<p>This study examined water-based non-occupying coatings used in aluminum alloy foundry technology. Initially, single-factor experiments were conducted to evaluate how the content of refractory powder, binder, and suspending agents affected the performance of the coatings. Key metrics, including viscosity, surface strength, and gas evolution, were assessed to determine the optimal coating ratio. Scanning electron microscopy was utilized to analyze both the surface and fracture micro-morphology of the coatings and to explore their transfer mechanisms. The sand mold was prepared using a CO₂-hardened water glass sand transfer process, ensuring that the non-occupying coatings were fully transferred to the mold's surface. A pouring test was subsequently performed with this prepared sand mold. The results indicated that the non-occupying coatings effectively addressed issues related to low dimensional accuracy and high surface roughness in sand molds (cores), which were often caused by brush marks and the flow and accumulation of coatings on the surface. As a result, the application of non-occupying coatings can significantly improve the surface quality of castings and meet the precision requirements needed in foundry processes for sand molds.</p>