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Catalogue
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HistoryCastolin Eutectic milestones in the evolution of coating technology
1906 Foundation of Castolin Eutectic in Lausanne, Switzerland
by Jean-Pierre Wasserman. His stroke of genius : to discover
a low temperature way to weld cast iron.
1940 Foundation of Eutectic Welding Alloys Corporation
in New York.
1960 International consolidation under Castolin Eutectic.
1963 Launch of powder spray-fuse Eutalloy® torch for powder
spraying with simultaneous fusion. More than 42000
units were sold.
1965 Powder production by water atomisation.
1969 Launch of EuTronic Gap® equipment for powder plasma
transferred arc welding.
1971 Launch of RotoTec® I torch for powder cold spraying. More
than 17000 units were sold.
1976 Powder production by gas atomisation.
1985 Marketed the world’s first amorphous powder for thermal
spraying.
1994 Patented powder wear plate production.
1995 Leading HVOF, Plasma and wire spraying with TAFA.
2000 Merger with Messer Cutting & Welding and creation of
the MEC Group - Messer Eutectic Castolin.
2005 Part of the Messer World gas supply company.
2006 World’s first anti-satellite gas atomiser for powder
production.
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IntroductionOne stop shop - Technical support, wear labs, production p. 4-5
Coating overview p. 6Quality Assurance p. 7
Powder production p. 8-9Spray wire production p. 10
Powder Spray-FusingEutalloy® Process - One step Spray & Fuse p. 12
Eutalloy® Powders p. 13-14Eutalloy® Equipment & Accessories p. 15-16
Eutalloy® SF Process - One Step Spray & Fuse for high yield p. 17Eutalloy® SF Powders p. 18
Eutalloy® SF Equipment & Accessories p. 19-20
Powder Cold or Hot Flame SprayingRotoTec®, ProXon® & MetaCeram® Processes - Cold Spraying p. 22
RotoTec®, ProXon® & MetaCeram® Powders p. 23-24
Eutalloy® RW Process - Two Step Spray & Fuse p. 25Eutalloy® RW Powders p. 26
Flame Equipment & Accessories p. 27-28
PTA WeldingEuTroLoy® Process - Plasma Transferred Arc p. 30
EuTroLoy® - PTA Powders p. 31-32EuTronic GAP® - PTA Equipment & Accessories p. 33-36
Wire SprayingEuTronic® Arc Process - Wire Arc Spraying Process p. 38
EuTronic® Arc Spray Wires p. 39EuTronic® Arc Spray Equipment & Accessories p. 40-42
Polymer SurfacingMeCaTeC® Process - Cold repairs & wear protection p. 44
MeCaTeC® Pastes and Fluids p. 45-46
Coating AccessoriesPowder Feeding p. 48Gas Accessories p. 49
Automation p. 50Protective Equipment p. 51
Other Accessories p. 52
ServicesIndustry partner p. 53
TeroLink® p. 53CastoLab® Services p. 54
Training p. 54
InformationTechnical data & Table p. 55-56
Contact p. 57Index p. 58
Table of contents
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Castolin Eutectic employs many en-gineers and technicians dedicated to solving the technical problems of our customers. The main Castolin Eutectic Research and Development centre for welding consumables and powder coat-ing alloys, is in Dublin. This R&D centre is one of the most advanced coating tech-nology laboratories in Europe. This modern facility is equipped for in-depth studies of all types of indus-trial welding and coating applications geared towards problem solving solu-tions. Dublin not only has an automat-ed Micro Hardness machine, G65, ICP and XRF units, but also employs a well trained and customer oriented techni-cal team.
Our team has undertaken more than 3500 metallurgical study reports over the last 15 years, to correctly identify the primary & secondary causes of complex wear problems as well as recommend-
CavitationFrictionErosion ImpactAbrasion Heat & Corrosion
Damage caused by wear phenomena costs money, especially in lost produc-tion downtime, replacement parts, repair and ongoing maintenance.
We have proved for over a century that preventive maintenance coating programs can extend the life of vital
Classical wear phenomena that occur in industry are :
Abrasion
Erosion
Impact
Friction
Heat
Corrosion
Cavitation
At Castolin Eutectic, we take the time to study industry specific wear phe-nomena because only when the natu-re of the wear is fully understood, can the correct solution be proposed.
machine parts by as much as 500%. Only Castolin Eutectic has the «know-how» to identify the key critical wear problems plus «show how» to over-come them thus greatly increasing your plant efficiency and profits.
ing the optimum solutions. After all, as a Castolin Eutectic customer, you deserve the best consultation, care and service to guarantee the quality and efficiency of your production operations.
Castolin Eutectic engineers and technicians are all highly qualified to understand industrial application problems in or-der to recommend optimised tailored solutions. The Research and Development centre is well equipped to resolve most complex wear phenomena affecting industrial productivity, using appropriate coating technology. Customers may be confident that dedicated, in-house development staff will work to fulfill their needs and expectations under a «one-stop shop» concept. Using state-of-the-art equipment, every batch of coating alloys produced according to strict procedures, is rigorously tested by professionals to ensure complete compliance with demanding Castolin Eutectic standards and exhaustive Quality Assurance criteria.
R&D / Technical Support
Overview of the wear phenomena
IntroductionOne stop shop
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Introduction
Wear Testing labs
Castolin Eutectic closely co-ope-rate with world renown Technical Institutes & Universities whose centres of excellence for model-ling wear mechanisms include fully equipped laboratories with scanning electron microscopes and wear testing equipment. Such latest state-of-the-art faci-lities and testing machines are essential to accurately monitor progress of wear mechanisms and to understand the complex relationship between materials, microstructures, processes and applications.
Integrated Production performance
The complete control of coating powder production within its own modern manufacturing plants, en-sures highest quality products to precisely meet user needs. A pro-ficient research centre staffed by skilled engineers and technicians in daily contact with OEM produ-cers and industrial users around the world, enables the powder plants to rapidly respond to speci-fic customer requirements.
The latest powder production technologies are perfectly inte-grated and managed within the logistics supply chain to assure the best service and value to cu-stomers.
Stringent Quality Controls
Every single stage of powder production from raw material selection passing via ingredient preparations and through the atomisation process to the final sieving operations, is subject to stringent quality assurance procedures. CEIL is ISO 9001 : 2000 certified and participates in a centralised Total Quality Management program with the primary aim of achieving complete customer satisfaction.
Only under such strict conditions can the finished product consistently conform to the highest performance demands of OEM producers and industrial users.
Introduction
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Coating families
Coating material
Base mate-rial
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield
EnergyEquipment investment
RotoTec Metals &polymer
Allmetals
Low 3 (10)*Medium to large
Lamelar 5 to 15%
Good.Mechanical
& micro-diffusion
Medium to high
Mediumto high
Combustiongases
Low
ProXonPowder.Metals
Allmetals
Low 2 (5)*Medium to large
Lamelar 5 to 15%
Good.Mechanical
& micro-diffusion
MediumMediumto high
Combustiongases
Low
Meta-Ceram
Powder.Ceramic
Allmetals
Low 0,4 (1)* Medium Lamelar 5 to 15%
Good.Mechanical
& micro-diffusion
Low MediumCombustion
gasesLow
EutalloyPowder.
Self-fluxingalloys
Steels,cast iron,
(aluminiumbronze) *
Medium to high
2 (10)*Small &precise
Homoge-neous
NegligibleVery good. Diffusion
Medium MediumCombustion
gasesLow
Eutalloy SF
Powder.Self-fluxing
alloysy
Steels & cast iron
High 2 (6)*Medium to large
Homoge-neous
NegligibleVery good. Diffusion
High HighCombustion
gasesLow
Eutalloy RW
Powder.Self-fluxing
alloysy
Steels &cast iron
High 2 (6)* MediumHomoge-
neousNegligible
Very good. Diffusion
Medium to high
Mediumto high
Combustiongases
Low
EuTroLoyPowder or
wire. Metals
Steels,cast iron,
(aluminiumbronze) *
Medium to high
2 (20)* LargeHomoge-
neousNegligible
Excellent.Fusion
Medium to high
HighElectricity
& shielding gas
Medium
EuTronic Arc
Wire.Metals
Allmetals
Low 1 (20)*Very large
Lamelar 3 to 10%
Good.Mechanical
& micro-diffusion
Very high MediumElectricity & compressed
airMedium
IntroductionCoating overview
Simplified surfacing polymer overview
Coating families
Coating material
Basematerial
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield Energy
Equipment investment
MeCaTeCPaste
or fluid.Polymeryy
All metals& others
None 10 (20)* LargeHetero-geneous
NegligibleGood.
ChemicalMedium High None Negligible
Best Second choice
There are many different coating ways to protect against wear, repair and rebuild your parts, each with theirrespective advantages and constraints. Below you will find simplified overviews of the different coating processes, to get a quick initial choice for your application.
Simplified thermal spray
(...)* request special precaution or coating material
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Abrasive sand
Test specimen
Force
Rotating wheel
Over the last few years, the need for quality assured, thermally sprayed coatings has steadily grown. A Total Quality Management system in a general spraying workshop, education, detailed procedures and quality control testing are the most important ele-ments for success.
cedure. It is essential to use adhesives with low penetration properties oth-erwise there is a risk that the glue will flow through the coating down to the substrate. This will influence the bond strength measurement and lead to incor-rect values.
HardnessThe coating hardness can be measured ei-ther on a ground area of the surface or in the cross section of the coating thickness. However due to the laminar nature of some coating structure, hardness values may vary depending on where the mea-surement is taken. A special Vickers hard-ness testing machine allows the thin cross section of the coating to be accurately measured in HV (Hardness Vickers num-ber). Different loading levels can be prese-lected depending on the coating hardness – the smaller the applied load, the higher the surface finish requirements.
Alternative macro hardness testing ma-chines such as Brinell (HB) or Rockwell (HRC) use spherical and conical indenters respectively.
PorosityThe coating porosity can be measured indirectly using the water impregnation method. This involves the diffusion of wa-ter to saturate the coating under vacuum conditions. By weighing the coating before and after water impregnation, the weight increase is mathematically recalculated into volume terms which indicates the coating porosity degree.
MicrostructureThe coating microstructure can be read-ily examined using an optical microscope. The operator can view directly the coat-ing microstructure, thickness, degree of bonding, delamination effects, micro or macro cracks, approximate porosity and oxide content.
EducationThe first step for a new operator is to complete a general training course in thermal spraying and then to work with thermal spraying over a period of at least 3 months. If a company is prepared to in-troduce a complete QA-system, the ETS (European Thermal Sprayer) course is the next step.
Detailed procedures The best way to produce consistent, re-peatable, high quality coatings is to follow a specific documented working procedure which guides the operator through all the necessary steps before, during and after spraying. The operator must detail every important step such as; work-piece data, surface cleaning method, preheating temperature, choice of spraying material, maximum temperature during spraying, final coating thickness and whether test pieces were sprayed etc.
He must confirm every completed step with a signature and the sprayed coating has also to be approved by the foreman before the part can be delivered.
The spray shop should store this docu-ment in a form suitable to be delivered together with the sprayed part to the cus-tomer.
Quality control
The quality control of sprayed parts can be done in many different ways. The most important coating properties to control are :
bond strength
hardness
porosity
microstructure
A typical spray shop can achieve a good understanding of the final coating integ-rity by spraying five test coupons. Four test coupons are then used for bond strength measurements and the last coupon can be used for hardness, porosity and micro-structure verification purposes.
Bond strengthThe coating bond strength is normally measured according to the EN 582 stan-dard which describes the complete pro-
Wear test methodsASTM G65 abrasion testThe ASTM G65 procedure simulates a three body wear system designed to gen-erate reproducible test data in order to rank materials by their resistance to low stress abrasion.
The testing equipment uses a rotating rubber wheel and dry sand to establish the abrasion resistance of different materials by measuring the degree of wear caused by hard quartz sand particles forced to move against and across the specimen surface.
CIAT - Continuous Impact and Abrasion TestThe CIAT is a wear test to measure resis-tance to abrasion combined with impact using an impeller tumbler machine.
The CIAT equipment consists of a drum with two internal impellers both rotating in the same direction but with different speeds. The test specimens are mounted on the faster impeller. As the drum rotates at a maximum 60 rpm whilst the impel-ler with the mounted specimens spins at 650 rpm, the rotating drum throws the loaded abrasive particles to hit the impel-ler thus provoking rapid combined wear to the mounted specimens.
IntroductionIntroductionQuality Assurance
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Yesterday’s Technology
Castolin Eutectic has made a major investment at its Dublin, Ireland consumables plant. In a bid to increase both efficiency and productivity, the new powder plant incorporates a substantial advance in atomisation technology. This improvement optimizes powder quality for Castolin Eutectic customers.
Historical Developmentof Thermal Spray PowderAtomisation
During the first half of the 20th century, the earliest thermal spray powders used to be limited to self-fluxing, nickel-based alloys. These earlier powders were very resistant to oxidation and were therefore atomised with steam, water or air and reached reason-able properties. Inert gas atomi-sation in earlier atomisers was carried out using nitrogen, and then quenching the particles into water. This process produced pow-ders with less oxidation than air, steam or water atomisation, and also with excellent particle shape. This was because freezing of the spray took place within an inert gas, allowing for better sphero-disation. Only with cobalt and other non self-fluxing alloys did dry, inert gas atomisation become the industry standard. However, while this avoided the risk of any oxidation by the water quench, it
was found that the particle shape was sometimes inferior to water-quenched powder. Small «satel-lites» were often found welded to the surface of the particles. And this seemed to happen more when finer powders were atomised. This feature reduced packing density, flowability and could disturb the thermal spray by satellites being detached.
Cause of Satellite Formation
During dry gas atomisation, sat-ellite formation is caused mostlywhen a dense dust-particle-cloudis formed in the atomising vessel.The hot plume of just-atomiseddroplets then passes through thiscloud, causing the droplets to col-lide with smaller, colder particles of the cloud.
