This literature review first describes the current state of the permanent mold coating technology used in most aluminum foundries. A need exists for a more robust mold coating, which requires less maintenance, maintains consistent physical prop- erties and reduces downtime. Following the introductory material, alternative methods, primarily thermal spray, are reviewed, to determine their feasi- bility for applying more durable and effective mold coatings. Background is provided for several thermal spray techniques and their current applications, and the pros and cons of each are reviewed. Recommendations for further research are made for the most probable replacement coating process and material(s).
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