Issue 1 - 2013
THE CUSTOMER NEWSLETTER from CASTOLIN EUTECTIC
COATINGS GALORE
Laser Cladding
Vertical Roller Mill Mobile Service Units CastoLabs速 reduce wear for steel industry Crushing Technology
SOLUTIONS - Issue 1 | 2013 EDITORIAL NEWS CUTS
> Asia > Western Europe > North & Eastern Europe > NAFTA
BUSINESS
> Coatings expertise deepens > Q&A - Bryan Allcock CEO OilTec Services
COATINGS
> Decked out
Editorial
2 3 4 6 8 9 10 11
CASTOLAB® SERVICES
> Cement giants benefit from growing CastoLab® network > E3 Technology at the service of steel
13 15
CASTOLIN EUTECTIC NEW MEDIA > Distribution Tradition 16 > World Wide Web 17 PRODUCTS > OilTec -
OTW 12Ti / OTW 10SS / OTW 16XS > Equipment - Micro GAP 50DC > Consumables - Laser Powders
18 19
CONTRIBUTORS Castolin Eutectic countries Austria Russia Belgium Serbia Canada Singapore Germany Spain Korea Sweden Mexico UK Norway USA
Dear Customer It has been a while since our last Solutions and we have all experienced many new developments over the last few years. New technologies, new trends, new rules, new emerging countries, new businesses etc. are developing on a global level in the world that are changing our lives locally.
Castolin Eutectic activities VRM & Roller Press CastoLab® OilTec Welding Consumables Content design Louis Dauwalder Design and concept Greg Williams - www.gergwills.ch
Front cover: “Mixer assemblies” used in aircraft engines at Monitor Coatings (p.9)
There is a saying that “If the USA sneezes, then the world gets a cold” and in Europe this happened after the USA banking crisis. Today, the world has become so global and interconnected that we forget how events on the other side of the globe can influence our daily lives. Volkswagen group sold more vehicles in China in 2012 than in the whole of Europe (2.5 million versus 1.7 million); for the
youtube.com/CastolinEutectic
first year ever, Asia has more billionaires than North America (608 versus 440) and in the Champions League “All German” Final, only half the players were German, with the remaining being nationals of seven other countries. Castolin Eutectic is a global company and we also think and act globally in order to grow and bring our local customers new ideas, solutions, products and provide the best service, support, technology, innovation and quality. In this edition of Solutions we bring you up to date with the changes in our world and the technical world of wear protection, specialist joining and repair.
Dr Gary Heath Vice President Marketing Castolin Eutectic
linkedin.com/company/castolin-eutectic
>> NEWS
8kW BUSAN, South Korea
BUSAN, Korea
SINGAPORE, Singapore
A laser cladding machine (the second in the group, after that in Trio, Norway) was installed in Busan, in May.
to brands such as Samsung, Kia and Hyundai, South Korea is being recognised the world over for its technical leadership.
This is an 8kW Direct Diode high capacity machine, designed with a focus on large surface-areas and high-speed coating. The unit is the largest of its kind in Asia and reflects the ambition and demands of this dynamic market. Home
Eutectic Korea is actively supporting this drive with appropriate investments, to rightfully take its place at the heart of the group’s LaserTec development team.
>> NEWS CUTS
Asia
3
www.eutectic.co.kr | jelee@ eutectic.co.kr
Island SINGAPORE, Singapore
Castolin Eutectic’s Asian presence is growing steadily. Singapore have recently appointed Mr Vinay Paradkar as CEO and Technical Manager, further to the outgoing CEO’s retirement. Mr Paradkar has 27 years of experience in welding and thermal spray - at sales, technical and management levels. He has worked in South East Asia since 1994. In this role, he will be responsible for managing and developing business in South East Asia, including Singapore, Thailand, Indonesia, Malaysia, Myanmar, Philippines, Vietnam and others. Also, the recent acquisition of Monitor Coatings (UK) brings the addition of fur-
ther offices and a workshop in the Tuas district of the capital. www.castolin.com vinay@messer-eutectic.com.
The laser cladding machine, in Busan.
Vinay Paradkar, new CEO Singapore.
Monitor Coatings offices in the Tuas district of Singapore.
