Zircon-Graphite Based Water Coatings
A dual-refractory water-based refractory wash combining premium micronized Zircon Flour and high-purity crystalline flake Graphite. Engineered for grey iron, ductile / SG iron, and non-ferrous foundries to eliminate sand burn-on, reduce veining, and achieve superior peel-off.
Dual-Refractory Performance for Heavy Iron & SGI Castings
Zircon-Graphite Water-Based Coating is a specialized composite refractory wash engineered for modern foundries producing heavy section Grey Iron (CI), Ductile / SG Iron, and specialized non-ferrous alloy castings. By combining the exceptional thermal resistance of micronized Zircon Flour ($\text{ZrSiO}_4$) with the non-wetting, lubricious, and high thermal-shock resistant properties of crystalline flake Graphite, this dual-component system creates an impenetrable thermal barrier between the molten metal stream and the bonded sand mould or core.
Formulated with advanced thixotropic rheology modifiers and inorganic-organic hybrid binders, our water-based coating forms a uniform, crack-free protective layer across sand surfaces. It completely prevents molten metal penetration, thermal cracking, and finning defects while facilitating effortless casting peel-off during knockout. At BR Chemicals, each production batch undergoes strict quality control for specific gravity, suspension stability, Bauma scale density, and dry-film hardness to ensure flawless performance on your foundry shop floor.
Engineered for Surface Integrity & Reduced Fettling
A synergistic blend of mineral refractoriness and carbonaceous non-wetting properties designed to slash casting cleaning costs.
Dual-Refractory Barrier
Zircon flour resists intense ferrostatic pressure and peak pouring temperatures, while graphite cushions against sudden thermal expansion shocks.
Superb Metal Non-Wetting
Crystalline graphite prevents liquid iron from wetting silica grains, guaranteeing smooth, defect-free casting skins with zero sand burn-on.
Excellent Suspension Stability
Advanced suspension agents prevent settling and hard packing in storage, allowing effortless remixing and uniform slurry consistency.
Clean Casting Peel-Off
Cores and moulds strip cleanly after knockout, significantly minimizing shot-blasting, grinding, and manual fettling labour.
Target Foundry Applications
- ✓ Grey Cast Iron (CI) and Spheroidal Graphite (SG / Ductile) Iron casting moulds and cores
- ✓ Heavy automotive engine blocks, heads, brake drums, and commercial differential housings
- ✓ Medium-to-heavy industrial pump bodies, valve casings, and compressor castings
- ✓ Furan No-Bake, Phenolic Resin (Acid Cured), and PUCB Cold Box sand systems
- ✓ Silicate- $\text{CO}_2$ bonded and Resin Coated Sand (Shell) core applications
- ✓ Multiple application techniques: Brushing, Dipping, Spraying, or Flow-coating
Core Formulation Chemistry
Zircon Flour ($\text{ZrSiO}_4$)
Ultrafine, low-expansion zircon silicate providing exceptional resistance against liquid metal erosion, thermal penetration, and chemical slag reactions.
Crystalline Flake Graphite
High-carbon natural graphite delivering natural lubricity, rapid heat dissipation, excellent thermal shock resistance, and complete molten metal repellence.
Water Carrier & Rheology
Zero-VOC, non-hazardous water carrier stabilized with organic-inorganic rheology modifiers to ensure zero sag, drip-free application, and uniform dried coat thickness.
Technical Specifications
| Property / Parameter | Pasty Grade (Concentrate) | Ready-to-Use (RTU / Thinned) |
|---|---|---|
| Refractory Filler | Zircon Flour + Crystalline Graphite | Zircon Flour + Crystalline Graphite |
| Carrier Base | Water (Solvent-Free) | Water (Solvent-Free) |
| Appearance / Color | Dark Greyish-Black Viscous Paste | Dark Grey / Black Homogeneous Liquid |
| Specific Gravity (at 25°C) | 1.70 – 1.95 g/cm³ | 1.35 – 1.55 g/cm³ (as per dilution) |
| Total Solid Content (%) | 68.0 – 74.0% | 50.0 – 58.0% |
| Viscosity (Ford Cup B4 at 30°C) | Thixotropic Paste (Thinned with water) | 16 – 28 Seconds (based on process) |
| Baume Gravity (°Be) | 55 – 65 °Be | 35 – 45 °Be |
| Recommended Diluent | Clean Tap / Deionized Water | Ready for direct application |
| Drying Mode | Air Drying, Oven Baking ($120-180^\circ\text{C}$), or Torch Drying | Air Drying, Oven Baking, or Forced Hot Air |
| Standard Packaging | 40 Kg / 50 Kg Polyethylene Buckets & 200 Kg / 250 Kg Open-Head Steel/HDPE Drums | |
| Storage & Shelf Life | 6 Months at room temperature ($5^\circ\text{C}$ to $35^\circ\text{C}$). Keep tightly closed when not in use. Protect from freezing. | |
*Specific gravity and viscosity can be tailored to suit automated dipping tanks, automated flow-coating machines, or manual spray booths. Contact our technical team for application-specific dilution guidelines.
Recommended Dilution & Application Practice
1. Agitation & Mixing: Stir the paste thoroughly using a mechanical stirrer before water dilution. Slowly add clean water while maintaining agitation until the desired Baumé or cup viscosity is achieved. Avoid excessive high-speed vortexing to prevent aeration and bubble entrapment.
2. Surface Application: Ensure cores and moulds are clean, dust-free, and loose sand particles are removed with compressed air. Apply an even layer via brushing (soft long-bristle brush), dipping, or pneumatic spraying. For heavy section thermal hot spots, apply two successive thin coats rather than one heavy, dripping coat.
3. Complete Moisture Removal: As a water-based product, all moisture must be completely evaporated prior to casting to prevent gas-induced porosity defects, pinholes, and metal blowouts. Dry thoroughly in a conventional core drying oven at $120^\circ\text{C}-180^\circ\text{C}$ for 30–60 minutes, or utilize radiant infrared / gas flame torch drying.
Upgrade Your Iron Casting Surface Finish Today
Connect with BR Chemicals' foundry technical specialists to receive tailored dilution ratios, TDS/MSDS documentation, and factory trial samples for your core and moulding operations.