Castolin Eutectic, with over 40 years of experience in water at-omisation and over 15 years in gasatomisation, is concentrating its know-how into the world’s mostadvanced powder plant in Dublin.
Leading-edge, powder production specialists were enrolled as part-ners to create a state-of-the-art and unique «anti-satellite» sys-tem. This system was designed using exhaustive Computational Fluid Dynamic (CFD) modelling to ensure that the intended suppres-sion of the dust cloud is indeed achieved. The number of particleswith satellites is therefore signifi-cantly reduced. As a material proof of this technology’s success, the visual appearance of the powders under the microscope was radi-cally improved.
The suppression of
the dust cloud reduces
significantly the number
of particles with satellites.
The visual appearance of
the powders under the
microscope was radically
improved.
Overview of the Powder production Processes
IntroductionPowder production
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Tomorrow’sTechnology - today
The customers of Castolin Eutectic benefit greatly from the reduction of «satelliting» of the product. Unwant-ed fines can no longer be found in the finished product, making sieving and handling actually easier. Another advantage is the increase in the flow rate through spraying system pas-sages, with fewer disturbances due to satellites. The chilling of the cir-culated gas also allows excellent and fast cooling of the powder particles. Therefore, temperatures at the outlet of the system are lowered, as much as the risks of oxidation by exposure to air. As a result the powder can be processed immediately through the sieves.The new gas atomisation allows for the production of highly alloyed pow-ders containing reactive elements. This would be impossible with water atomisation. Such powders can be formulated to produce unique com-binations of wear and corrosion re-
sistant coatings. With confidence in its future, Castolin Eutectic increased output capacity to answer additional customer requests. From the atomi-sation deck to the powder packaging, many improvements are aimed to emphasize efficiency and productiv-ity. By developing and producing in-house, every step of the production is controlled. Only high quality raw materials are used and every batch is strictly controlled and tested. Ad-ditionally products can be adapted to customers needs.
Yesterday’s Technology, Tomorrow’s Technology - today
g
as
gas
IntroductionIntroduction
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Overview of thespray wire production Processes
Today the vast majority of wires used for arc wire spraying are solid, extruded wires of standard com-positions of zinc and aluminium. By shifting to the more advanced «cored wire», innovation in surface protection is easier to achieve. Co-red wires consist of a hollow metal wires filled with different powders (metal and mineral). The flexibility in choice of metal and powder com-positions, have enabled us to pro-duce wire compositions with new high-tech production equipment that are impossible to produce as solid wires. Such wires have been tuned for arc wire spraying and to produce unique combinations of wear and corrosion properties for applications in boiler protection for example.
Unique wire characteristics
Unique wire production unit
Quality wire awaiting baking
IntroductionSpray wire production
Thermal spraying with wires
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Simplified overview
Coating families
Coating material
Base mate-rial
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield Energy
Equipment investment
EutalloyPowder.
Self-fluxing alloys
Steels,cast iron,
(aluminiumbronze) *
Medium to high 2 (10)*
Small & precise
Homoge-neous
NegligibleVery
good. Diffusion
Medium MediumCombustion
gasesLow
Eutalloy SF
Powder. Self-fluxing
alloys
Steels & cast iron
High 2 (6)*Medium to large
Homoge-neous
NegligibleVery
good. Diffusion
High HighCombustion
gasesLow
Best Second choice
(...)* request special precaution or coating powder
PowderSpray Fusing
Eutalloy® - Eutalloy® SF
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Basic Principles of Eutalloy® process
FunctionThe powder is introduced into the torch flame and sprayed in a semi-molten state onto the preheated part, for fusion. Bonding is achie-ved by diffusion of the alloys into the base metal.
Powder Spray-FusingEutalloy® Process - One step Spray & Fuse
ApplicationsThe Eutalloy® process is designed for protective coating of machine parts and tools subject to a variety of wear phenomena. Eutalloy®-type oxy acetylene torches are ca-pable of delivering a wide range of alloys in powder form. The Eu-talloy® system has a coating di-mension range from 0.10 mm to thicknesses of several millimetres. The spraying followed by fusion method can fine-coat to 0.05 mm. The hardness of a deposit can vary from 15 to 65 HRC, depending on the alloy composition. Such depo-sits are perfectly homogeneous and dense.
Technical dataFlame temperature: 3200 °C
Particle velocity: not relevant
Deposition rate: 2 to 6 kg/h
Coating material: Self-fluxingNi, Co or Fe base in powder form
Coating thickness: 0.05 to 10 mm
Coating density: 100%Noise level: 70 - 80 dB(A)
AdvantagesEutalloy® provides a wide range of benefits compared with conven-tional arc welding process and PTA processes:
No dilution of the base material
Best purity and performanceof the coating alloy
Homogeneous and pore freecoatings
Smooth surface for low postwelding machining and also when compared with coldthermal spraying
Higher bond strength
Better shock resistance
Thicker coatings capabilities
Bonding of the coating alloy and base metal is similar to that ob-tained in brazing: a liquid phase is linked with a solid phase, by diffusion. The wetting qualities of alloys are due to the synergis-tic nature of certain constituents. These resist oxide formation on the substrate surface during spraying, and promote bonding with the base metal. An oxide-free surface is essential. Melting ranges, depending on the type of alloy, vary between 850°C and 1100°C. Spraying distances vary between 6 and 20 mm.
Metallurgical bonding with no dilution of Eutalloy® alloy, on stainless steel (enlarged x 500).
A) Deposit
B) Diffusion zone
C) Base metal
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Designations Product Type
Applications Properties
Eutalloy® 10009Part N° / Esc Code100603 10009 0.7 kg
100604 10009 3.5 kg
AlloyNi-Cr-B-Si-Fe
Resurfacing cams, pushers, stops, guide wheels, filterpress cake stone remover for sugar mill, decanting screw, steam gate components. Coating elements subject to friction.
~63 HRCLow friction coefficient. Good resis-tance to corrosion, erosion and abra-sion under light load.
Eutalloy® 10011100605 10011 0.7kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
Coating elements of chains, transport screw, wiper segments, brick die frames, claw excavators, rock drill, brush cutter rake, debarking knives
~65 HRC80% tungsten carbides.Excellent resistance to abrasion by fine to coarse sized abrasives
Eutalloy® 10112100608 10112 0.7kg
103508 10112 12.5kg
100609 10112 3.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
Coating of machine parts used in the transport, handling and processing of minerals: transport screws, clay mixers, dies, segments, wipers, turbine impeller, fan impeller, pump screw, etc.
~64 HRC60% tungsten carbides.Excellent resistance to erosion and abrasion by fine to coarse sized abra-sives.
Eutalloy® 10185100610 10185 0.7kg
100611 10185 3.5kg
AlloyNi-B-Si
Coating of cast iron and steel molds for plastic material and glass.Recoating shafts, eccentrics, bearingsSoldering tungsten carbide biscuits on drilling stabilizers, etc.
~390 HV30Well suited for metal-to-metal fric-tion.Excellent corrosion resistance.Machinable with cutting tool.
Eutalloy® 10224100613 10224 0.7kg
103509 10224 12.5kg
100614 10224 3.5kg
AlloyNi-B-Si
Repairing glass mold edges, gear teeth, exhaust manifolds, pump bodies, brakes on drawing tools.Bonding layer before welding with electrode on cast iron that is difficult to weld, etc.
~250 HV30Appropriate for new or worn cast iron.Good resistance to corrosion.Machinable with cutting tool.
Eutalloy® 10611100617 10611 0.7kg
100618 10611WS 12.5kg
Co-Ni-Cr-B-Si alloy and tungstencarbide
Resurfacing chemical transport screws, fan blades at cement works, augers, and extrusion screws. Blades and segments of mixers, etc.
~55 HRC50% tungsten carbides.Excellent resistance to abrasion under pressure and to corrosion.
Eutalloy® 10680100621 10680 0.7kg
100622 10680 3.5kg
AlloyNi-B-Si
Repair of gears, cast iron valve seats, molds, keyways, bearing seating. Renewing drawing tools Correction of machining errors, etc.
~240 HV30Good resistance to shocks and oxida-tion while hot.Machinable with cutting tool.
Eutalloy® 15999202799 15999 0.7kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
Coating of molds for ceramics, rasps. Distributor blades for fertilizer spreaders, cyclone blades, hopper for sand sprea-ding machines, mouths of baggers, etc.
~65 HRC15% tungsten carbides.Excellent resistance to erosion and abrasion by fine abrasives.
Powder Spray-FusingEutalloy® Powders
PowderSpray-Fusing
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Powder Spray-FusingEutalloy® Powders
Designations Product Type
Applications Properties
Eutalloy® LT PE
8418103398 4.5kg
103404 12.5kg
Self-fluxing, nickel base alloy
Repair of mould damage on the seams or edges. Easy to machine or file.
~ 240 HV30 (~18 HRC)Grain size -106 µm.Low energy input for the fusion.Spot repairs.
Eutalloy® LT PE
8422103399 4.5kg
103405 12.5kg
Self-fluxing, nickel base alloy
Repair or protection of mould compo-nents: seams, blow heads, guide rings.
~ 270 HV30 (~22 HRC)Grain size -106 µm.Low energy input for the fusion.Small to medium repairs.
Eutalloy® LT PE
8426103400 4.5kg
103406 12.5kg
Self-fluxing, nickel base alloy
Brazing of tungsten carbides on stabiliz-ers.Extensive repairs and preventive coat-ings on seams, edges and guides.
~26 HRC (~300 HV30)Grain size -106 µm.Low energy input for the fusion.Fast deposition.
Eutalloy® LT PE
8431103401 4.5kg
103407 12.5kg
Self-fluxing, nickel base alloy with addition of Cr and Mo
Fast repairs and extensive preventive coatings on mould edges and guides.
~31 HRCGrain size -106 µm.Low energy input for the fusion.Good wetting properties and fast.
Eutalloy® LT PE
8435103402 4.5kg
103408 12.5kg
Self-fluxing, nickel base alloy with addition of Cr and Mo
Extensive repairs and preventive coatings on neck rings or blow head.
~35 HRCGrain size -106 µm.Low energy input for the fusion.Enhanced fluidity and fast.
Eutalloy® LT PE
8440103403 4.5kg
103409 12.5kg
Self-fluxing, nickel base alloy with addition of Cr and Mo
Enhanced weldability at high hardness level on bottom plates, baffles and guide plates.
~40 HRCGrain size -106 µm.Low energy input for the fusion.Fast deposition with enhanced fluidity.
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Powder Spray-Fusing PowderSpray-Fusing
SuperJet-S- Eutalloy® Kit
KoolTip
1 torch with heat shield
6 tip assemblies for different flamesizes to be used according tothe size of the part or type ofcoating required (refer to operatingpressure table, page 6)
Contents of the equipment case:
Accessories such as:
adjustable spanner
spark lighter
welding goggles
hose couplings
set of nozzle cleaners *
set of injector cleaners
special screwdriver *
cleaning rad *
set of Teflon washers *
* packed in a plastic box
Also included are Eutalloy® powders for a wide range of applications.
Alloy types: 10680 – 10009 – 10185 – 10112
Solution R 103 to protect the adjacent areas from undesirable overspray.
Special water cooled tip assemblies called KoolTip® kits are recommended whenever the SuperJet -S- torch is subject to high duty cycle usage or
prolonged thermal reflections.
C6 water-cooled tip assembly kit contents:
Eutalloy® Equipment
assembly with cooling deviceset of connecting water hosesspecial heat shield
Accessories such as:spark lighterwelding gogglesnozzle cleaner *injector cleaner *set of Teflon washers *
* packed in a plastic box.
Part N° / Esc Code750731 SuperJet-S- complete kit
Part N° / Esc Code203867 KoolTip C6S kit
SuperJet-S- Eutalloy® is an oxy-acety-lene thermal spray torch, whichdelivers very precise anti-wear pro-tective coatings, thanks to its sensiti-ve controls. Alloy powders are sprayed onto the part to be coated and are fusedsimultaneously. Diffusion bondingwith the base metal ensures that it does not reach its melting point. The dense coating is not affected by dilution and retains all its designed properties. For thermal spraying of Eutalloy® powders.
SuperJet-S-Eutalloy®
Advantages Flexible, multi purpose and fast
Rapid shut-off of acetylene andoxygen while maintaining setting
Reliable and precise coatings
Usable in all positions on a widerange of base metals, includingsteels, alloy steels, stainless steelsand cast-iron
Part N° / Esc Code290102 SuperJet-S- kit with A1S, B3S and C5S
Other kits with different content are available on request. Please ask your local Castolin Eutectic company
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Powder Spray-Fusing
Part N° / Esc Code205077 Refill Powder Container
Refill Powder Container
An aluminium refill container may be mounted onto the torch when powder alloys need to be transferred from bulk packages. Refilling is easily executed via the lid without removing the container.
Nozzles
This nozzle is made out of highly Cu with structural hardening, a special wear resistant copper alloy which improves service life. It can be screwed on & off easily. Every standard kit is delivered with this nozzle type.
Heavy duty Nozzles
Reinforced with Tungsten–Carbide
This nozzle can be supplied as an option. Each type can be screwed easily onto the corresponding standard tips. It is recommended when using powders containing abrasive hard particles such as tungsten-carbides.
This wear-resistant spray nozzle will help you in terms of longer service life or consistent quality coating.
C6-3 is special nozzle with 3 holes for the powder outlet to coat large sur-faces.
Compact heavy duty tip
Tungsten–Carbide brazed on the tube
This is the solution for all applications where access is a problem and visibility of the fusion bath is a must. It is recommended for Glass Works and all big users of powders containing hard particles. It is available as an option.
Compact heavy duty tube
Tungsten–Carbide brazed on the tube
Same as the compact heavy duty tip, however without the gas mixer. It is available as an option.
