{"id":1420,"date":"2026-05-30T20:51:56","date_gmt":"2026-05-30T17:51:56","guid":{"rendered":"https:\/\/cfc.codev-eg.com\/?page_id=1420"},"modified":"2026-06-02T21:17:44","modified_gmt":"2026-06-02T18:17:44","slug":"high-performance-moulding-materials","status":"publish","type":"page","link":"https:\/\/cfc.codev-eg.com\/fr\/products\/metallurgical-chemicals\/ferrous-metal-treatment\/high-performance-moulding-materials\/","title":{"rendered":"Mat\u00e9riaux de moulage \u00e0 haute performance"},"content":{"rendered":"\t\t
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Division 01 \u2014 Metallurgical \/ Ferrous \/ Moulding Materials\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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High-Performance\nMoulding Materials<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Binders, setting agents, and sand treatment additives for ferrous casting moulds and cores \u2014 engineered to deliver the green strength, hot strength, and controlled shakeout collapsibility that dimensional accuracy in grey iron, ductile iron, and steel castings demands.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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The mould is the primary tool of the foundry. Its strength and dimensional stability under the pressure and heat of a metal pour determine whether a casting meets its dimensional specification or requires costly correction. CFC Egypt's high-performance moulding materials \u2014 EGYBINDER sand binder and EGYSET setting agent \u2014 are formulated for the chemical and thermal demands of ferrous no-bake and core-making operations. EGYBINDER provides the bonding strength that holds sand grains in position from stripping through to shakeout. EGYSET controls the rate of cure, allowing foundries to dial in strip times that match their production cycle, from single-piece job work to mechanised core-making lines. Together, they give complete control over mould quality \u2014 strength during casting, reliable breakdown at shakeout, and sand that reclaims cleanly for reuse.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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What It Covers\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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High-performance moulding materials address the full chemical bond cycle of a no-bake mould or core: from mixing and mould-making through pouring and solidification to shakeout and sand reclamation.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Sand Binders \u2014 EGYBINDER\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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EGYBINDER is the primary bonding component mixed with foundry sand to build the mould or core body. It develops green strength for safe handling of the mould before the pour, adequate hot strength to resist deformation under the weight of the metal, and a controlled breakdown profile at elevated temperature that allows clean shakeout without excessive force. Binder addition rate is matched to the sand type, core geometry, and the metal being cast.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Setting Agents \u2014 EGYSET\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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EGYSET is the hardener or catalyst component that triggers and controls the cure reaction of the binder system. By adjusting the EGYSET addition rate, foundries can calibrate strip time to match their moulding or core-making cycle \u2014 faster set for high-volume production, slower set for large or complex moulds that require more time to compact and finish before stripping. EGYSET also influences the final strength profile and the shakeout behaviour of the cured mould.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Binder System Selection\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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The right binder system depends on the metal, mould size, production volume, and available sand reclamation. For grey and ductile iron, binder systems must provide adequate hot strength up to approximately 1200 \u00b0C and then collapse reliably to allow shakeout. For steel, higher hot strength is required to withstand pouring temperatures above 1550 \u00b0C. Our technical team supports system selection, addition rate optimisation, and troubleshooting of common binder-related defects including gas porosity, veining, and dimensional scatter.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Sand Reclamation Compatibility\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Chemically bonded sand can be reclaimed thermally or mechanically after shakeout and returned to the moulding cycle. The binder system used directly affects the quality of reclaimed sand \u2014 binder residues that are not fully burned off during casting reduce the effective clay or chemical bond of new additions. CFC Egypt's moulding materials are formulated for compatibility with standard thermal and attrition reclamation systems used in ferrous foundries.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Where It's Used\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Chemically bonded moulding materials are used in ferrous foundries wherever castings require dimensional precision and surface quality beyond what green-sand moulding can deliver, or where core complexity demands chemical bonding.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Steel Foundries (No-Bake)\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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All sand-cast steel production uses no-bake chemically bonded sand \u2014 green sand cannot withstand steel pouring temperatures. Steel foundries producing pump casings, valve bodies, structural castings, and wear parts require binder systems that maintain mould integrity at pouring temperatures above 1550 \u00b0C and that develop sufficient residual strength to hold the casting in position during the extended solidification cycle of heavy steel sections.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Heavy Ductile Iron Castings\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Large section ductile iron castings \u2014 counterweights, gear housings, hydraulic valve bodies, and agricultural machinery components \u2014 are typically produced in no-bake or shell moulds. The high section weights and long solidification times require binder systems with sustained hot strength, and the complex cored cavities in these castings require dimensionally accurate cores that do not shift or collapse during filling.