>> NEWS CUTS
Western Europe >> NEWS
4
REDDITCH, UK ENGHIEN, Belgium KRIFTEL, Germany NEUDORF, Austria
Nano REDDITCH, UK
MADRID, Spain
Brazing MADRID, Spain The Castolin Ibérica brazing experts are developing different types of aluminium alloys to help Original Equipment Manufacturers (OEM) in their production of steel transformers and refrigeration units.
The 38512 BFF used offers high fluidity and a non corrosive flux. Similarly, the presence in the same rod of both the alloy and the flux make for ease of use.
Steel transformers and refrigeration components treated with aluminium alloys.
www.castolin.es marketing@castolin.es
A paper mill on the West coast of the UK commissioned their own biomass power station to supply power to the plant. Chipped virgin timber and recycled wood products fuel the power station and accelerated wear experienced within the feed screws and chutes were an inherent concern for the customer, particularly with regard to the two main feed screws (12m x 1m) and several smaller silo screws. Castolin Eutectic proposed its tailored solution drawing on a combination of CastoDur Diamond Plate (CDP), EnDOTec DO*390N and TeroCote 7888T and
won the contract, in tandem with a local CastoLab® subcontractor. Sections of CDP were welded into place with a combination of proprietary welding products. This project was run during the annual shutdown of the plant (April). Over nine days, the Castolin Eutectic team reconstructed the screw flights and chute linings and further Applications were identified during the project which enabled the proposal of added solutions to the customer. This application will soon be recorded on the TeroLink database for future reference at other sites throughout Europe. CastoLab® www.castolin.com vwheeler@castolin.co.uk
Biomass feed screw with CDP flight segments.
Art work KRIFTEL, Germany King Wilhelm 1 of Würtemberg commissioned 8 cast iron fire urns in 1824. In 2009, these pieces were vandalised and Castolin Eutectic was asked to restore these objects to their former glory. The welding experts decided on a gas-powder weld, in the form of the Eutalloy solution. The powder was projected
and melted into the seam formed by the separate broken elements. The controlled and directional application of the S-Burner's flame allowed powder fusion such that the different segments could be reunited without altering the base metal of which the urns were made.
Open day Over 200 customers and prospective clients from Belgium, The Netherlands and North France were invited to an Open Day at Castolin Benelux. Participants watched - or in some cases tried their hand at - twelve different workshops show casing all the procedures, welding, thermal projection and brazing
The renovated fire urns have now been returned to their original positions at the memorial chapel in Stuttgart-Rotenberg.
Welder repairing one of the King Wilhelm I fire urns.
5
www.castolin.de wilfried.beer@castolin.de
ENGHIEN, Belgium
capacities of the local technicians. Colleagues from Messer Cutting and Messer Gas were also involved, underlining the Messer Group's ability to offer a total solution-package.
and providing the appropriate solution-products and operational procedures.
www.castolin.com vmartin@castolin.fr
Six presentations were also made (in both national languages) detailing all of Castolin Eutectic's proficiency in treating wear issues
Visitors at Castolin Benelux’s Open day.
HD2
NEUDORF, Austria Only days after the launch of the HD2 wear strips, Wiener Neudorf CastoLab® received its first customer order. These wear strips are a composite material made with mild steel and coated with a thick wearresistant alloy, specifically designed to resist high abrasion. Experience shows that, compared to hardened plates, they have considerably higher resistance to
Wear strips are commonly used to protect earth moving machines.
>> NEWS CUTS
Western Europe
wear. This allows customers to reduce costs and maintenance time and also to decrease the weight of buckets, due to the lightness of this solution. Wear strips are today commonly used to protect earth moving machines buckets, shovels and dump truck boxes. CastoLab® www.castolin.at eplassnig@castolin.at
>> NEWS CUTS 6
North & Eastern europe 100+
STAVANGER, Norway GOTHENBURG, Sweden
STAVANGER, Norway The highest powered diode laser in Scandinavia was on show at the Laser Technology Day, at the Trio OilTec Services site. The event was open to all customers and this inaugural event attracted over 100 participants. A speech outlining laser fundamentals, basic laser
>> NEWS
theory and exciting new applications launched the day, followed by demonstrations and lunch. Many in the audience were surprised to learn that experiments with laserdrilling were currently taking place in the USA. The speed and accuracy of the laser cladding equipment
impressed and ideas about new Applications were exchanged.