Accessories for SuperJet-S- Eutalloy®
Eutalloy® Accessories
Part N° / Esc Code205117 A2S WC205104 B3S WC205116 B4S WC205105 C5S WC290138 C6S-3 WC
Part N° / Esc Code290129 A0S290130 A1S290131 A2S290132 B3S290133 B4S290134 C5S
Part N° / Esc Code290078 A0S WC/HT290079 A1S WC/HT290080 A2S WC/HT290081 B3S WC/HT290082 B4S WC/HT290083 C5S WC/HT
Part N° / Esc Code290084 A0S WC/HT290085 A1S WC/HT290086 A2S WC/HT290087 B3S WC/HT290088 B4S WC/HT290089 C5S WC/HT
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Powder Spray-Fusing PowderSpray-Fusing
Eutalloy® SF Process - One Step Spray & Fuse for high yield
Cooling Water
Alloy Powder
Powder Injector
Oxygen
Compressed AirAcetylene
FunctionThe Eutalloy® SF flame spraying process is designed to deposit a range of wear resistant powder coatings with high deposit effi-ciency. It uses the CastoDyn DS 8000 oxy-acetylene powder spray system equipped with an SF Lance to coat onto slowly moving or sta-tionary even surfaces of massive steel parts in a one step spray & fuse operation.
The water cooled SF Lance robust design has been engineered to perform higher powder deposi-tion spraying rates with simul-taneous fusion capabilities. This creates wear resistant requisite coatings from 0.8 mm to 3 mm thickness with strong metallur-gical diffusion bonds to the steel substrate.
AdvantagesHigh deposition yield
No dilution of the base material
Best purity and performanceof the coating alloy
Homogeneous and pore freecoatings
Smooth surface for lowpost machining
High bond strength
Good shock resistance
Thick coatings capabilities
Technical dataFlame temperature: 3200 °C
Particle velocity: not relevant
Deposition rate: 2 to 10 kg/h
Coating material: Self-fluxingNi, Co or Fe base in powder form
Coating thickness: 0.8 to 3 mm
Coating density: 100%
Noise level: 70 - 80 dB(A)
ApplicationsA range of self fluxing Eutalloy® SF powder alloys has been developed to meet the precise granulometry and morphology tolerances of the SF Lance system thus ensuring highest possible deposition rates combined with efficient yield, re-liable deposit quality and ease of application. This comprehensive range of corrosion resistant nic-kel based Eutalloy® SF powder al-loys is available to meet different hardness and machinability re-quirements when protecting in-dustrial machine parts in service against wear by friction, abrasion, erosion, pressure etc.
Coating with densely packedhard tungsten carbides in
a matrix to form an impenetrable barrier to abrasive particles.
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Powder Spray-Fusing
Designations Product Type
Applications Properties
Eutalloy® SF 15211Part N° / Esc Code
202789 15211 4.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
All round powder for anti-abra-sion.
~60 HRC60% tungsten carbidesExcellent resistance to erosion and abrasion by fine to coarse sized abrasives.
Eutalloy® SF PE 8213202536 PE 8213 12.5kg
202537 PE 8213 4.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
For thick coatings. Stabilizer in oil and gas drilling industry.
~55 HRC55% tungsten carbides.Excellent crack resistance. Abrasion and corrosion resistance.
Eutalloy® SF PE 8215202538 PE 8215 4.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
For smooth coatings and parts sub-ject to severe abrasion such as agri-culture parts, centrifugal screws.
~850 HV3060% tungsten carbides.Excellent abrasion resistance even by fine particles.
Eutalloy® SF PE 8217205951 PE 8217 12.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
For parts needing a rough surface and subject to severe abrasion such as scraper blades, drill heads, scraper parts.
~62 HRC70% tungsten carbidesBest edge build-up capability. Abrasion and corrosion resistance.
Eutalloy® SF Powders
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Powder Spray-Fusing PowderSpray-Fusing
Eutalloy® SF Equipment & Accessories
The CastoDyn SF Lance kit increases the already wide range of applications by allowing the CDS 8000 to perform spraying with simultaneous fusion.
Technical data
Standard Spray Module SSM 50 SSM 51 SSM 52 optional
Deposition rate 4-9 kg/h 2-4 kg/h 1-2 kg/h
Typical Yield >90 % >90 % >90 %
Oxygen flow rate 2000 NI/h 1000 NI/h 500 NI/h
Acetylene flow rate-Flame 1900 NL/MN 950 NL/MN 475 NL/MN
Oxygen flow rate - Carrier gas 330 NL/MN 240 NL/MN 80 NL/MN
Flame power ~ 28 KW ~ 14 KW ~ 7 KW
Deposit thickness(one pass)
1-3 mm 0,8-2,5 mm 0,8-2 mm
CastoDyn SF Lance
Castolin Eutectic’s modular CDS 8000 torch performs more flame spraying processes, with more alloy powder types than any other comparable system. Its robust, water-cooled design permits sustained high-intensity spraying, and is ideal for both automated and manual applications.
Advantages
Increased energy outputfor highest deposition rate
Advanced nozzle design deliversexceptional yield (>90%)
Consumable : Eutalloy® SF powders
Schematic showing the assembly of SF Lance on CastoDyn DS 8000
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Powder Spray-FusingEutalloy® SF Equipment & Accessories
CastoDyn® Extra-Flat SF Lance
The kit’s two Standard Spray Modules (SSM 50 and SSM 51) offer different flame powers, so workplaces of any mass or thickness can be coated.
CastoDyn® SF Lance
Part N° / Esc Code203766 CastoDyn SF Lance kit 500 mm 205527 CastoDyn SF Lance kit 450 mm 203784 CastoDyn SF Lance kit 350 mm 205530 CastoDyn SF Lance kit 250 mm
CastoDyn® DS 8000
Part N° / Esc Code203754 CDS 8000 kit without SSM
The CastoDyn DS 8000 torch is de-livered in a robust carrying and stor-age case. This CDS 8000 kit is ready to be used with an SF lance kit and contains no Standard Spray Modul (SSM).
The CastoDyn Extra-Flat SF Lance is the solution where the access is a pro-blem. A minimum free opening of 60 mm is enough to enable the Extra-Flat SF Lance to penetrate in the gap and to apply a coating. It is typically used to apply wear resistant coatings on decanter screws.The special Extra-Flat kit contains the SSM 51 and a SF Lance with a length of 380 mm
Part N° / Esc Code203763 CastoDyn Extra-Flat SF Lance kit
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RotoTec®- ProXon®- MetaCeram®- Eutalloy® RW
Powder Cold orHot Flame Spraying
Simplified overview
Coating families
Coating material
Base material
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield Energy
Equipment invest-ment
RotoTecPowder.
Metals & polymer
Allmetals
Low 3 (10)*Medium to large
Lamelar 5 to 15%
Good. Mechanical & micro-diffusion
Medium to high
Medium to high
Combustion gases
Low
ProXonPowder. Metals
Allmetals
Low 2 (5)*Medium to large
Lamelar 5 to 15%
Good. Mechanical & micro-diffusion
MediumMedium to high
Combustion gases
Low
Meta-Ceram
Powder. Ceramic
Allmetals
Low 0,4 (1)* Medium Lamelar 5 to 15%
Good. Mechanical & micro-diffusion
Low MediumCombustion
gasesLow
Eutalloy RW
Powder. Self-fluxing
alloys
Steels & cast iron
High 2 (6)* MediumHomoge-
neousNegligible
Very good.
Diffusion
Medium to high
Medium to high
Combustion gases
Low
Best Secondary choice
(...)* request special precaution or spray powder
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Powder Cold Flame SprayingRotoTec®, ProXon® & MetaCeram® Processes - Cold Spraying
FunctionRotoTec®, ProXon® & MetaCeram® are «cold» processes whereby a new alloy or ceramic is reliably coated onto a cylindrical surface of a metal workpiece or part. The sprayed coat-ings are applied to the desired thick-ness at temperatures that do not overly stress, change the base metal properties or create distortion. These «cold» processes mean that the part should not exceed about 150°C dur-ing coating.
These thermal spray powders are categorized into the following pro-cesses:
ProXon® process where theself-bonding powders are«cold» sprayed in «one-step».
RotoTec® & MetaCeram® processeswhere the powders are sprayedin «two-steps».
The first step is to «cold» spray a bond coat to ensure the bondingwith the part. The second step is to «cold» spray a final coating withthe required wear resistanceproperties.
AdvantagesLow heat input to the basemetal minimizes distortion,warping and changes in thebase metal.
«Cold» is key to simplicity,efficiency, speed and reliability.
Wide range of powders canbe sprayed.
Spraying equipment isinexpensive.
Easy to handle.
The low level of noise and fumesduring spraying facilitates settingup a new low cost spraying facility.
Applications«Cold» powder flame sprayed coat-ings have a very broad field of appli-cations. Both metals and ceramics are sprayed for different application needs.
In particular, parts suitable for coat-ing consist of those which can be ro-tated and require repair due to wear on surfaces which are cylindrical in shape. This represents a wide range of applications, consisting of shafts, journals, rolls and bearings on areas such as bearing seats, press fits, seal and packing zones.
Technical dataFlame temperature: 3200 °C
Particle velocity: up to 50 m/s
Deposition rate: 1 to 6 kg/h
Coating material: Alloys andceramics in powder form
Coating density: 85 - 95%
Noise level: 70 - 80 dB(A)
Rotor repair with RotoTec® «cold» spray process for lowest heat input
Compressed Air
Powder
Oxygen
Acetylene
Powderspraystream
These «cold» thermal spray powders are applied with
a flame powder spray system, such as the oxy-acety-
lene CastoDyn DS 8000. The powder is fed with help of
injector effect or a carrier gas (nitrogen, argon or air)
into a gas flame (often acetylene/oxygen). The flame
heats the powder particles and propels the droplets
towards the substrate forming a dense coating with
good bonding properties. Due to the moder-
ate transfer of heat to the powder parti-
cles and to the workpiece, the base metal
stays relatively cool.
Microstructure of a coldsprayed coating
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Powder Cold Flame SprayingRotoTec® Powders
Designations Product Type
Applications Properties
RotoTec® 51000Part N° / Esc Code100658 51000 1.25kg
AlloyNi-Al-Mo
Bond coat for RotoTec® 19000 and MetaCeram 28000 powder families, on all metals except Cu and Mg.
~170 HV10 - Fusion reaction during spraying creates strong bond with subs-trate.
RotoTec® 19300100639 19300 1.35kg
AlloyFe-Cr-Ni-Mo
Pieces operating with metal-to-metal friction such as shafts, bearing surfaces, pistons, etc.
~250 HV10 - Machinable with tools. Good coefficient of friction. Good resis-tance to corrosion.
RotoTec® 19310100640 19310 1.35kg
AlloyFe-Cr-Ni
Pieces operating with metal-to-metal friction. Wear sleeves for pumps.
~335 HV10 - Machinable with tools (very good machinability by turning). Good resistance to frictional wear.
RotoTec® 19400100641 19400 1.35kg
AlloyFe-Cr-Ni
Protective couplings for shafts, press pis-tons, motor casing.
~420 HV10 - The best surface finish is obtained by grinding.
RotoTec® 19404202903 19404 1.35kg
AlloyFe-Cr-Co-Mo
Pieces operating with metal-to-metal friction and corrosion such as bearingseats, etc. For replacing hard-chrome.
~400 HV10 - Excellent combination of corrosion, wear resistance and low friction. Machinable with nice surface finish.
RotoTec® 19800202905 19800 1.35kg
AlloyCu-Sn-Zn
Guides, slides, journal bearings, bearings. ~100 HV10 - Very good machinability by turning. Excellent coefficient of friction. Low sensitivity to residual stress.
RotoTec® 19850202907 19850 1.35kg
AlloyCu-Al
Compressor pistons, trunnions and pul-leys.
~120 HV10 - Very good machinability by turning. Low coefficient of friction.
RotoTec® 19868202909 19868 1.35kg
AlloyCu-Al-Ni
Interior coatings of chocks, ram slides, foundry models.
~150 HV10 - Good machinability by turning. Low coefficient of friction and good pressure resistance. Good corro-sion resistance.
RotoTec® 19940100643 19940 1.35kg
AlloyNi-Cr-Fe-Mo
Wear sleeves for pumps, cylinder rods, drying cylinders for papermaking.
~370 HV10 - The best surface finish is obtained by grinding. Good resistance to friction under pressure.
RotoTec® 19985100644 19985 1.35kg
AlloyNi-Cr-Fe
Bearing seatings, pistons.Used in rebuilding worn parts.
~200 HV10 - Very good machinability by turning.
RotoTec® 19999100646 19999 1.35kg
Alloy Ni-Cr-Fe and carbides
Drag roll, wear plates, gripping finger. ~250 HV10 - 50% carbides. High resis-tance to abrasion. Rough deposit.
RotoTec® LT 29230203013 29230LT 1.35kg
Zn base Sign panels, pylons, gantries, metallic structures, machine casing, port equi-pment, repair of accidental damage to galvanized structures.
Zn >99% - Low melting temperature.Sacrificial layers ensuring cathodic pro-tection of ferrous supports against cor-rosive atmospheric phenomena.
RotoTec® LT 29240203014 29240LT 1.35kg
AlloySn-Sb-Cu
Antifriction alloys. Resurfacing bearings. The best adhesion is obtained by prepara-tory tinning using CastoTin # 1.
Excellent behavior under friction.Low melting temperature.
RotoTec® – Alloy powders for "cold" two step spray process
PowderCold Flame Spraying
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Powder Cold Flame SprayingProXon® & MetaCeram® Powders
Designations Product Type
Applications Properties
ProXon® 21021Part N° / Esc Code100648 21021 1.25kg
100649 21021 2.5kg
AlloyNi-Al-Mo
Mechanical seats, feathering sides.Thin and thick anti-wear coatings.
~170 HV10 - Used without bonding layer.The best surface condition is obtained by grinding.
ProXon® 21023202940 21023 2.5kg
AlloyFe-Ni-Al
Bearing seatings, guides, slides, feathe-ring sides.
~200 HV10 - Used without bonding layer.Max. service temperature 800 °C.Thick deposit capability (<3mm).
ProXon® 21031100671 21031 2.5kg
AlloyNi-Cr-Al-Fe-Mo
For components subject to wear and corrosion such as fan blades, shaft slee-ves and roller bearing seats
~280 HV10 - Used without bonding layer. Thick deposit capability (<3mm).
