Division 01 — Metallurgical / Non-Ferrous / Copper / Fluxes
Copper Fluxes
Covering, oxidising, and deoxidising flux powders applied to the surface of molten copper and copper-alloy melts — forming a protective liquid layer that prevents atmospheric oxidation, captures cuprous oxide and other impurities, and suppresses zinc vapour loss in brass for clean, inclusion-free pours.
Copper and its alloys are among the most reactive metals in common foundry use. Molten copper oxidises rapidly on contact with atmospheric oxygen, forming cuprous oxide (Cu2O) that disperses throughout the melt and, if not removed, casts as non-metallic inclusions that reduce mechanical properties and block porosity testing. In brass, zinc evaporation from the melt surface above 950 °C causes surface porosity, composition drift, and white fume that is a health and housekeeping concern. CFC Egypt's EGYFLUX CU copper flux range — four grades covering the full spectrum of copper alloy types and melting temperatures — addresses these problems at source. Applied as a powder or granule to the melt surface, EGYFLUX CU fluxes melt and spread to form a continuous protective barrier that prevents oxidation, coalesces dispersed oxide into a skimmable slag layer, and actively suppresses zinc vapour loss in brass melts. All four grades are manufactured at our Sadat City plant.
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O que abrange
The EGYFLUX CU range provides covering, protective, and cleaning flux chemistry for the principal copper alloy families — from general-purpose copper and tin bronze through to brass and chromium-containing copper alloys.
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General Purpose — EGYFLUX CU
EGYFLUX CU is the standard covering and protective flux for copper, tin bronze, gunmetal, and the common copper alloy families. It melts at copper-alloy melting temperatures to form a fluid, protective layer on the bath surface, preventing atmospheric oxidation and coalescing dispersed cuprous oxide into a skimmable slag. It is the starting-point flux grade for copper foundries treating standard alloy grades in induction or oil-fired furnaces.
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Mid-Temperature — EGYFLUX CU 500
EGYFLUX CU 500 is formulated for copper alloys melted in the 900–1050 °C temperature range. Its flux chemistry is balanced to melt and provide fluid surface coverage at these temperatures without premature decomposition or insufficient melting. It is used for tin bronze, phosphor bronze, and other mid-melting-point copper alloys where precise flux melting behaviour at the operating temperature is required for optimal coverage and oxide capture.
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High-Temperature — EGYFLUX CU 900
EGYFLUX CU 900 is designed for high-temperature copper alloys including copper-nickel alloys, aluminium bronze, and pure copper applications where the melt temperature approaches or exceeds 1100 °C. At these temperatures, standard flux grades may decompose prematurely or fail to maintain fluid surface coverage. EGYFLUX CU 900 chemistry is formulated for stability and effective coverage at elevated temperatures, providing oxidation protection and oxide capture throughout the melting and holding cycle.
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Chromium Alloys — EGYFLUX CU CR
EGYFLUX CU CR is a specialist flux for copper-chromium and copper-chromium-zirconium alloys where the presence of chromium creates specific oxide chemistry challenges. Chromium oxidises preferentially from the melt surface, forming chromium oxide (Cr2O3) — a highly refractory, non-wetting oxide that standard copper flux chemistry cannot effectively capture. EGYFLUX CU CR is formulated to dissolve and capture chromium oxide alongside cuprous oxide, maintaining a clean melt surface and preventing Cr2O3 inclusions in the solidified casting.
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Onde é utilizado
Copper flux is used wherever copper alloys are melted — in induction furnaces, oil-fired crucible furnaces, and channel furnaces — across the sectors that produce copper-alloy castings.
Marine & Naval Bronze Castings
Propellers, sea valves, through-hull fittings, and pump bodies in tin bronze and aluminium bronze require pressure-tight, porosity-free metal throughout the casting cross-section. Marine classification societies require clean metal — free of oxide inclusions and gas porosity — as a condition of certification. EGYFLUX CU provides the melt protection needed to achieve the metal cleanliness demanded by marine casting standards when used consistently throughout the melting and holding cycle.
Bronze Valves, Pumps & Fittings
Bronze and brass pump casings, valve bodies, and pipe fittings for water, gas, and chemical service must pass pressure testing and dimensional inspection. Oxide inclusions entrained from a poorly protected melt produce micro-pores in the casting that become leak paths under pressure. Effective flux coverage from charge to pour eliminates the oxide particles that cause these defects, producing consistently pressure-tight castings that pass hydrostatic testing without repair.
Brass Castings — Zinc Retention
Brass foundries face the additional challenge of zinc evaporation. Zinc begins to vaporise significantly above 950 °C, reducing the zinc content of the melt below specification and causing surface porosity on the casting face where zinc vapour has condensed and been entrapped. An EGYFLUX CU flux layer on the melt surface physically prevents zinc vapour from escaping by maintaining an impermeable liquid barrier between the melt and the atmosphere throughout the hold and pour cycle.
Phosphor Bronze Bearings & Wear Parts
Phosphor bronze and gunmetal bearings, worm wheels, and wear bushings are used in industrial gearboxes, marine propulsion systems, and hydraulic machinery. These components are loaded in service — subsurface oxide inclusions act as stress concentrations and initiation sites for fatigue cracks, reducing service life under cyclic loading. Sound, inclusion-free metal produced with proper flux coverage is the foundation of long service life in bearing and wear-part bronze castings.