MOSCOW, Russia
This will certainly become a yearly event after attendants expressed the value of being able to meet, talk and exchange with competitors on “neutral ground�. www.trioaf.no
BELGRADE, Serbia
Attendants of open day watch a demonstration of the laser diode at OilTec Services in Trio.
Automotive An Open Day was organised for the automotive industry in Gothenburg, to demonstrate the new Castolin Eutectic Micro GAP 50 DC. Seventeen participants from Volvo and Scania attended workshops where the advantages for laser brazing of the Micro GAP 50 DC - over the TIG method
GOTHENBURG, Sweden
- were exposed to the visiting technicians. Various welding tools were also presented. Castolin Scandinavia AB has started delivery of the Micro GAP 50 DC units (see Products >>page 19) www.castolin.se hans.liljenfeldt@castolin.se Micro GAP 50DC demonstration during the Open Day at Gothenburg.
Growth
The Moscow CastoLab® Services workshop.
MOSCOW, Russia Active in Russia with its own company since 2004, Castolin Eutectic is continuously taking steps to strengthen its market presence and to enhance the range of products and services offered to regional customers. Three new sales staff and one OilTec team member have been hired this year. Headquarters are in Moscow with a growing number of sales staff specialised in traditionally important key branches such as the cement and glass industries. A CastoLab® workshop is located in Fryazino and manufactures an increas-
ing number of sophisticated parts to meet national customers’ expectations. The Russian CastoLab® team recently carried out on-site repairs of vertical roller mills in Tula (see CastoLab® Services >> page 14), and have also the sophisticated HVOF thermal spray capability.
7
A further regional presence is offered by offices in the important industrial areas of Saint-Petersburg, Yekaterinburg and Rostov on Don.
www.castolin.com/ru-RU/ jesco.oser@mec-castolin.ru
Hvof BELGRADE, Serbia
CJK5 HVOF Thermal Spray booth in preparation, in Belgrade.
>> NEWS CUTS
North & Eastern europe
The HVOF facility in Serbia started operating in March. The installation comprises : a Castolin CJK5 HVOF thermal spray system, a spray booth (7m x 4m x 2.8m) with 3m wide doors for loading the work, 22kw fume and dust extraction system and a grit blasting container. Rotation for cylindrical parts of up to 250kg in weight and 6m in length is provided by a robot integrated turntable which can spin parts at speeds of up to 750rpm. HVOF gun manipulation is done with an ABB IRB 2400 robot with integrated 4m tracks, which
allows for spraying of whole 6m pipes in one step. With this investment, CastoLab® Serbia is extending its expertise in thermal spraying beyond its established arc spraying of thermal power-plant boilers and entering other industries, where top quality coating and best wear resistance are also required. The powders most used are Tungsten Carbide based such as 10Co4Cr86WC and 12Co88WC whilst the innovative NiCrBSi alloys are also finding applications. www.castolin.com aleksandar.djordjevic@messer.rs
>> NEWS CUTS
NAFTA
8
>> NEWS
Partner
MILWAUKEE, North Amercia
MILWAUKEE, USA Eutectic Corporation announced that Asteco has expanded its role in serving Castolin Eutectic customers in Latin America. An agreement between the two companies means that as well as covering Columbia, Asteco are now official dis-
VAUDREUILDORION, Canada
tributor in : Guatemala, El Salvador and Nicaragua. www.castolin.com/en-US marketing@eutecticusa.com
NUEVO LEON, Mexico Guatamala, El Salvador, Nicaragua
500kg
Excellence
VAUDREUIL-DORION, Canada
NUEVO LEON, Mexico Training courses continue to be developed at the Eutectic Mexico Training Institute.
Eutectic Canada technician work on Evraz steel mill in Regina.
The Arc Spray Application of the BoilerTec wire (BTW) range of wear and corrosion protection coatings within steel mills and waste industries is a strategic initiative for the Canadian CastoLab® Team. After being invited by colleagues in France to participate in their first BTW application, Eutectic Canada was successful in providing an identical service to the same customer at their Canadian location. More recently, Eutectic Canada targeted the steel industry and concluded an in-situ Application for the
Evraz Steel Mill in Regina, Saskatchewan. This test involved the application of different BTC solutions such that controlled tests of the different wear properties could be profiled. Upon completion of the wear tests, the customer is looking to standardise this process as a routine maintenance solution.