ProXon® 21071202941 21071 1.25kg
AlloyCu-Al
Compressor pistons, trunnions and pulleys.
~120 HV10 - Used without bonding layer. Good machinability. Low coefficient of friction. Thick deposit capability (<4mm).
MetaCeram® – Ceramic and refractory powders for "cold" two step spray processMetaCeram®28010Part N° / Esc Code203004 28010 1.2kg
Cr2O3 On RotoTec 51000 bonding layer. Cable gland seatings, shaft protector sleeves, seam ring joint seatings, plun-gers, pump shafts, feed chutes.
Microhardness ~2400 HV10gMax. service temperature 500 °CProduct density 5.2 kg/dmHigh hardness, excellent resistance to corrosion, low coefficient of friction.
MetaCeram®28020203005 28020 1.2kg
Al2O3TiO2(2.2%)
On RotoTec 51000 bonding layer. Seam ring joint seatings, cable gland seatings, shaft protector sleeves, elec-trical isolation of machine parts, press rings for making radial tyres, sifting plate.
Microhardness ~1950 HV10gMax. service temperature 1000 °CProduct density 4.0 kg/dmHigh hardness, excellent resistance to corrosion.Good electrical insulation (dependent on deposit thickness).
MetaCeram®28030203006 28030 1.2kg
Al2O3TiO2(13%)
On RotoTec 51000 bonding layer.Printer cylinders, paper transport rol-lers, thread guide, wear and sliding pla-tes, induction oven parts.
Microhardness ~1600 HV10gMax. service temperature 1000 °CProduct density 4.0 kg/dmGood resistance to corrosion and good friction properties.
MetaCeram®28095203009 28095 0.7kg
Mo Used without bonding layer.Sliders, bearings, spindle guide, cable gland seatings, pistons for high-pres-sure pumps.
Microhardness ~900 HV10gMax. service temperature 400 °CProduct density 10.2 kg/dmGood resistance to abrasion and excel-lent coefficient of friction.Non-magnetic deposit.
ProXon® – One-step alloy powders for "cold" one step spray process
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Powder Hot Flame SprayingEutalloy® RW Process - Two Step Spray & Fuse
FunctionEutalloy® RW is a 2-step hot flame spraying process.
The first step is to «cold» spray a thin, regular layer of «RW» self-fluxing quality powder onto a precleaned, preheated steel substrate using a oxy-acetylene powder spray system such as the CastoDyn DS® 8000.
The second step is then to heat the “RW” powder deposit “red hot” using a flame torch, such as the Casto-Fuse torch, until a reflective fused surface finish is visible locally. An induction system or an oven can also be used. Strong metallurgical diffusion bonding of the resultant wear resistant coating is thus achieved without melting or dilution with the substrate. The coating thickness may then be further increased by continuing to spray & fuse the powder simultaneously followed by controlled slow cooling to ambient temperatures.
AdvantagesSmooth surface for lowor no post machining
No dilution of the base material
Best purity and performanceof the coating alloy
Homogeneous and porefree coatings
High bond strength
Good shock resistance
First step: Cold spraying with CastoDyn® DS 8000
Second step: red hot fusion using the CastoFuse® flame torch
PowderHot Flame Spraying
Microstructure of a 2-stepsprayed & fused coating
ApplicationsThe Eutalloy® RW process is designed to hot flame spray a range of wear resistant powder coatings onto fast rotating or stationary even surfaces.Final «RW» pure precision coatings are characterised by smooth surface finish requiring little or no post machining operations for optimum ser-vice performance.
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Designations Product Type
Applications Properties
Eutalloy® RW 12112Part N° / Esc Code100627 12112 3.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
Recoating wear pieces of agricultu-ral machines, mixer blades, ceramic press feeder plungers.Resurfacing pump wear sleeves, steel industry transport rollers.
~710 HV3035% tungsten carbides.Excellent resistance to erosion and abrasion.
Eutalloy® RW 12494100629 12494 3.5kg
AlloyNi-Cr-B-Si-Fe
Coating incineration boiler tubes.Machine elements in food and chemistry industry.
~310 HV30Very good resistance to corrosion.Suitable for friction under light loads.Machinable with cutting tool.
Eutalloy® RW 12495100630 12495 3.5kg
AlloyNi-Cr-B-Si-Fe
Coating of wear sleeves for pumps, glassworks feed plunger, valve parts: seats, flaps, etc.
~390 HV30Suited for impact and friction.Machinable with cutting tool.
Eutalloy® RW 12496100632 12496 3.5kg
103352 12496 50kg
AlloyNi-Cr-B-Si-Fe
Coating cylinder rods, wear sleeves, pump pistons and faucet parts.Resurfacing coal dust separators, etc.
~680 HV30Very low coefficient of friction and good abrasion resistance.Excellent resistance to corrosion and especially to seawater.
Eutalloy® RW 12497100634 12497 3.5kg
AlloyNi-Cr-B-Si-Fe-Mo-Cu
Coating protective couplings, cylin-der rods, wear and seal sleeves, Pelton turbine, injection needle valves, etc.Coating stainless steel pieces.
~740 HV30Excellent frictional and corrosion resistance.Excellent corrosion resistance.
Eutalloy® RW 12999100637 12999 3.5kg
Ni-Cr-B-Si-Fe alloy and tungstencarbide
Coating fan blades, mixers, trans-port screws, tensioning pulleys, guides.Wear parts for agricultural equipment, etc
~760 HV3040% tungsten carbides.Excellent resistance to abrasion.
Eutalloy® RW 17535202878 17535 3.5kg
AlloyNi-Cr-B-Si
Coating paper mill and household waste boiler tubes. Resurfacing machine parts operating in corro-sive environments.
~480 HV30High Cr alloy.Well suited for metal-to-metal friction.Excellent resistance to oxidation while hot.Good resistance to cracking.Machinable with cutting tool.
Eutalloy® RW 53606100662 53606 3.5kg
AlloyNi-Cr-Mo-Si-B-Cu
Boiler tubes, shafts and sleeves in waste incineration, chemical, pulp and paper industries.
~600 HV30Excellent wear and corrosion resistance to both reducing and oxidizing environments.
Powder Hot Flame SprayingEutalloy® RW Powders
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Powder Flame SprayingCastoDyn® DS 8000
Accessories for CastoDyn® DS 8000
Technical data CastoDyn® DS 8000 is an advanced modular oxy-acetylene thermal spray system, designed to spray a wide range of alloys and other materials for many different appli-cations, from anti-abrasion coatings to thermal shielding. The CDS 8000 can be inte-grated into automated installations for large-scale mass-production applications.For «hot» thermal spraying of Eutalloy® RW powdersFor «cold» thermal spraying of RotoTec® and Proxon® alloy powdersFor «cold» thermal spraying of MetaCeram® alloy powdersFor «cold» thermal spraying of CastoPlast thermoplastic powders
Advantages Outstanding operator safety and ease-of-use
Ready-for-use CDS 8000 kit in a robustcarrying/storage case
Standard Spray Modules (SSM)
Unique rapid shut-off lever for safety andfor relighting without touching any other control
Oxygen flow rate - Flame Acetylene flow rate-Flame Oxygen flow rate - Carrier gas
Module NL/MN NL/MN NL/MN
SSM10 1000 950 240SSM20 1000 950 240SSM30 2000 1800 80SSM40 1000 950 330
CastoFuse®
Kit with optional lances
Technical data The advantage of local heating using the CastoFuse® torch is obvious compared with an oven. Local preheating and fusing prevents the dispersion of heat in the rest of the workpiece, to the surrounding area and into the oven walls. CastoFuse® offers the heat where needed. Furthermore, only a small investment is required.
Advantages Performance: nozzles designed specifically to fuse self-fluxingpowder coatings
Safety and ease-of-use: unique rapid shut-off leverFull line: assortment of lances to ensure optimum flame power
CastoFuse Lance 20 30 40
Oxygen consumption 0.8 - 1.1 m3/h 1.5 - 1.66 m3/h 2.3 - 3.3 m3/hAcetylene consumption 0.7 - 1.0 m3/h 1.05 - 1.5 m3/h 2.1 - 3.0 m3/hFlame power ~ 11 KW ~ 20 KW ~ 40 KWRequired acetylene cylinders 1 2 4Length 270 mm 320 mm 590 mm
Part N° / Esc Code203756 CDS 8000 complete kit with SSM10, SSM20, SSM30 and SSM40
Part N° / Esc Code290020 CastoFuse complete kit with lances 20, 30 and 40
Flame Equipment & Accessories
PowderFlame Spraying
Part N° / Esc Code203758 CDS 8000 Extension neck
Extension Neck
Spray extension neck for coating internal surfaces or difficult access areas.
Length 465 mm
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Technical data Connections
Fuel gas (acetylene): LH 3/8" left, Oxygen: RH 1/4" right,Compressed air: M10 x 1
Spraying efficiency
Powder throughput: ~ 3.0 – 6.0 kg/h (depending on powder type,instrument adjustment, etc.)
Operating pressures and gas consumption values
Oxygen, 3.0 bar: 1400 NL/h ± 50 NL/h,
Acetylene, 0.7 bar: 1130 NL/h ± 50 NL/h
Fuel gas-oxygen mixture, Injection principle (gas-mixing squirting and heat-ing nozzle) Weight approx. 1.25 kg (without powders and gas hoses)
RotoTec® 800
Contents of the equipment case: Flaming spraying gun RotoTec® 800 equipped with:
Flaming spraying nozzle (standard, surface layers) Turning ring nozzle P/K Powder connection head for surface layersØ 1.5 mm (silver) Heat shield (installed)
Powder connection head for wash primer, Ø 1.0 mm (gold) Monkey wrench, SW 24 mmOpen-ended spanner, SW 24 mm Manual gas lighter Autogenous eye protector A1, stage 5 Nozzle drill in metal suitcase No.: 0 - 8 Manual/parts catalogue
Accessories for CastoFuse®
Konstantherm
Heat resistant heating tip for acetylene and hydrogen.
Available on request, please ask your local Castolin Eutectic company.
Line Heating Torch
For heating, brazing, forming, hardening, stress relieving.
Available on request, please ask your local Castolin Eutectic company.
Ring Torches
For pre and post heating, soldering and brazing, forming.
Available on request, please ask your local Castolin Eutectic company.
Part N° / Esc Code307100 RotoTec 800 complete kit
Powders Flame SprayingFlame Equipment & Accessories
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PTA Welding
PTA
Simplified overview
Coating families
Coating material
Base material
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield Energy
Equipment investment
EuTroLoyPowder or
wire. Metals
Steels,cast iron,
(aluminium bronze)*
Mediumto high
2 (20)® LargeHomoge-
neousNegligible
Excellent. Fusion
Medium to high
HighElectricity &
shielding gasMedium
Best Second choice
(...)* request special precaution or PTA powder
EuTroLoy®
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PTA WeldingEuTroLoy® Plasma Transferred Arc Process
Smooth surface and spatter free coating
1) Cathode holding device2) Plasma gas3) Cathode4) Cooling water 5) Shielding gas
Plasma Transferred Arc (PTA)
FunctionIn the PTA process, the plasma is focused while forced through the heat resistant anode, causing a considerable increase of the arc density, energy and temperature. The filler alloy in powder form is conveyed into the plasma arc colu-mn where a shielding gas protects the weld pool from the atmosphe-re. The plasma arc and the heat input can be far better controlled than a conventional electric arc and the energy is almost comple-tely spent to melt the filler metal, reducing the heat input and dilu-tion to the minimum.
AdvantagesPTA technology provides a wide range of benefits compared with conventional arc welding pro-cesses:
Lowest dilution, heat input,distortions and HAZ than anyother arc welding process
Maximum purity and performance of the coating alloy
Extra smooth surface for leastpost-weld machining
Higher bond strength
Pore free coating
Thicker coatings capabilities
ApplicationsThe EuTronic® GAP is the Castolin Eutectic Plasma Transferred Arc (PTA) equipment. GAP is ideal for coating and joining operations. Castolin Eutectic has developed special EuTroLoy powders for ap-plications done with the EuTro-nic® GAP.
Wear resistant coating with metallurgi-cal bonding and minimum dilution.
6) Feeding gas and powder7) Welding direction8) Ignition 9) Double power supply
Technical dataPlasma arc temperature:up to 20 000 °C
Particle velocity: not relevant
Deposition rate: 2 to 20 kg/h
Coating material: Metals inpowder or wire form
Coating thickness: 0.1 to 20 mm
Coating density: 100%
Noise level: 70 - 80 dB(A)
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PTAPTA WeldingEuTroLoy® - PTA Powders
Designations Product Type Applications Properties
EuTroLoy®16006.04
Part N° / Esc Code
420004 16006.04 12.5kg
420005 16006.04 4kg
AlloyCo-Cr-W-Ni-Fe(Gr. 6 Type)
Valve seats, protective shaft sleeves, shaft seal surfaces, tools in the wood and plastic processing industry, stir-rer components, valve parts, extruder screws, buffer layer for EuTroLoy® 16001 alloy powders.
~40 HRCHigh abrasion resistance under pressure and impact stress (cavitation). Heat and corrosion resistant. Low coefficient of sliding metal friction, insensitive to adhesive wear. For operating temperatures up to 750°C.
EuTroLoy®16008.04103704 16008.04 12.5kg
420006 16008.04 4kg
AlloyCo-Cr-Mo-Ni(Gr. 21 Type)
Calibration matrices for steel forming, hot working tools such as dies and shearing blades, valve seats, seal surfaces of shafts and spindles, pump and turbine parts. Buffer layers for EuTroLoy® 16001, 16006, 16012 alloy powders.
~30 HRCCorrosion, oxidation, heat, cavitation, thermal shock and creep-resistant weld metal. Workhardening. Low coefficient of sliding metal friction, insensitive to adhe-sive wear. Nonmagnetic, easily machined and polished coatings.
