Division 01 — Metallurgical / Raw Materials

Raw Materials

Foundry raw materials are the base inputs and additives that go into the melt — ferro alloys, carbon raisers, inoculants, and metallurgical inputs — supplied to control composition and metallurgical quality.

Controlling the chemical composition of the melt is the foundation of casting quality. The right ferro alloy additions set the carbon equivalent, silicon level, manganese, chromium, and trace element content that determine the mechanical properties of the solidified casting. Carbon raisers restore carbon lost to oxidation or adjust the charge composition to target. Inoculants added to iron melts control the graphite structure that governs tensile strength and machinability in grey and ductile iron. CFC Egypt supplies EGYFLUX SSF from our Metallurgical Chemicals division, while broader raw material sourcing — ferro alloys, carbon raisers, and other metallurgical inputs — is available through our Trading Division, which sources and supplies metallurgical inputs to complement the manufactured product range.

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What It Covers

Foundry raw materials span the principal metallurgical input categories required to set melt composition, adjust carbon content, and control microstructure in the final casting.

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Ферросплавы

Master alloys of iron with silicon, manganese, chromium, nickel, molybdenum, and other elements — added to the melt in precise quantities to achieve the required composition for the target alloy grade. Ferro silicon controls graphitisation in cast iron; ferro manganese adjusts manganese for hardness and desulphurisation; ferro chrome is used in abrasion-resistant and corrosion-resistant alloy irons and steels. Sourced through the CFC Trading Division.

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Carbon Raisers

Carbon-containing materials — calcined petroleum coke, graphite, and anthracite — added to the furnace or ladle to increase or adjust the carbon content of the melt. Correct carbon equivalent control is central to the properties of grey and ductile iron castings. The choice of carbon raiser grade depends on target carbon, acceptable sulphur, and furnace type. Sourced through the CFC Trading Division.

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Inoculants

Ferro silicon-based inoculants containing trace-level active elements (calcium, barium, strontium, aluminium) that provide nucleation sites to control graphite distribution in grey and ductile iron. Added in small quantities to the ladle or in-stream immediately before pouring, inoculants prevent undercooling, hard spots, and chill formation, and improve the consistency of casting properties across a section. Sourced through the CFC Trading Division.

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EGYFLUX SSF — Sodium Fluorosilicate (Na₂SiF₆)

EGYFLUX SSF is sodium fluorosilicate (sodium silico-fluoride, Na₂SiF₆) — a white powder with very low solubility in water and insoluble in alcohol — manufactured by CFC Egypt. It is used as the active fluoride component in light-metal and aluminium melting fluxes, where it lowers surface tension and reduces adhesion between liquid aluminium and oxide particles for cleaner, more efficient melting. Available from our Metallurgical Chemicals division as a standalone product for foundries and flux processors with in-house blending capability. Contact us for specifications and pricing.

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Where They're Used

Foundry raw materials are consumed in every furnace heat. Their correct selection and dosing determines the final properties of every casting produced — making raw material supply reliability as important as manufacturing quality.

Grey Iron Foundries

Grey iron foundries use ferro silicon and carbon raisers in every heat to maintain carbon equivalent and control graphite type. Inoculants are added at the ladle or in-stream to ensure consistent flake graphite distribution, mechanical properties, and machinability across the batch. Raw material consistency — particularly in sulphur and nitrogen content of carbon raisers, and in the active element composition of inoculants — directly determines casting consistency and scrap rate.

Ductile Iron Foundries

Ductile iron production requires very low sulphur base iron (typically below 0.01% S) before magnesium treatment — making desulphurising ferro alloys and low-sulphur carbon raisers critical inputs. After Mg treatment, inoculation is mandatory to nucleate the spheroidal graphite that gives ductile iron its high elongation and impact strength. The iron chemistry window for ductile iron is narrow; consistent raw material quality reduces the risk of undercooled graphite structures and carbide formation that would cause casting rejection.

Steel Casting

Steel foundries use ferro alloy additions — ferro manganese, ferro silicon, ferro chrome, ferro nickel, ferro molybdenum — to achieve the specified composition of carbon, alloy, or stainless steel grades. Carbon raisers are used to adjust carbon levels in the melt and are selected for minimal sulphur and nitrogen contribution. The alloy addition sequence and timing in the EAF or induction furnace must be optimised to minimise loss of volatile alloying elements and achieve the target analysis within the narrowest possible compositional range.

Non-Ferrous Melting

Aluminium and copper foundries use master alloys — aluminium-silicon, aluminium-copper, aluminium-titanium-boron — to adjust composition in the furnace. Grain refiners and modifier alloys are specialist raw material inputs that control the solidification microstructure of aluminium castings — finer grain and modified silicon eutectic both improve mechanical properties and reduce sensitivity to porosity. These materials complement CFC's flux and degassing range in the overall aluminium treatment cycle.

