Control metal-mold interaction, improve casting quality
OPTES manufactures high-performance foundry and die coatings in Egypt for ferrous, steel, non-ferrous, die casting, and lost foam applications. Developed through technical collaboration with EKW Refractories (Germany) and Orane Refractories (India), these refractory coating systems are designed to control metal-mold interaction, reduce casting defects, and improve surface quality.
COATING RANGE| Product Group | Key Properties | Typical Applications |
|---|---|---|
| Graphite Coatings | Strong non-wetting / release performance; clean, easy shakeout; good surface finish on iron, aluminium, and copper alloy castings. | Iron castings; aluminium and copper alloy castings; applications where improved release and surface finish are priorities. |
| Zircon Coatings | High refractoriness; low thermal expansion; strong resistance to metal penetration. | Heavy-section steel and iron castings; valve bodies; crusher components; high-quality industrial castings. |
| Alumino-Silicate Coatings | Balanced refractoriness and thermal shock resistance; cost-efficient alternative where zircon performance is not required. | General iron and steel castings; medium-section castings; pump casings; automotive components. |
| Magnesite Coatings | High refractoriness; resistance to basic slags and alkaline attack. | High-manganese steel castings; alloy steel castings; components exposed to basic slag conditions. |
Coating systems for low-pressure, high-pressure, and gravity die casting, applied to control heat transfer and protect die surfaces across repeated casting cycles. They improve die release and reduce sticking, soldering, and thermal fatigue.
A water-based coating/slurry applied to EPS or PMMA foam patterns, forming a permeable refractory layer for the full-mould (lost foam) casting process. It supports pattern integrity, controls metal penetration, allows gas evacuation, and improves the surface quality of iron castings.
| Series | Base | Notes |
|---|---|---|
| ORAKOTE | Water-based | Selected by drying requirements, mold/core process, coating method, and foundry operating conditions. |
| ORALITE | Solvent / alcohol-based | Selected by drying requirements, mold/core process, coating method, and foundry operating conditions. |
Coating selection depends on the alloy being cast, mold or core type, casting temperature, section size, and application method. Our technical team can help match the right coating system to your process and quality requirements.
Foundry coatings create a controlled refractory barrier between molten metal and the mold or core surface. This helps reduce metal penetration, sand burn-on, veining, erosion, gas defects, and surface roughness while improving casting surface quality and shakeout performance.
Coating selection depends on the metal being poured, pouring temperature, mold or core material, casting section size, surface quality requirement, and defect history. OPTES supports customers in selecting the suitable coating based on the alloy, application method, and operating conditions.
Graphite coatings are commonly used where strong non-wetting behavior, easy peel-off, good release, and clean shakeout are required. They are suitable for many iron, aluminium, and copper alloy applications where improved release and surface finish are important.
Zircon coatings are recommended for high-temperature and demanding casting applications requiring high refractoriness, low thermal expansion, and strong resistance to metal penetration. They are commonly used for heavy-section steel and iron castings, valve bodies, crusher components, and high-quality industrial castings.
Alumino-silicate coatings provide a balanced combination of refractoriness, thermal shock resistance, and cost efficiency. They are suitable for general iron and steel casting applications, medium-section castings, pump casings, automotive components, and other applications where zircon may not be economically required.
Magnesite coatings are recommended for high-manganese steel, alloy steel, and applications exposed to basic slags or alkaline attack. They provide high refractoriness and chemical resistance in severe steel casting conditions.
Die coatings are used in low-pressure, high-pressure, and gravity die casting processes to control heat transfer, improve die release, protect die surfaces, and support consistent surface quality. They help stabilize the casting process and reduce sticking, soldering, and thermal fatigue issues.
Lost foam coating is applied to EPS or PMMA foam patterns before casting. It creates a permeable refractory layer that supports foam pattern integrity, controls metal penetration, allows gas evacuation, and improves the surface quality of iron castings produced by the lost foam process.
Yes. OPTES provides technical support for coating selection, application trials, viscosity and Baume control, drying practice, layer thickness, and defect analysis. The objective is to match the coating system with the foundry's alloy, mold/core process, and casting quality requirements.
Let our metallurgical experts help you select the optimal coating for your application.