EuTroLoy®16012.04103651 16012.04 12.5kg
420008 16012.04 4kg
AlloyCo-Cr-W-Ni-Fe(Gr. 12 Type)
Slide valve seats, extruder screws for plastic masses, feed screws for sawdust and hydropulpers in the paper industry, tools in the timber industry, segments of nose rings and clinker cooling plates, tools for the paper, plastics and timber processing industries.
~46 HRCHigh abrasion resistance under pressure and impact stress (cavitation). Heat and corrosion-resistant. Low coefficient of sliding metal friction, insensitive to adhesive wear. For operating temperatures up to 750°C.
EuTroLoy®16221.04205146 16221.04 12.5kg
205144 16221.04 4kg
AlloyNi-Cr-B-Si-Al
Highly suitable for use with molten glass. Mould bottoms, tailstocks, blowheads in cast iron and Cu-Al.Drawing matrices in cast iron, coke oven door. Bonding layer on flake and spheroidal graphite cast iron parts.
~30 HRCExcellent bonding with lamellar and spheroidal graphite grey cast iron, as well as steel. Excellent resistance to heat and thermal shock.
EuTroLoy®16223.04205145 16223.04 4kg
205147 16223.04 12.5kg
AlloyNi-Cr-B-Si-Al
Gray cast iron forming tools, gray cast iron and bronze glass moulds, valve and slide valve parts, dies, anti-corrosion hardfacings on gray cast iron workpiec-es, buffer layers on gray and nodular cast iron.
~34 HRCGood wetting of the base metals. Creep resistant, thermal fatigue resistant and cavitation resistant hardfacings. Low coefficient of sliding metal friction. Good adhesive strength and corrosion resist-ance. Polishable.
EuTroLoy®16316.04103693 16316.04 4kg
103443 16316.04 12.5kg
AlloyFe-Cr-Ni-Mo
Workpieces in the chemical industry and food processing industry and buff-er layers for hard-facing.
~170 HV30Austenitic weld metal with ~9 % -ferrite and low carbon content. Resistant to pitting and intercrystalline corrosion up to temperatures of 400 °C, also scale resistant up to 800 °C. May be polished to a mirror finish.
EuTroLoy®16454.04205839 16454.04 4kg
205838 16454.04 12.5kg
Self-fluxing Ni base alloy
Hardfacing of seal surfaces in valves, sliding seals and slideways, forming tools, valves, valve flaps, pump rotors, cams and worm screw parts.
~53 HRCHighly creep resistant, heat and corrosion resistant weld metal.Low coefficient of sliding metal friction. High adhesive strength.
The suffix “.04” indicates the particle size distribution 150+53 µm
PTA Welding
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PTA WeldingEuTroLoy® - PTA Powders
Designations Product Type Applications Properties
EuTroLoy®16496.04204549 16496.04 4kg
Self-fluxing Ni base alloy
Hardfacing of seal surfaces in valves, sliding seals and slideways, forming tools, valves, valve flaps, pump rotors, cams and worm screw parts.
~58 HRCHighly creep resistant, heat and corro-sion resistant hardfacing. Low coefficient of sliding metal friction. High adhesive strength.
EuTroLoy®16604202863 16604 4kg
AlloyFe-Co-Cr-Mo
Tools for hot and cold metal shaping: clipping bed, rolling mills, bending machines Gate components. Sealing joints.Buttering layer before coating with cobalt based alloys.
~45 HRCWork-hardening deposit with very fine martensitic structure. Ecellent resistance to heat, thermal shock and corrosion. Good resistance to cracking.
EuTroLoy®16606A.04103714 16606A.04 12.5kg
103713 16606A.04 4kg
AlloyFe-W-Cr-Mo-V
Temperature-stressed dies and man-drels, cutting tools, also for natural fibres, punching, compression moul-ding and drawing dies, forging inserts, worm screw parts, valves, barrel extru-ders.
~58 HRCMartensitic weld metal based on cold work tool steel. Wear-resistant to abrasion and fatigue stress as well when subject to a combination of abrasion and fatigue stress. Hot wear resistant. Good tempering properties. Heat treatable.
EuTroLoy®16625M.04750152 16625M.04 4kg
750153 16625M.04 12.5kg
AlloyNi-Cr-Mo-Nb-Fe
Marine engine components, power plant components, installations on drilling rigs, valve components for min-eral oil, tools for underwater work and low-temperature equipment.
~210 HV30High ductility. Very good corrosion resist-ance (e.g. seawater). Tough at subzero temperatures, suitable for cryogenic use.
EuTroLoy®16800103419 16800 4kg
AlloyNi-Mo-Cr-W
Mixer arms, components in the paper industry, hot shears, hot trimming dies, extrusion dies, valve seats, pump com-ponents in the chemical industry.
~260 HV30Very high resistance to intercrystalline corrosion, interfacial corrosion and stress corrosion cracking. Excellent corrosion resistance to oxidising media such as nitric, phosphoric, sulphuric and sulphurous acid. Also resistant to ethanoic, lactic, citric and fatty acids, caustic soda as well as media containing chloride.
EuTroLoy®PG 6503202433 PG 6503 12.5kg
202434 PG 6503 4kg
Ni-B-Si-Fe alloy and tungsten carbide
Decanting and transport screw. Mixer pieces. Drilling tools. Brick or tile dies. Protective sleeves. Wood-working tools.
~60 HRC60% tungsten carbides.Excellent resistance to abrasion.
EuTroLoy®PG 8426.04750556 PG 8426.04 12.5kg
Self-fluxing Ni base alloy
Gray cast iron and bronze glass moulds, Floodfilling of WC/Co Tiles, buffer layers on gray cast iron and nodular cast iron.
~270 HV30Low energy input for the fusion. Good wetting of the base metals. Good adhe-sive strength and corrosion resistance. Polishable.
The suffix “.04” indicates the particle size distribution 150+53 µm
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PTA WeldingEuTronic GAP® - PTA Equipment
Option
Description CharacteristicsLike basic with powder and Cold Wire settings
260062
EuTronic GAP® 2001 DC basic & Touch Screen
Description Basic Touch ScreenVoltage supply 3x400 + N ± 10% 3x400 + N ± 10%Power supply 5X16A CEE plug 5X16A CEE plugSupply frequency 50/60 Hz 50/60 HzWelding current (100%ED) 160A 160AAdjustment range 1.0 - 160A 1.0 - 160AMax power consumption 16 KVA 16 KVAOpen circuit V main inverter 90 V 90 VOpen circuit V pilot inverter 110 V 100 VPilot current (100%ED) 20A 10AAdjustment range pilot current 5 - 20A 0.5 - 10AProtection index IP 23 IP 23Dimensions L x W x H (mm) 815 x 455 x 635 815 x 455 x 635Weight 63 Kg 70 Kg
Trolley mounting facilityGAP® 2001DC touch screen withMicro plasma weldingGAP® 2001DC touch screen withsetting technologyGAP® 2001DC touch screen with moni-
toring of external cooling units
Plasma weldingManual settingsWorks with WF cold wire feederHand held torch or machine torchesavailable50 job settings storableTIG welding & cold wire TIG welding
Part N° / Esc Code260233 EuTronic GAP® 2001 DC touch screen
PTA Welding
GAP® 2001DC basic
GAP® 2001DC touch screen
EuTronic GAP® 3001 DC & 3002 AC/DC
Description 3001 DC 3002 AC/DCVoltage supply 3x400 + N ± 10% 3x400 + N ± 10%Power supply 5X16A CEE plug 5x32A CEE plug 6mm2
Supply frequency 50/60 Hz 50/60 HzWelding current (50%ED) 350A 380AWelding current (100%ED) 250A 280AAdjustment range 6 - 350A 6 - 380AMax power consumption 20 KVA 20 KVAOpen circuit V main inverter 80 V 80 V DCOpen circuit V pilot inverter 110 V 110 V DCPilot current (100%ED) 30A 30AAdjustment range pilot current 3 - 60A 3 - 60AProtection index IP 23 IP 23Dimensions L x W x H (mm) 815 x 445 x 635 750 x 430 x 630Weight 77 Kg 85 Kg
Works with cold wire feeder WFHand held and machine torchesfor both welding and powder coatings GAP® 3001 DC for plasma weldingGAP® 3002 AC/DC plasmawelding facilitiesGAP® 3002 AC/DC AC ARC foraluminium plasma welding
For full automation or manual operationsPlasma weldingPowerful PLC 72 pin harting plug automated interfaces (on request)100 memory cells for parameter storagePowder coating using powder feeder EP2Optional GAP control software packagefor enhanced control and display ofparameters
Part N° / Esc Code
260065 EuTronic GAP® 3001 DC
Part N° / Esc Code
300995 EuTronic GAP® 3002 AC/DC
Part N° / Esc Code260234 EuTronic GAP® 2001 DC basic260063 With powder and Cold Wire settings
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PTA WeldingEuTronic GAP® - PTA Equipment
Provides repeatable precision for plasma joining, coating and brazingTurn-key robotic cell to increase productivityAC/DC version available for welding of Al, Mg and their alloys Completely modular for immediate, tailor made configuration and cost effective fit-ting of applications Wide range of options, accessories and welding consumablesAlloy fexibility
Description Characteristics
Gas supply Ar + AR/H2, @ 30 psi
Water supply 5 l/min
Supply voltage 460V 3 phases 60 Hz
Max. power consumption 20 kva
Welding current (100% duty cycle) 220 amps
Welding current adjustment range 6-280 amps
Open circuit voltage 80 volts
Pilot current at 100% duty 30 amps
Pilot current adjustment range 3-60 amps
Dimensions L x W x H (mm) 1795 x 750 x 2500
Weight 350kg
EuTronic GAP® Universal Unit
Part N° / Esc Code
260445 EuTronic Gap® Automated Unit
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PTA WeldingEuTronic® GAP - Accessories
PTA Welding
For Powder Feeder information have a look at the "Coating Accessories" section
Part N° / Esc Code
260395 Cold Wire Feeder GAP® WFG
Cold Wire Feeder
For GAP® 2001 series / 3001 and 3002
Description CharacteristicsDegree of protection IP23
Weight 25 Kg
Dimensions L x W x H (mm) 725 x 230 x 450
Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feederfor 16 Kg wire coils. Special designed pressure arms care for a smooth and reproducible pressureof the wire onto the feeder rolls within the drive.
Part N° / Esc Code
260425 For MPM / TIG series
Cold Wire Feeder Electronic
For GAP® 2001 series / 3001 and 3002
Power supply 230VAC
Max. power consumption 370VA
Max.wire speed 10 m/min
Suitable wire diameters 0.8 – 3.2 mm
Weight 30 Kg
Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feeder for 16 Kg wire coils. Special designed pressure arms care for a smooth and reproducible pressureof the wire onto the feeder rolls within the drive.Electronically motor controller for the four roll wire feeder. Functions: forward/backward movement, wire inching, wire feedback, pulse functions, control signals for fault indication. Buttons for: wire inching, forward/backward movement, speed and pulse adjustment.
Part N° / Esc Code
260058 Cooling GAP® (*)
260059 Cooling GAP® Twin (*)
Cooling GAP® *
Weight 40 kg
Dimensions L x W x H (mm) 900 x 445 x 360
Weight Twin 45 kg
Dimensions Twin L x W x H (mm) 900 x 445 x 360
(*) Use only Castolin Eutectic dedicated cooling liquid
Single or twin circuit heat exchangers additional water-water heat exchanger available.Additional water-water heat exchanger available
Part N° / Esc Code
260056 Trolley
Trolley
Weight 45 kg
Dimensions L x W x H (mm) 1.190 x 740 x 1.415
Holds gas cylinders, powder feeder, power source and cooling.
Wide range of additional trays and accessories for better configuration and easeof use of the trolley.
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Part N° / Esc Code
400900 GAP® E12N 4m
GAP® E12NDescription Characteristics
Max current at 100% 100A
Weight with hose pack 1.9 kg (4m)
Liquid cooled manual torch, available also with 70° and 180° neckHose pack: 4 metres; longer hose packs on requestCold wire holder available
Part N° / Esc Code
260581 GAP® E15 4m
GAP® E15NConstruction horizontal
Max current at 100% 150A
Weight with hose pack ca. 2.5 kg (4m)
Liquid cooled manual torch, available also with 70° and 180° neckHose pack: 4 metres; longer hose packs on requestCold wire holder available
Part N° / Esc Code
260434 GAP® E150 3m
260435 GAP® E150 4m
GAP® E150P
Max current at 100% 150A
Powder flow rate 5-20 g/min
Weight with hose pack 2.0 kg (3m)
3m hose pack Liquid cooled Powder manual torch
Part N° / Esc Code400861 GAP® E54 (length: 330 mm) 4m402272 GAP® E54 (length: 550 mm) 4m
GAP® E54 S-M-D-DLConstruction horizontal
Max current at 100% 200A
Powder flow rate 10 - 40 g/min
Powder machine torch for inner coatings of parts with diameter > 80mmAvailable in four different lengths (models): 330(S), 550(M), 920(D) and 1770(DL)mmLonger hose packs on request
Built on request, please ask for delivery time
Part N° / Esc Code400204 GAP® E52 4m
GAP® E52Construction vertical
Max current at 100% 200A
Powder flow rate 3 - 80 g/min
Weight with hose pack 4.8 kg (4m)
Liquid cooled powder machine torch for general applicationsCold wire holder availableHose pack: 4 metres; longer hose packs on requestWide range of anodes and powder nozzles
Part N° / Esc Code400238 GAP® E42 4m
GAP® E42Construction vertical
Max current at 100% 200A
Powder flow rate 3 - 140 g/min
Weight with hose pack 3.7 kg (4m)
Liquid cooled powder machine torch for high duty applicationsCold wire holder available
Part N° / Esc Code400238 GAP® IMPA100
GAP® IMPA100Construction vertical
Max current at 100% 400A
Powder flow rate about 370 g/min
Weight without hose pack 5 kg
Liquid cooled powder machine torch for heavy duty applications with high deposition rate.Build on request : please ask your local Castolin Eutectic company.
