, and dipping coatings for mechanised core production. All manufactured in Sadat City, Egypt.

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Questions fréquemment posées

Technical questions on mould and core coating selection and application answered plainly. For a product recommendation matched to your metal and moulding system, contact our technical team.

Mould and core coatings are refractory suspensions applied to the surfaces of sand moulds and cores before the metal is poured. They form a thin refractory barrier between the sand and the liquid metal that prevents burn-on (sand grains fusing to the casting surface), veining and finning defects caused by thermal expansion cracking of the sand, and metal penetration into the mould pores. A properly applied coating also gives a smooth casting surface finish and makes shakeout easier by reducing adhesion between the casting and the mould.

Zircon (ZrSiO4) coatings are chemically inert at high temperatures, have a low thermal expansion coefficient that resists cracking, and produce very smooth casting surfaces. They are the standard choice for steel and high-quality ductile iron castings. Graphite coatings rely on carbon's non-wetting behaviour with molten iron — they give excellent burn-on resistance and are cost-effective for grey iron in green-sand moulds. Magnesia (MgO) coatings are used for high-manganese steels and other alloys where silica-based refractories would react chemically with the metal, causing inclusions and surface degradation.

Application method depends on the mould geometry and production volume. Brushing is used for large moulds, intricate cores, and repair work where precision matters more than speed. Flow coating (flooding the coating over the mould surface) is used in mechanised or semi-mechanised moulding lines for consistent coverage of large mould halves. Dipping is the preferred method for small and medium cores in automated core production — the core is immersed in a tank of coating, withdrawn, drained, and dried. Spraying is used where access is limited or where a thin, even coat is required on complex geometries. Each EGYCOAT product specifies a recommended dilution range and application method on its technical data sheet.

Burn-on occurs when liquid metal penetrates the pores between sand grains and, on solidification, bonds the sand to the casting surface. The driving forces are the metallostatic pressure of the metal head and capillary pressure that draws liquid metal into fine pores. A refractory coating prevents burn-on by filling the surface pores of the mould with a dense, high-melting-point layer that the liquid metal cannot wet or penetrate. Zircon and magnesia coatings achieve this through high refractoriness and low wettability; graphite coatings additionally create a reducing atmosphere at the mould surface that prevents iron oxide formation, a known driver of burn-on in iron castings.

CFC Egypt produces the EGYCOAT series across three principal refractory chemistries. The GR series (EGYCOAT 110 GR, 155 GR, 210 GR, 211 GR, 212 GR, 213 GR, 250 GR, 255 GR) are graphite- and carbon-based coatings for grey and ductile cast iron. The ZR series (EGYCOAT 100 ZR, 101 ZR, 102 ZR, 104 ZR, 200 ZR, 202 ZR, 205 ZR, 206 ZR) are zircon-based coatings for steel and premium ductile iron. The MG series (EGYCOAT MG, MG 65, MG 100, MG 165) are magnesia-based coatings for high-manganese steels. Dipping grades (EGYCOAT 342, 345, 360, 370) serve automated core production. Contact our technical team for grade selection matched to your metal and process.

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Catégories apparentées

Explore adjacent product categories within CFC's ferrous metal treatment range.

Ferrous

Matériaux de moulage haute performance

Binders, additives, and sand treatments for strong, dimensionally stable moulds and cores.

Ferrous

Alimentation et traitement de surface

Exothermic and insulating feeding compounds that control solidification and reduce shrinkage defects.

Ferrous

Agents de démoulage et de séparation

Release and parting agents for clean casting release and tooling protection.

Division 01

Traitement des métaux ferreux

Overview of all ferrous foundry chemistry — coatings, binders, feeding, patching, and release agents.

Parlez-nous

Need a mould coating for your casting process?

Tell us your metal (grey iron, ductile iron, or steel), your moulding system (green sand, no-bake, or shell), and your current surface quality issues. Our technical team will recommend the right EGYCOAT grade and application method for your specific operation.

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