Aluminium Treatment — Mould Release
Mould Release Agent
Mould release agents for aluminium casting are applied to permanent moulds, gravity-casting dies, and sand cores to form a barrier layer that prevents the solidifying aluminium from bonding metallurgically to the die surface, ensuring clean casting release, protecting the die from erosion and soldering, and maintaining casting surface quality over many production cycles.
When molten aluminium contacts bare steel or iron at casting temperatures without a release layer, iron-aluminium intermetallic compounds form at the interface and cause the casting to solder — sticking to the die on ejection and requiring mechanical removal that damages both the casting and the die surface. CFC Egypt's EGYDYE 10 and EGYDYE 88 release agents are sprayed onto the die surface between cycles, where they flash-dry to leave a thin, uniform release and thermal barrier layer. Correct release agent selection and application gives smooth casting surfaces, consistent cycle-to-cycle dimensional control, extended die life, and the ability to run production at the target cycle time without die maintenance stoppages. Both grades are manufactured at our Sadat City plant and supplied to gravity foundries and permanent mould casting operations across the MENA region.
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Where Mould Release Agent Is Used
Release agent is required in every aluminium casting process that uses a permanent metallic die or mould surface — gravity, low-pressure, and some semi-permanent mould processes.
Gravity Permanent Mould Casting
Gravity permanent mould (GPM) casting pours molten aluminium directly into a steel die under gravity. The die is opened, the casting ejected, and the cycle repeats — typically at 2 to 6 cycles per hour depending on casting size and section thickness. Release agent is sprayed between each cycle to maintain the release layer on the die face. A release agent that provides effective release at the die operating temperature, without building up carbonised residue over repeated cycles, is critical for maintaining casting surface quality and die face integrity over a full production campaign.
Low-Pressure Permanent Mould (LPPM) Casting
Low-pressure casting forces aluminium upward from a pressurised holding furnace into a closed permanent mould — used extensively for alloy wheels, cylinder heads, and suspension components requiring fine surface detail and controlled directional solidification. Release agent applied to the upper die halves between cycles protects the die cavity surfaces and cores from aluminium adhesion. LPPM tooling is expensive and has long lead times; release agent that minimises die erosion and extends the period between die maintenance operations directly reduces tooling cost per casting.
Sand Core Surfaces in Permanent Mould & HPDC
Sand cores used in conjunction with permanent moulds and HPDC tools to form internal cavities — water jackets, oil passages, and hollow sections — benefit from a release coating on the core surface. A thin release layer applied to the cored surfaces helps the core break out cleanly after solidification, reduces finning at the core-die joint, and prevents mechanical damage to core surfaces during assembly into the die. CFC's EGYDYE grades can be applied to sand core surfaces as well as metallic die faces.