PTA WeldingEuTronic® GAP - Accessories
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EuTronic® Arc
Wire Spraying
Simplified overview
Coating families
Coating material
Base material
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield Energy
Equipment investment
EuTronic Arc
Wire.Metals
Allmetals
Low 1 (20)*Very large
Lamelar 3 to 10%
Good. Mechanical
& micro-diffusion
Very high MediumElectricity & compressed
airMedium
Best Second choice
(...)* request special precaution or coating material
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Wire SprayingEuTronic® Arc Process
FunctionEuTronic® Arc is the highest productivity thermal spraying process. EuTronic® Arc is an Arc Spray Process using a pair of wires which are melted by an electric arc. The arc has a temperature of 5 000 - 6 000°C that melts the wires continuously. Compressed gas - most often air - is used to atomise the molten wire tips and to propel the droplets towards the substrate at velocities exceeding 100 meters per second. This molten mate-rial is atomised by compressed gas and propelled towards the workpiece to form a coating. This combination of high temperature and high particle velocities gives arc sprayed coatings very good coating properties with high bond strengths and low porosity.
Arc spraying often produces large amounts of fume and high noise levels.
Arc spraying is a cold thermal spraying process where the temperature of the substrate is held below 150°C. Because of the low temperature, the work piece is not exposed to any metallurgical changes or distortion.
Arc Spraying Structure of cold arc sprayed coating
AdvantagesThe arc spraying process is the thermal spraying process that has the highest spray rates and lowest running costs.
Safe process
No flammable gases used
Cold spray process
Not requiring the use ofoxygen, kerosene or acombustible gas which meansmore economic coatings
Operator can use two differentwires during spraying toproduce new suitable coatings.
ApplicationsThe main applications of the arc spray process are anti-corrosion coatings of zinc and aluminium and spraying work on large compo-nents. The material to be sprayed Schematic of Arc Spray process
must be electrically conductive. The most common materials are metallic material or cored wires. . Low running costs, high spray ra-tes and efficiency make it a good tool for spraying extensive areas or a large number of parts.
Technical dataArc temperature: up to 6000 °C
Particle velocity: 150 - 300 m/s
Deposition rate: 2.5 to 40 kg/h
Coating material: Metals ormetal alloys in solid and coredwires form
Coating thickness: 0.1 to 20 mm
Coating density: 90 - 97%
Noise level: 100 - 120 dB(A)
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Wire SprayingEuTronic® Arc Spray Wires
Designations Product Type
Applications Properties
EuTronic® Arc 502Part N° / Esc Code205375 Arc 502 1.6mm 15kg
AlloyFe-Cr-Ti-Si-Mn
Cement cooler plates, boiler water wall protection, pulp production digesters, steam turbine casings, cracking installations, high tempe-rature cyclone, fume extractors etc.
Hardness ~860 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat erosion, thermal shock up to 650°C.
EuTronic® Arc 509205373 Arc 509 1.6mm 15kg
AlloyFe-Cr-Al-Mo
Corrosion and erosion resistant protective coatings in boiler equip-ment up to 900°C.
Hardness ~260 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat corrosion, erosion up to 900°C and oxidation.
EuTronic® Arc 532103129 Arc 532 1.6mm 15kg
AlloyFe-Cr-Mn-C
Alternative to 13%Cr-steel. Hard chrome replacement on hydraulic pistons. Wear resistant layers for rollers in paper machines, bearing- and sealing seats.
Hardness ~640 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat metal-to-metal friction, corrosion and oxidation.
EuTronic® Arc 579331426 Arc 579 1.6mm 15kg
AlloyFe-Ni-Cr-Si-Mn
Worn general engineering compo-nents, undersize external or internal diameters, bearing seats and faces, housings, shrink or force fit areas, flat surfaces etc. Hot gas corrosion protective coatings in heat exchan-gers, process piping, etc.
Hardness ~230 HV0.3 Self bonding alloy for thick or thin coatings with good corrosion resis-tance. Easy machinabillity, like machining solid mild steel.
EuTronic® Arc 595206118 Arc 595 1.6mm 15kg
AlloyFe-Cr-B-Si-Mn-C
Exhaust fans, pump components, coal-fired boilers, super-heaters, economiser waterwalls, boiler tubes, boiler installations, lamella seals and «Füller» cooler plates in cement works etc.
Hardness ~965 HV0.3Self bonding alloy with enhanced surface wear resistance properties to slurry erosion, corrosion and low stress abrasion. Withstands service environment up to 925°C.
Wire Spraying
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Standard Configuration (Push/Pull)
ower source, push/pullrive & wire feeder.
rc Spray Gun.
rive unit position :n power source or floor.
m Push/Pull from Wire.
upplies package includes ower and control cables,ir hose, wire conduits andexible drive.
ELECTRIC DRIVE UNITWIRE FEEDER ARC SPRAY GUN
TS
S PACKAGE
DRIVE CABLE
The EuTronic® Arc Spray 4 isrobust, reliable and easy to use.The Arc Gun and the drive system are coupled to a 350 amp, switchedvoltage power source. This power source features sealed electron-ics for excellent reliability in theharshest spray environments. The wire feeder unit is neatly mountedon the power source, leaving it freeto swivel and follow the operatorwhilst spraying. Other options in-clude either floor or trolley mount-ing. There is no motor in the gun.Instead, the Gun 4 uses a patented ‘Synchrodrive’ system, where a sin-
gle, sealed motor with a flexibledrive arrangement, powers a reli-able, positive drive push/pull upto a distance of 20 m. This resultsin a long reach and lightweight flexibility of the gun and supplies.For the operator, working condi-tions are more comfortable andproductive.
EuTronic® Arc Spray Supplies Setup
EuTronic® Arc Spray 4 systemSealed 350 amp power source for reliability
1.6 mm wires standard. From1.6 mm to 2.5 mm optional
Air cooled cables for low weight
Excellent gun manoeuvrability
5 m supplies packages standard
Steel reinforced, PTFE lined wire conduits
Easy to maintain for lower downtime costs
Wire spool, coil and drum feeder option capabilities
Soft start for smooth start ups
Wire SprayingEuTronic® Arc Spray Equipment
Part N° / Esc Code263000 EuTronic Arc Spray 4 complete kit
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The Gun has been designed to give consistent throughputs with high coating quality. It is a lightweight, heavy-duty unit with robust but com-pact construction.
Optional conversions of wire size
The Gun can also be converted to use other wire diameters by using the following parts in the front end assembly :
Wire Size Nozzle X 1 Air Cap 1 Contact Tubes X 2
1.6 mm 263245 263063 263252
2.0 mm 263244 263242 263133
2.3 mm 263071 263241 263134
2.5 mm 263072 263241 263144
EuTronic® Arc Spray Gun 4
Power & air requirements
Description Characteristics
Power Requirements 380/440 V 50-60 Hz 3 Phase
Power Option 220 V 50-60 Hz 3 Phase
Fuses Required 32 A/Phase (415 V input)
Fuses Required Option 40 A/Phase (220 V input)
Max Power Consumption 18 KVA
Duty cycle (100%) 0-350 Amps
Output Voltage 0-50 Vdc (nominal) Switched High/Low & 1 - 5
Air Requirements 1.56 m3/min @ 6 bar (55 cfm @ 90 psi)
Power source specification
Description Characteristics
Weight 215 Kg
Width 665 mm
Length 900 mm
Height 913 mm
Power Source
Wire SprayingEuTronic® Arc Spray Equipment
Part N° / Esc Code263266 Gun 4 complete for 1.6 mm wires
Part N° / Esc Code263227 Power source 4 for Inverter Drive
The wire feeder unit can be neatly mounted on the power source, leaving
it free to swivel and follow the operator whilst spraying.
Wire Feeder and Drive
Part N° / Esc Code263223 Wire Feeder for Spools with drive
Wire Spraying
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Accessories for EuTronic Arc
Wire SprayingEuTronic® Arc Spray Accessories
Power, Air and Control Cables
Flexible Drive Cable
Wire Conduits
Part N° / Esc Code263273 5 m supplies package 263272 10 m supplies package 263274 20 m supplies package 263275 Extension from 10 to 20 m supplies package
Supplies packages
Standard Supplies Package includesThe supplies packages consistingof cables and conduits are availablein different lengths 5, 10 and 20 meters.
Part N° / Esc Code Part N° / Esc Code263283 Remote wire feeder for spools
263282 Skid frame for electric drive
Optional Spool Wire Feeder
Remote wire feeder devices for spools
are available for limited access
applications such as via man holes.
Part N° / Esc Code263270 Arcjet 4 for 1.6 mm wires
ArcJet
The ArcJet fits on the gun to inject air in front of the nozzle. The ArcJet constricts the spray pattern thus reducing overspray and allowing more confined areas such as deep slots, to be sprayed. Therefore significant improvements in deposit efficiency can be made especially on small diameter components.
Technical overview
• Reduces Arc Spray footprint • Finer coatings.• Improved deposit efficiency when • Less apparent porosity.
spraying onto small components. • Improved hardness.
Description Characteristics
Maximum Current 350 Amps
Compressed Air 0.7 m3/min @ 3.5 Bar
Part N° / Esc Code263269 Extension neck 0.5 m long263267 Extension neck 1 m long263268 Extension neck 1.5 m long
Arc Spray Extension neck
The Arc Spray extension neck enables an improved access to awkward areas such asdeep bores with a minimum diameter of 75 mm and rear sides of welded stiffenersetc. The extension neck allows for spraying either straight ahead or at an angle andfor applications using power up to 200 amps.
Description Characteristics
Maximum Current 200 Amps
Compressed Air 0.6 m3/min @ 4.5 Bar
Part N° / Esc Code263326 EAS remote control
Remote Control
The 5 meters remote control allows a remote operation of the EuTronic Arc® Spray4 system with robust design for use on semi-automatic installations. The remotecontrol buttons and switch mimic those of the Gun.
Electric drive moin the s
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MeCaTeC®
Polymer Surfacing
Simplified overview
Coating families
Coating material
Base material
Heating of work-
piece
Max coating
thickness mm
Coating surface
size
Coating structure
Coating micro-
porosityBonding
Deposition rate
Deposition yield Energy
Equipment investment
MeCaTeCPaste
or fluid. Polymer
Allmetals &
othersNone 10 (20)* Large
Hetero-geneous
NegligibleGood.
ChemicalMedium High None Negligible
Second choice Secondary application
(...)* request special precaution or special surfacing polymer
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Polymer SurfacingMeCaTeC® Process - Cold repairs & wear protection
FunctionMeCaTeC® is a polymer surfacing technology for COLD repairs and wear protection. It is a synthetic, three dimensionally cross-linked, thermosetting polymer, reinforced with advanced composite com-pounds. It produces strong, adhe-sive bonding to most base material substrates through physicochemi-cal surface reactions.
MeCaTeC® reinforced with wear resistant compoundsand high strength ballistic grade Kevlar® fibresAdvantages
MeCaTeC® polymers are formulated to provide wear-resistant and repairsolutions for:
Extending the life of originalparts.
Cost effective coatings appliedwith no energy e.g. fuel,electricity or gases.
Ease of application in-situ orin workshop.
Difficult-to-weld metals e.g.Ni-Hard castings.
Components with thin wallsor fragile sections.
Environment where noadditional heat is allowed.
Non-metallic surfaces such asconcrete, ceramics, rubber, etc.
Machine parts of any size orintricate geometry. It quicklyconforms to odd shapes.
Workshop with no weldingequipment, power source orgas supply.
Casting into irregular shapesto be used as wear tube, pad,plate, etc.
ApplicationsMeCaTeC® is a polymer surfacing technology for COLD rapid repairs and wear protection of industrial equipment and machine parts, which provides wear life beyond that of original parts. It is easy to apply manually, requiring no ad-ditional energy, no special equip-ment, power supply or gases which make it cost effective and ideal for repairing either on-site or in the workshop.
Technical dataTemperature: not relevant
Particle velocity: not relevant
Deposition rate: 4 to 20 kg/h
Coating material: thermoset-ting polymer, reinforced withadvanced composite in pastor fluid form
Coating thickness: 0.2 to 30 mm
Coating density: 100%
Noise level: None dB(A)
MeCaTeC® formulations are availa-ble in easy-to-apply Paste (P) or Fluid (F) forms which, after mixing the bulk polymer (X) and hardening reagent (XX) ingredients, rapidly so-lidify and polymerise completely at ambient temperatures.
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Polymer SurfacingMeCaTeC® Pastes and Fluids
Designations Applications Type Properties
MeCaTeC® Express 100Part N° / Esc Code103140 Express 100 0.6kg
Cold, ultra-rapid setting paste.Emergency rebuilding, protecting and re-pairing damage or cracks in machine parts such as: foundry casting defects, cast iron housings, machine bearing journals, fuel pipes, containers, engine, gear box casings, worn pump housings, etc.
Formulated for applications needing a fast reaction with an application or handling time of 5 minutes. Curing will even occur at temperatures down to +5°C. Can also be easily machined, drilled or tapped.
Service temperature up to 90 °C.
MeCaTeC® 101F103138 101F 2kg
Cold, rapid setting fluid for general re-pairs.Protecting and repairing damaged ma-chine parts such as keyways, machine beds, bearing housings, engine, gear-box casings, cast iron machine housings, pump and valve parts, etc.
Repairs of deep cracks or to fill narrow cav-ities in steel, cast iron, aluminium, bronze and concrete. Can also be easily machined, drilled or tapped.Service temperature up to 120 °C.
MeCaTeC® 101P103139 101P 2kg
Cold, rapid setting paste for general repairs. rebuilding, protecting and repairing dam-aged machine parts such as: keyways, ma-chine beds, bearing housings, engine, gear-box casings, cast iron machine housings, pump and valve parts, etc.
All-positional patch repairs of cracks or fis-sures in steel, cast iron, aluminium, bronze and concrete. Easy to fit machine, drill, tap or sand. Service temperature up to 120 °C.