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Complex Cored Grey Iron Castings\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Engine blocks, cylinder heads, gearbox housings, and pump casings incorporate intricate internal cored passages \u2014 water jackets, oil galleries, and valve ports \u2014 that require chemically bonded cores with precise dimensions, adequate strength during the pour, and reliable shakeout to cleanly remove core sand from internal cavities after casting. Binder addition rate, cure profile, and the relationship between EGYBINDER and EGYSET determine whether cores strip cleanly, survive the pour, and shake out completely.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Jobbing & Batch Foundries\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Jobbing foundries producing a wide range of casting types and sizes in small batches rely on flexible binder systems that can be adjusted quickly for different metals, section weights, and mould sizes. No-bake binder systems allow rapid changeover between jobs without the plant investment of mechanised green-sand lines. CFC Egypt's moulding materials support this flexibility with adjustable set times through EGYSET addition rate modification.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Ductile Iron Pipes, Valves & Fittings\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Sand-cast ductile iron fittings \u2014 flanges, bends, tees, and valves for water and gas distribution \u2014 are produced in no-bake sand with high dimensional accuracy requirements. Wall thickness must be within tolerance across the full fitting for pressure integrity; mould shift or deformation during the pour is a rejection cause. Reliable binder strength and consistent EGYSET cure control are the foundations of dimensional consistency in fitting production.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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CFC Moulding Material Products\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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EGYBINDER sand binder and EGYSET setting agent \u2014 the core of CFC Egypt's ferrous moulding materials range. Both manufactured at our Sadat City plant.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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Frequently Asked Questions\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Technical questions on foundry binders and moulding materials answered plainly. For addition rate recommendations and system troubleshooting, contact our technical team.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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What are moulding materials in ferrous foundry practice? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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Moulding materials are the chemical binders, hardeners, and additives mixed with foundry sand to create moulds and cores capable of withstanding the thermal and mechanical stresses of iron and steel casting. The binder holds sand grains together to give the mould green strength for handling, hot strength during solidification, and then controlled collapsibility for clean shakeout. Without a suitable binder system, moulds crack, shift, or collapse under the weight and pressure of the molten metal, producing dimensionally inaccurate or structurally unsound castings.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t
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What is the difference between EGYSET and EGYBINDER? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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EGYBINDER is the primary sand binder \u2014 the component that develops the bond strength of the mould or core. EGYSET is the setting or hardening component that triggers and controls the cure reaction, allowing foundries to adjust strip time to match their production cycle. Together, EGYBINDER and EGYSET give complete control over the mould strength profile from mixing through to shakeout. Contact our technical team for the correct ratio and mixing procedure for your specific moulding system and metal.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t
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How does binder choice affect casting dimensional accuracy? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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The binder system is the primary determinant of mould dimensional stability. Insufficient binder strength allows the mould to shift or deform under metallostatic pressure, producing out-of-tolerance castings. Excessive retained hot strength causes difficult shakeout and mechanical casting damage. The optimal binder system provides adequate strength during solidification, then degrades predictably at elevated temperature for clean, low-force shakeout. Binder addition rate also affects gas evolution \u2014 high binder levels or incorrect chemistry can generate gas that causes porosity or blow defects.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t
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What moulding systems are these materials used in? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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CFC Egypt's EGYBINDER and EGYSET are designed for no-bake (cold-setting) moulding and core making systems, where the binder and setting agent are mixed with sand and the mould hardens at room temperature through a chemical reaction. No-bake systems are used in jobbing and batch foundries across all ferrous metal types, and are the standard method for all steel foundries producing sand castings. They are also used for the cores used in high-volume grey and ductile iron production lines.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t\t
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What is shakeout and why does binder chemistry affect it? <\/div><\/span>\n\t\t\t\t\t\t\t\n\t\t\t<\/path><\/svg><\/span>\n\t\t\t<\/path><\/svg><\/span>\n\t\t<\/span>\n\n\t\t\t\t\t\t<\/summary>\n\t\t\t\t
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Shakeout is the separation of the solidified casting from the mould sand after cooling. The force required depends directly on the hot strength retained by the binder at shakeout temperature. Binders that retain high strength at 300\u2013600 \u00b0C require aggressive shakeout that can damage fragile sections. Well-formulated binders degrade progressively at elevated temperature, losing bond strength to allow low-force shakeout while maintaining adequate strength during the solidification phase. Balancing binder addition rate and EGYSET ratio to achieve this profile is key to efficient, damage-free shakeout.\n\n<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/details>\n\t\t\t\t\t<\/div>\n\t\t\t\t\t