Mould And Core Coatings For Ferrous And Non-Ferrous Foundries
A mould coating is a refractory barrier between the sand and the metal: it stops penetration and burn-on, gives the casting its surface finish, and in centrifugal casting protects the die itself. Pyroflux India makes mould and core coatings in Noida in the three refractory families Indian foundries use most: zircon for steel and high-temperature alloys, alumina-silicate for grey and SG iron, and graphite for non-ferrous and for die faces, each in water-based and alcohol-based versions and in paste, powder and ready-for-use forms. A separate range of water-based alumina, alumina-silicate and zircon coatings covers centrifugal casting of ferrous and non-ferrous alloys, where coating life and surface finish decide die life. The coatings are exported as well as supplied across India.
Coatings For Sand Moulds And Cores
| Range | Refractory | Carrier | For |
|---|---|---|---|
| Zircon coatings | Zircon | Water or alcohol | CO₂-silicate and green-sand systems; mild steel, stainless and alloy steel castings; heavy sections |
| Alumina-silicate coatings | Alumina-silicate | Water or alcohol | Grey iron and SG iron castings; general ferrous work |
| Graphite coatings | Graphite | Water or alcohol; paste, powder and ready-for-use | Non-ferrous castings, die faces, patterns, and iron where a graphite finish is wanted |
Water-based coatings are dried in the mould with hot air or gas; alcohol-based coatings are lit off and suit cores and moulds that cannot wait for a dryer. Both are supplied as concentrates for dilution on site or ready for use.
Die Coatings For Centrifugal Casting
For centrifugal casting of ferrous and non-ferrous alloys Pyroflux supplies water-based coating systems based on alumina, alumina-silicate and zircon, sprayed onto the preheated rotating die. The coating insulates the die, controls solidification, releases the casting and protects the die surface, so coating life is die life. Grades are matched to the alloy and the die temperature; tell us both and we recommend one.
- Alumina-based for general ferrous work
- Alumina-silicate-based where insulation matters
- Zircon-based for steel and the most demanding alloys
Getting a Consistent Coat
- Dilute to the Baumé or density on the data sheet and check it every shift; a drifting density is the usual cause of finish problems.
- Keep the tank agitated. Refractory coatings settle, and a settled tank gives a thin coat on top and a thick one at the end of the shift.
- Apply by brush, swab, spray or dip to an even thickness; two thin coats beat one heavy coat on cores.
- Dry fully before closing the mould or pouring: water-based with heat, alcohol-based by lighting off.
- Record density, coat count and finish per pattern; it makes the next trial shorter.
Named Grades And Where To Read About Them
Common Questions
Water-based or alcohol-based?
Water-based where you can dry the mould or core with heat and where you want to avoid flammable solvents; alcohol-based where there is no drying capacity, for quick turnaround and for lit-off cores.
Which refractory for which metal?
Zircon for steel and the highest temperatures; alumina-silicate for grey and SG iron; graphite for non-ferrous and for a graphite finish. Mixed systems are available where cost and performance need balancing.
Do you export?
Yes. Mould coatings are shipped from Noida to customers across India and overseas with export packing and documents included.
Do you supply a technical data sheet and SDS?
Yes, per grade, by email within one working day of a request.
Tell Us The Process; We Will Recommend The Grade
Substrate, process temperature, atmosphere and how you prefer to apply it. That is everything we need to point you at the right product, send a sample, or quote.
- Phone
- +91 98181 87838
- sales@pyroflux.in
- Office
- G-5, Sector 63, Noida 201301, Uttar Pradesh, India
- Factory
- G-15, Sector 63, Noida 201301, Uttar Pradesh, India
- Hours
- Monday to Saturday, 9 am to 6 pm IST