MeCaTeC® 102P103142 102P 2kg
Cold, rapid setting paste for anti-corrosion and anti-abrasion coatings.Rebuilding, protecting and repairing dam-aged or new machine parts such as butterfly valve, gate valves, pump housings, propel-lors, hydraulic rams, diaphragms, etc.
All-positional protection against wear by avariety of corrosive liquids, abrasive media,slurry erosion and cavitation effects. Can beprecision machined, drilled or tapped whilst exhibiting exceptional resistance to pressure and deformation. Service temper-ature up to 175 °C.
MeCaTeC® 103F103143 103F 2kg
Cold, rapid setting fluid for anti-abrasioncoatings.Protecting and repairing damaged or new machine parts such as mixer blades, hop-pers, vessels, chutes, pump impellors, fan blades, elbows and conduits.
Brushable in thin layers over large areas orcomplex forms. Protection against wear by low pressure abrasion and erosion. Smooth surface finish and high electrical insulat-ing properties. Machinable by grinding.Service temperature up to 175 °C.
MeCaTeC® A3370005 A3 2.5kg
Cold, rapid setting paste for anti-erosion coatings of medium thickness.Protecting and repairing damaged ma-chine parts such as Pipe elbows, ash han-dling valves, coal pulverisers, coal exhaust-ers, pump housing, impellors and lining, etc.
Protection against wear in severe erosion and abrasion. The tough, composite ma-trix is reinforced with ultra resilient Kevlar fibres and a dense dispersion of hard, wear resistant ceramic phases.Service temperature up to 120 °C.Minimum thickness : 3 mm.
MeCaTeC® A5370001 A5 9.09kg
370002 A5 2.27kg
Cold, rapid setting paste for anti-erosion coatings. All applications needing thick coat-ings to resist wear by abrasion and erosion. Rebuilding, protecting and repairing dam-aged machine parts such as sand pumping equipment, slurry pumps, screw conveyors, pipe elbows, chutes for clinker, cement and ash handling pipes, etc.
Protection against wear in severe erosion and abrasion. The tough, composite ma-trix is reinforced with ultra resilient Kevlar fibres and a dense dispersion of hard, wear resistant ceramic phases.Service temperature up to 120 °C.Minimum thickness : 5 mm.
Polymer Surfacing
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Product Designations Applications Type Properties
MeCaTeC® A5HTPart N° / Esc Code370003 A5HT 9.09
370004 A5HT 2.7
Same applications as MeCaTeC® A5 but forincreased service temperatures.
Similar wear resistant properties as MeCaTeC®A5 but using a special heat resistant composite matrix suitable for service up to 250°C for a brief exposure.
MeCaTeC® 110F103145 110F 2kg
Cold, rapid setting fluid for anti-impact coat-ings. Protecting and repairing damaged parts such as expansion joints, fluid transport systems, fan blades, pump parts, vibration dampers, rubber parts, conveyor belts and chutes, hydraulic installations, etc.
Pourable, durable elastomer resistant to tearing. Useful for damping machine vibrations, reducing sound waves and harmful noise levels. Good electrical insulating properties. To be used with primer compounds MeCaTeC® Bond M or Bond R. Service temperature up to 80 °C (dry).
MeCaTeC® 110P103144 110P 2kg
Cold, rapid setting paste for anti-impact coatings. Rebuilding, protecting and repair-ing damaged or new machine parts such as conveyor belts, hydraulic installations, fluid transport systems, anti-slip surfaces, fan blades, pump parts, vibration dampers, rub-ber components, etc.
All-positional repairs. Elastomer resistant to tearing. Useful for damping machine vibra-tions, reducing sound waves and harm-ful noise levels. Good electrical insulating properties. To be used with primer compounds MeCaTeC® Bond M or Bond R.Service temperature up to 80 °C (dry).
MeCaTeC® Bond R103165 Bond R 0.672kg
Primer fluid for optimum substrate bondingto rubber. Same applications as MeCaTeC® 110F and 110P.
MeCaTeC® Bond R is a primer compound usedfor optimising the adhesive bonding proper-ties of MeCaTeC® 110F or 110P to Rubber substrates. MeCaTeC® Bond R is additionally used for bonding to other non-metallic sub-strates such as already cured MeCaTeC® 110F or 110P coatings, fibreglass materials, concrete surfaces, wooden parts.
MeCaTeC Express100
101F/P 102P 103F A3, A5 A5HT 110F/P
Abrasion
Cavitation
Corrosion
Erosion
Friction
Impact
Electric Insulation
Emergencies
General repair
Machining
Max temperature °C*Brief exposure **wet/dry
90 120 175 175 120 250* 50/80**
Best
Polymer SurfacingMeCaTeC® Pastes and Fluids
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Coating Accessories
Coating Accessories
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Coating Accessories
Part N° / Esc Code
260229 Powder Feeder EP
Part N° / Esc Code
260229 CastoDyn Ep Controller
Powder Feeder EP2
The Powder Feeder EP2 is suitable for GAP 2001, GAP 3001, CastoDyn DS 8000and CastoDyn SF Lance.
Description Characteristics
Carrier gas Ar, Ar-H2
Carrier gas flow rate 0 - 4 l/min
Powder reservoir 2 l capacity
Degree of protection IP 23
Weight (without powder) 7.5 kg
Dimensions L x W x H (mm) 200 x 170 x 470
Stepless feeding rate control via feeding wheel speed directly from inverter PLC.
Powder feed rate 3-120 g/min, depending on feeding wheel configuration, torch, anode and powder density.
Connections for CastoDyn DS 8000 and SF Lance
CastoDyn Ep Controller Powder feeder EP2
CastoDyn DS 8000
CastoDyn DS 8000
Gas connections
CDS 8000 - Refill powder container
Quick mounting aluminium container with bayonet coupling. Top lid for refilling powder without dismantling from torch. It is suitable for CastoDyn DS 8000 and CastoDyn SF Lance.
Part N° / Esc Code204782 Refill powder container
Powder Feeding
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Compressed air unit
Compressed air control system consisting of compressed air pressure regulator with oil and water separator, 6 m, with connections 3/8" and M 10 x 1 (both with tapered seals).
Part N° / Esc Code203742 Compressed air control system
Cylinder couplingCylinder coupling for connecting several acetylene cylinders.Part N° / Esc Code840036 Coupling for 2 Ac cylinders 840038 Coupling for 3 Ac cylinders
Fast Flam
FastFlam quick coupling for oxy-fuel gas including coupling pin for direct connection to spray gun.
Part N° / Esc Code840014 Quick coupling oxy-fuel, 8.0mm, G 3/8" LH840015 Quick coupling oxy-fuel, 6.3 mm, G 3/8" LH840017 Quick coupling oxygen, 6.3 mm, G 1/4" RH
Hose
Hose unit of 5 meter for Ox/Ac DN 6.0 x 3.5 mm with threaded sleeve 1/4" RH / 3/8"
LH and with explosion prevention Ox/Ac.Part N° / Esc Code204933 Hose Ox/Ac 5 m with explosion prevention
Sliding cut- offSliding cut-off valve with ball seal for connecting to compressed air.Part N° / Esc Code209173 Cut-off valve
SecureGasOxygen, pressure regulator, single-stage, primary pressure up to 200 bar,working pressure up to max. 10 bar, connections G 3/4" RH (f) / G 1/4" RH (m).Acetylene, pressure regulator, primary pressure up to 40 bar, working pressure up to max. 1.5 bar, bracket DIN, connection G 3/8« LH (m).Part N° / Esc Code800001 Ox pressure regulator 800004 Ac pressure regulator
StopFlam 1StopFlam1 - oxy-fuel gas backflow prevention with flame inhibitor and gas backflow valve for connecting to the pressure regulator.Part N° / Esc Code840001 Oxy-fuel backflow prevention G 3/8" LH / G 3/8" LH840002 Oxygen backflow prevention G 1/4" RH / G 1/4" RH
Coating Accessories Coating Accessories
Gas Accessories
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Coating Accessories
Part N° / Esc Code
260314 Oscillation Unit (OU)
260315 Vertical Unit (VU)
260316 Vertical Unit (VU) with AVC
Part N° / Esc Code
260519 Control Box
Part N° / Esc Code
260522 Turn Table Control (TTC)
260523 Turning tilting table TTT200
For more information please contact your local Castolin Eutectic representative.
Oscillating Unit (OU)Oscillation width Max 100 to 500 mm depending
of the axis
Oscillation speed 0,1 - 60 mm/s
Dwell time 0 - unlimited
Max load 5 Kg
Vertical Unit (VU)Max transverse path 100 mm
Oscillation speed 0,1 - 20 mm/s
Max load 10 Kg
Vertical Unit (VU) with Arc Voltage Control (AVC)Possibility to upgrade with AVC to keep the distance between the torch and the workpiece constant.
Control BoxSupply voltage 230V AC 50/60Hz
Degree of protection IP 23
Weight 20 kg
Dimensions L x W x H (mm) 564 x 264 x 440
Turning Tilting Table TTT200
Max. load 200 kg
Diameter turntable 400 mm
Continuously tilting range -110°/+110°
manual adjustable by hand wheel Driven by an DC motor, 90W power con-sumption, encoder for position feedback
Nominal turning moment 100Nm
Automation
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Part N° / Esc Code
750462 Fume exhauster 3002
Part N° / Esc Code
750473 Fume exhauster 4002
BIAW3
geprüft
Fume extraction
Description 3002 4002
m3/h 2.700 4.200
Inlet diameter mm 200 250
Max. depressure Pa 2.300 3.200
Voltage V 400 400
Power supply kW 3 4
Noise level dB <80 <80
Filtration area m2 28 56
Dust container l 50 2x50
Dimensions mm 1.620 x 860 x1.943 2.180 x 860 x1.943
High filtration efficiency (>99,9%)
Fully automatic filter cleaning
Easy to empty the dust containerMobile
Coating Accessories Coating Accessories
Personal Protective Equipment
We have a full range of Personal Protective Equipment.
Please ask your local Castolin Eutectic company.
Protective Equipment
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Coating AccessoriesOther Accessories
Mounted grindingMounted grinding point (with ceramic bond), Ø 50 x 25 mm, retainer (mounting) pin Ø 6.0 mm (10 pc./pkg). For preparing metal surfaces prior to the thermal spray coating process.Part N° / Esc Code390137 Mounted grinding Ø 50
Stylus
Part N° / Esc Code205163 Stylus 1/2"205164 Stylus 3/8"
RotoTool
RotoTool I cutting tool, with reversible cutter for Tool I made of carbide ISO K10.
Part N° / Esc Code205165 RotoTool I
Reversible cutter
Reversible cutter with chip breaker, made of carbide ISO K10.
Part N° / Esc Code204619 Cutter for Tool I204620 Cutter for Tool II
RotoTool III
RotoTool III cutting tool with cutting stylus made of carbide ISO K01.
Part N° / Esc Code204109 RotoTool III straight & stylus 3/8"204110 RotoTool III right & stylus 3/8"204111 RotoTool III right & stylus 1/2"
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Services
Industry partner
A century at the forefront of protective materials technology has positioned Castolin Eutectic as the world’s premier industrial partner. Our comprehensive know-how is unrivalled, and our industry partnerships continue to thrive. We provide solutions to all of the major companies operating in industry with global industrial programs for glass, steel, cement, automotive, power, oil, waste & recycling, ...
Services
TeroLink®
The unique TeroLink® database of Castolin Eutectic contains over 7,600 fully documented approved applications from around the glo-be. The case studies include pho-tographs, technical data, detailed descriptions and cost-saving ana-lyses.
Application report
No.: BR_M1_0764/3
Workpiece :Industry:Base Metal :Dimensions :
Machine:Producer
:Weight
:
Cooling CilinderIron and steel worksWear resistant cast iron Laminator
Ferro fundido coquilhadoCopyright © Eutectic+Castolin® 2007
Image 4
Image 5
Grinded and painted part, ready to be
delivered.
Grinded and painted part, ready to be
delivered.
Alternative industries:
Recipient:
27/03/2008 / 27/03/2008
H. Frese11/12/2008
Further information available via E+C Brasil, Technique & Marketing, Tel. +55 11 247 5655, Fax. +55 11 521 0545
Application reportNo.: BR_M1_0764/2Workpiece :
Industry :Base Metal :Dimensions :
Machine :Producer :
Weight :
Cooling CilinderIron and steel worksWear resistant cast iron
Laminator
Ferro fundido coquilhado
Copyright © Eutectic+Castolin® 2007
Image 2
Image 3
Eutronic Arc 500 being sprayed.
Surface aspect, after application.
Alternative industries:
Recipient :27/03/2008 / 27/03/2008
H. Frese 11/12/2008Further information available via E+C Brasil, Technique & Marketing, Tel. +55 11 247 5655, Fax. +55 11 521 0545
Application report
No.: BR_M1_0764/1
Workpiece :
Industry:
Base Metal :
Dimensions :
Machine:
Producer:
Weight:Cooling Cilinder
Iron and steel works
Wear resistant cast iron
Laminator
Ferro fundido coquilhado
Preventive maintenance:
Production
Joining:
Repair:
OEM
User
OEM
User
Fracture/crack
Coating
Reconstitution
Adhesion / friction
Abrasion:
Corrosion
Thermal fatigue
Mechanical fatigue:
Cavitation
Erosion:
Temperature:
High pressure
Low pressure
Impact
Alternating load
gas medium
liquid medium 250 °C
Copyright © Eutectic+Castolin® 2007
Operator applying Eutronic Arc
595T.
Description : The cooling cilinders suffer friccion wear at variable temperature, in function of its position on the
table.This wear leaves a groove on the roll that goes from 1,0 to 2,0mm of depht, marking the finished
product, having to be substituted.
Solution: Part recovering by Arc Spray process, using Eutronic Arc 500S as base layer and Eutronic Arc
Spray 595T as finish layer.
Advantages : Allowed the part recuperation by the lowest cost.
Increase of lifetime from 8 months to 2 years.
Significative reduction of the part reposition cost, allowing an anual profit of more than
US$295,000.00.
Previous solution : Replacement for a new part.