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CFC Raw Materials Products

EGYFLUX SSF — sodium fluorosilicate (Na₂SiF₆) — is the principal raw material manufactured by CFC Egypt's Metallurgical Chemicals division, used as the active fluoride component in light-metal and aluminium melting fluxes. For broader foundry raw material requirements — ferro alloys, carbon raisers, inoculants — contact our Trading Division.

EGYFLUX SSF

Замедлитель схватывания бетона и суперпластификатор (ASTM C-494 - тип A, D и G)

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Frequently Asked Questions

Technical questions on foundry raw materials answered plainly. For sourcing enquiries or application support, contact our technical team or Trading Division.

Foundry raw materials are the base inputs and additives that go into the melt — ferro alloys, carbon raisers, inoculants, and metallurgical inputs — supplied to control composition and metallurgical quality. They are the charge materials and alloy additions added to the furnace to set the chemical composition of the melt before casting, as distinct from the process chemicals (fluxes, coatings, binders) applied during or after melting. Raw materials include metallic inputs such as ferro silicon, ferro manganese, and ferro chrome; carbon additives such as graphite and calcined petroleum coke; and treatment additives such as inoculants and magnesium wire for ductile iron production. Consistent, certified raw material supply is fundamental to maintaining casting quality and reducing batch-to-batch composition variation.

A carbon raiser (also called a carburiser or recarburiser) is a high-carbon material added to the furnace or ladle to increase the carbon content of the melt. In grey and ductile iron production, the target carbon equivalent must be maintained precisely — too low produces hard, brittle iron; too high causes graphite flotation and reduced strength. Carbon raisers in common use include calcined petroleum coke (CPC), synthetic graphite, and anthracite. Each differs in carbon content (typically 85–99% C), sulphur level, nitrogen content, and absorption efficiency in the melt. Low-sulphur grades are required for ductile iron and for grey iron with tight sulphur specifications. The carbon raiser is typically added to the furnace during melting and may be added to the ladle to fine-tune carbon before pouring.

Ferro alloys are master alloys of iron combined with one or more alloying elements — silicon, manganese, chromium, nickel, molybdenum, or vanadium — added to the melt in controlled quantities to achieve the required chemical composition and mechanical properties in the final casting. Ferro silicon (FeSi) is the most widely used: in grey and ductile iron it raises silicon content to promote graphitisation and prevent chill, and it acts as a mild deoxidiser. Ferro manganese (FeMn) desulphurises the melt by combining with sulphur to form MnS, and adjusts manganese content for hardness and hardenability. Ferro chrome (FeCr) is used in alloy cast irons and steel castings where abrasion resistance or corrosion resistance is required. Dosing accuracy and consistent analysis in each ferro alloy lot are critical to maintaining casting specifications batch to batch.

Inoculation is the addition of a small quantity of inoculant — typically a ferro silicon-based alloy containing trace amounts of calcium, barium, aluminium, or strontium — to molten iron shortly before pouring. These trace elements provide nucleation sites that promote the formation of fine, evenly distributed graphite during solidification. In grey iron, effective inoculation produces uniform flake graphite that improves tensile strength and machinability, and prevents the formation of hard white iron (chill) at thin sections. In ductile iron, inoculation — used after the magnesium treatment that converts graphite from flake to spheroid form — prevents undercooled graphite structures and carbide formation. Inoculation fades rapidly in the ladle (typically within 10–15 minutes) so consistent timing and dosing are critical process controls. In-stream inoculation — adding inoculant to the metal stream as it fills the mould — is preferred for critical castings because it minimises fade.

Foundry raw material sourcing — including ferro alloys, carbon raisers, inoculants, and other metallurgical inputs — is handled through CFC's Trading Division. The Trading Division sources and supplies a range of metallurgical inputs to complement the manufactured product ranges of the Metallurgical Chemicals and Construction Chemicals divisions. EGYFLUX SSF — sodium fluorosilicate (Na₂SiF₆), a manufactured flux raw material — is available directly from our Metallurgical Chemicals division. Contact CFC via the enquiry page to discuss your raw material requirements, volumes, specifications, and delivery logistics.

EGYFLUX SSF is sodium fluorosilicate (sodium silico-fluoride, Na₂SiF₆) — a white powder with very low solubility in water and insoluble in alcohol. It serves as the active fluoride component in light-metal and aluminium melting fluxes, where it lowers surface tension and reduces adhesion between liquid aluminium and oxide particles for cleaner, more efficient melting.

Поговорите с нами

Discuss your raw material requirements with CFC.

Tell us your metal, your furnace type, your target composition, and your volumes. Our technical team and Trading Division can help you identify the right ferro alloy grades, carbon raiser specification, and inoculant type for your casting process — and coordinate supply through a single point of contact.