Products:
Processes :
ARC 500
595
Arc wire
Recipient:
27/03/2008 / 27/03/2008
H. Frese11/12/2008
Further information available via E+C Brasil, Technique & Marketing, Tel. +55 11 247 5655, Fax. +55 11 521 0545
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CastoLab® Services
We believe in making our exten-sive know-how fully available to our customers, but for situa-tions where technology transfer is complex or requires a rapid turn-around, we have our own maintenance service workshops. These fully resourced skill centers develop advanced procedures for transfer to end users.
Castolin Eutectic workshops are located in several countries around the world, and are best contacted via our website. In coun-tries without CastoLabs, Castolin Eutectic collaborates with appro-ved workshops who are in close contact with Castolin Eutectic’s specialists and technologies.
Flame Spraying
Arc Wire Spraying
Remachining
Training
At Castolin Eutectic, we offer a wide range of welding, braz-ing, and thermal spray training courses. These courses can be designed according to the needs of each customer. There are training sessions for managers, engineers and technicians.
Each course is composed of both theoretical as well as practical training. Castolin Eutectic can offer these courses in almost every European country. The courses are carried out in our own in-house training facilities, with qualified instructors or with our trainers at your loca-tion.
For more information about training, please contact your lo-cal Castolin Eutectic company.
Contact information can be found in our website.
Fusing of thermal sprayed coating
Services
These are some coatingapplications examples from the wide range of services providedby our CastoLab® Services.
Thermal spray training course
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InformationInformationInformationTechnical data & Table
Hardness Conversion Table in accordance with DIN 50150 (Extract)
Particle size conversion table
Tensilestrength
[MPa]
Hardness in accordance with
Vickers [HV]
Brinell [HB]
Rockwell [HRC]
800820835850865
250255260265270
238242247252257
22.223.124.024.825.6
880900915930950
275280285290295
261266271276280
26.427.127.828.529.2
965995
103010601095
300310320330340
285295304314323
29.831.032.233.333.4
11251155119012201255
350360370380390
333342352361371
35.536.637.738.839.8
12901320135013851420
400410420430440
380390399409418
40.841.842.743.644.5
14551485152015501595
450460470480490
428437447
(456)(466)
45.346.147.748.449.1
Microns Inches Mesh per inch
US* Tyler BS*
76 0.003 200
80 0.0032
90 0.0035 170 170 170
106 0.0041 140 150 150
125 0.0049 120 115 120
147 0.0058 100
152 0.006 100
160 0.0063
175 0.0069 80
180 0.007 80 85
200 0.0079
208 0.0082 65
212 0.0083 70 72
246 0.0097 60
250 0.0098 60
251 0.0099 60
259 0.0116 48 52
300 0.0117 50
Tensilestrength
[MPa]
Hardness in accordance with
Vickers [HV]
Brinell [HB]
Rockwell [HRC]
16301665170017401775
500510520530540
(476)(485)(494)(504)(513)
49.850.551.151.752.3
18101845188019201955
550560570580590
(523)(532)(542)(551)(561)
53.053.654.154.755.2
19952030207021052145
600610620630640
(570)(580)(589)(599)(608)
55.756.356.857.357.8
2180 650660670680690
(618) 57.858.358.859.259.7
700720740760780
60.161.061.862.563.3
800820840
64.064.765.3
Microns Inches Mesh per inch
US* Tyler BS*
315 0.0124
350 0.0139 45 42 44
400 0.0158
417 0.0164 35
420 0.0165 48
495 0.0195 32
500 0.0197 35 30
600 0.0234 30 28 25
630 0.0248
699 0.0275 22
701 0.0276 24
710 0.0278 25
800 0.0315
833 0.0328 20
850 0.0331 20
853 0.0336 18
991 0.039 16
1000 0.0394 18
* standard
Tensilestrength
[MPa]
Hardness in accordance with
Vickers [HV]
Brinell [HB]
Rockwell [HRC]
320335350370385
100105110115120
95100105109115
400415430450465
125130135140145
119124128133138
480495510530545
150155160165170
143147152156162
560575595610625
175180185190195
166171176181185
640660675690705
200205210215220
190195199204209
720740755770785
225230235240245
214219223228233
20.321.3
Microns Inches Mesh per inch
US* Tyler BS*
1 12500 (theoritical)
2 6250 (theoritical)
5 2500 (theoritical)
10 1250 (theoritical)
15 800 (theoritical)
20 625 (theoritical)
25 500 (theoritical)
33 0.0013 (425)
38 0.0015 400
41 0.0016
45 0.0017 325 (325)
50 0.002
53 0.0021 270 (270) (300)
56 0.0022
63 0.0025 230 (250)
66 0.0026 240
71 0.0028
75 0.0029 200 200
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InformationPeriodic Table of the Elements
Technical data & Table
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Global with local support
Castolin Eutectic has a presence in almost all European countries. With over 350 sales engineers travelling around Europe everyday, we are able to provide unbeatable service to our customers. We can literally be at 90% of customers in Europe within 2 hours, this allows us to give unsurpassed service and support.
We supply all technical documen-tation and material safety data sheets in local languages. Our salesmen all live in their territo-ries and speak local dialects and understand local cultures. We manage warehouses and keep stocks adapted to local require-ments in every European country (including the new countries).
Our 350 sales engineers are sup-ported by over 50 process and ap-plication experts. These experts are multi-lingual and communi-cate daily with our 4 production centers and research laboratories.
For more information oraddresses of Castolin Eutectic companies, please visit ourwebsites www.castolin.comor www.eutectic.com
Austria, Hungary, South East EuropeCastolin Eutectic GmbHBrunner Strasse 691235 Wien+43-(0)1-869 45 41-0
Belgiumsa Messer Eutectic Castolin Benelux nv224-228, Blvd de l’Humanité1190 Bruxelles+32-(0)2-370 1370
Czech RepublicMesser Eutectic Castolin spol.s.r.o.Trojska 80/12218200 Praha 8+42-(0)2-83 09 00 77
FranceMesser Eutectic Castolin S.A.R.L.22, Av. du Québec BP 325Z.A. Courtaboeuf 1- Villebon91958 Courtaboeuf Cedex+33-(0)1-69 82 69 82
GermanyCastolin Eutectic GmbHGutenbergstrasse 1065830 Kriftel+49-(0)6192-403-0
PortugalCastolin Eutectic PortugalRua Maestro Ferrer Trindade, 4B2770-201 Paco de Arcos+351 707 200 855
Netherlandssa Messer Eutectic Castolin Benelux nvRotterdamseweg 4062629 HH Delft+31-(0)15-256 9203
NorwayCastolin Eutectic ScandinaviaTeknologiparken, Akersvn. 24 C 0177 Oslo +47-22-11 18 70
PolandMesser Eutectic Castolin Sp.z.o.o.P.O. Box 502, ul. Robotnicza 244-100 Gliwice+48-(0)32-230 6736
SpainCastolin Eutectic Ibérica S.A.P. I. de Alcobendasc/ San Rafael, 628108 Alcobendas (Madrid)+34-914 900 300
Sweden, DenmarkCastolin Eutectic Scandinavia ABTransportgatan 3742204 Hisings-Backa+46-(0)31-570 470
LithuaniaMesser Eutectic CastolinSp.z.o.o. filialasV. Nageviciaus 3-6408237 Vilnius+370 5 278 8448
Switzerland
Messer Eutectic CastolinSwitzerland SASwiss Market CentreLangwiesenstrasse 128108 Dällikon+41(0)44 847 1717
Russia
Messer Cutting & Welding OOOUl. Bolschaja Tulskajya 10/9Office 9506 - 115191 Moscow+7 (0)095 771 7412
Turkey
Castolin Eutectic Kaynak San. Ve Tic. Ltd Sti.Yukari Dudullu MahallesiBostanci Yolu Sehit Sokak 5334775 Istanbul
United Kingdom & Ireland
Eutectic Company Ltd.Merse RoadNorth Moons MoatRedditch B98 9NZ+44-(0)1527 58 2200
For all others Countries please contact:
Messer Eutectic CastolinSwitzerland SAExport Market Center P.O. Box 360CH-1001 Lausanne, Switzerland+41-(0)21-694 1111
Contact
InformationContactInformationInformation
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Other coating consumables and equipmentThis brochure contains only a selection of Castolin Eutectic coating products. Other materials or services are available. Please ask your local Castolin Eutectic company.
Eutalloy® Powders
Eutalloy 10009 p. 13Eutalloy 10011 p. 13Eutalloy 10112 p. 13Eutalloy 10185 p. 13Eutalloy 10224 p. 13Eutalloy 10611 p. 13Eutalloy 10680 p. 13Eutalloy 15999 p. 14Eutalloy LT PE 8418 p. 14Eutalloy LT PE 8422 p. 14Eutalloy LT PE 8426 p. 14Eutalloy LT PE 8431 p. 14Eutalloy LT PE 8435 p. 14Eutalloy LT PE 8440 p. 14
Eutalloy® Equipment
SuperJet-S - Eutalloy® p. 15SuperJet-S - Eutalloy® kit p. 15KoolTip p. 15
Eutalloy® Accessories
Refill Powder Container p. 16Nozzles p. 16Heavy duty Nozzles p. 16Compact heavy duty tip p. 16Compact heavy duty tube p. 16
Eutalloy® SF Powders
Eutalloy SF 15211 p. 18Eutalloy SF PE 8213 p. 18Eutalloy SF PE 8215 p. 18Eutalloy SF PE 8217 p. 18
Eutalloy® SF Equipment
CastoDyn SF Lance p. 19
RotoTec® & ProXon® Powders
RotoTec 51000 p. 23RotoTec 19300 p. 23RotoTec 19310 p. 23RotoTec 19400 p. 23RotoTec 19404 p. 23RotoTec 19800 p. 23RotoTec 19850 p. 23RotoTec 19868 p. 23RotoTec 19940 p. 23RotoTec 19985 p. 23RotoTec 19999 p. 23RotoTec LT 29230 p. 23RotoTec LT 29240 p. 23ProXon 21021 p. 24ProXon 21023 p. 24ProXon 21031 p. 24ProXon 21071 p. 24MetaCeram 28010 p. 24MetaCeram 28020 p. 24MetaCeram 28030 p. 24MetaCeram 28095 p. 24
Eutalloy® RW Powders
Eutalloy RW 12112 p. 26Eutalloy RW 12494 p. 26Eutalloy RW 12495 p. 26Eutalloy RW 12496 p. 26Eutalloy RW 12497 p. 26Eutalloy RW 12999 p. 26Eutalloy RW 17535 p. 26Eutalloy RW 53606 p. 26
Flame Thermal Spray Equipment
CastoDyn DS 8000 p. 27RotoTec 800 p. 28
CastoDyn DS 8000® Accessories
Extension Neck p. 27CastoFuse p. 27
CastoFuse Accessories
Konstantherm p. 28Line Heating Torch p. 28Ring Torches p. 28
EuTroLoy Powders
EuTroLoy 16006.04 p. 31EuTroLoy 16008.04 p. 31EuTroLoy 16012.04 p. 31EuTroLoy 16221.04 p. 31EuTroLoy 16223.04 p. 31EuTroLoy 16316.04 p. 31EuTroLoy 16454.04 p. 32EuTroLoy 16496.04 p. 32EuTroLoy 16604 p. 32EuTroLoy 16606A.04 p. 32EuTroLoy 16625M.04 p. 32EuTroLoy 16800 p. 32EuTroLoy PG 6503 p. 32EuTroLoy PG 8426.04 p. 32
EuTronic GAP® Equipment
EuTronic GAP 2001 DC basic p. 33EuTronic GAP 2001 DCtouch screen p. 33 EuTronic GAP 3001 DC p. 33EuTronic GAP 3002 AC/DC p. 33 EuTronic GAP Automated Unit p. 34
EuTronic GAP® Accessories
Cold Wire Feeder p. 35Cold Wire Feeder Electronic p. 35Cooling GAP p. 35Trolley p. 35GAP E12N p. 36GAP E15N p. 36GAP E150P p. 36GAP E54 S-M-D-DL p. 36GAP E52 p. 36GAP E42 p. 36GAP IMPA100 p. 36
EuTronic Arc Spray Wires
EuTronic Arc 502 p. 39 EuTronic Arc 509 p. 39EuTronic Arc 532 p. 39EuTronic Arc 579 p. 39EuTronic Arc 595 p. 39
EuTronic Arc Spray Equipment
EuTronic Arc Spray 4 system p. 40EuTronic Arc Spray Gun 4 p. 41Power Source p. 41Wire Feeder and Drive p. 41
EuTronic Arc Accessories
Supplies packages p. 42Optional Spool Wire Feeder p. 42ArcJet p. 42Arc Spray Extension neck p. 42Remote Control p. 42
MeCaTec Pastes and Fluids
MeCaTeC Express 100 p. 45MeCaTeC 101F p. 45MeCaTeC 101P p. 45MeCaTeC 102P p. 45MeCaTeC 103F p. 45MeCaTeC A3 p. 45MeCaTeC A5 p. 45MeCaTeC A5HT p. 46MeCaTeC 110F p. 46MeCaTeC 110P p. 46MeCaTeC Bond R p. 46
Coating Accessories
Powder Feeder EP2 p. 48CDS 8000 -Refill powder container p. 48
Compressed air unit p. 49Cylinder coupling p. 49Fast Flam p. 49Hose p. 49Sliding cut-off p. 49SecureGas p. 49StopFlam 1 p. 49
Oscillating Unit p. 50Vertical Unit / with AVC p. 50Control Box p. 50Turning tilting table TTT200 p. 50
Fume Exhauster 3002 p. 51Fume Exhauster 4002 p. 51Personal Protective Equipment p. 51
Mounted grinding p. 52Stylus p. 52RotoTool p. 52Reversible cutter p. 52RotoTool III p. 52
InformationIndex
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Note
Table of contentsEuropean Product Catalogue
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Your resource for protection, repair and joining solutionsStatement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggested product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fitness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Messer Eutectic Castolin and its affiliates shall have no liability in respect there of.
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