Twenty five participants have this year taken part in five different courses. The latest held at ICA in Aguascalientes Mexico was on TIG and Flux Oxi processes. A range of seminars and practical training has been developed at four levels: basic, advanced, TIG or MIG Process and industrial seminars tailored for the automobile, cement, pulp
& paper, aeronautic, glass, recycling and oil and gas industries. The aim is to increase customers’ know-how in antiwear technology by the application of the latest techniques in welding and repair. The level of knowledge and experience allows Eutectic Mexico to offer a high-level training with resulting matching performances for the customers. www.castolin.com/es-MX lflores@eutectic.com.mx
This job involved the application of 500 kg of BTW 55/ 62 / 66 on cooling components within the steel mill. CastoLab® www.castolin.com/en-CA groseborough@eutectic-na.com
A practical session during one of Eutectic Mexico's training courses.
Castolin Eutectic has acquired Monitor Coatings (UK), recognised specialists in surface engineering for extreme environments.
>> BUSINESS
Coatings expertise deepens
9
Post-spraying operations to clean down “mixer assemblies” used in aircraft engines.
Castolin Eutectic enriched its offer in the coatings services sector through its acquisition, in May, of Monitor Coatings (UK). Originally founded in 1927, Monitor Coatings is today a technology leader for surface engineering in extreme environments. It has facilities in the UK, Singapore and China and its customers include household names such as Bombardier, Rolls Royce, Halliburton and Tata Group - amongst many others in the oil and gas, steel, power and aerospace industries. The company has earned its reputation and market position on technology solutions that offer the highest level of performance available in the market today. After the recent award of part of a regional business growth fund, a senior executive from the fund said of Monitor Coatings : “Companies don’t build a client list as impressive (as Monitor’s) without consistently providing high quality services, and their expertise in a very specialised sector gives them an excellent opportunity to achieve impressive commercial returns.”
In keeping with Castolin Eutectic’s own drive for excellence, Monitor Coatings operates to the highest quality standards recognised throughout the world, and has obtained ISO9001, AS9100 and NADCAP accreditation, as demanded by Rolls Royce. Dr Bryan Allcock, former Managing Director of Monitor Coatings will take up the position of CEO, OilTec Services within the Castolin Eutectic group. bryan@monitorcoatings.com
Quality Inspector undertaking rigorous inspection and surface-finish assessment.
Masking up aerospace parts in preparation for coating.
Q&A >> BUSINESS
Bryan Allcock, newly appointed CEO of Castolin Eutectic OilTec Services
10
How did you come into this industry? Following completion of my PhD in Corrosion Engineering, I joined Cobham Aerospace, heading up their Specialist Coatings division. In 1999 I was approached by the then owners of Monitor to join as MD. Its experience in specialist coatings and high standards were a natural attraction for me.
To your mind, what has been one of the greatest technological innovations in coatings? This has to be the advent and commercialisation of Densification technology. Monitor owns a range of proprietory ceramic densifiers and slurry coatings which, either acting in conjunction with thermally sprayed coatings or simply on their own, provide significant enhancements to the wear properties of the particular item being coated. In particular, when used with our patented HVOF applications in the Oil & Gas sector, the results have been remarkable, with our coatings lasting up to three times longer than that of the traditional competition. In the Steel sector, our solution was described as a stepwise change for the industry.
What are the main challenges facing surface engineer experts over the next 10 years? Undoubtedly the REACH initiative, which outlaws the use of chromebased coatings in Europe from 2016. Many thermally sprayed coatings rely upon an element of
chrome and it is extensively used, particulary in aerospace coatings. We are working on a collaborative R&D project with companies, including Rolls Royce, to develop chrome-free coatings prior to this deadline. This will be a major challenge for all involved, but I believe we will find solutions and when we do Castolin Eutectic will be at the forefront of a new generation of coatings which will eventually be used throughout the world.
Is there one clientindustry which calls on more intensive R&D from coatings experts? Aerospace is always looking for new solutions, as evidenced by our work. Lately, we have done a significant amount of work in the renewable energy sector, looking at applications varying from Wind Turbines through Boiler Tube coatings to Steam Turbine blades and engines. All have high wear and corrosion issues and all are being invested in heavily throughout Europe, and indeed the rest of the world. Again, looking to the future, the Nuclear industry has many requirements for coating development and we collaborate in UK and European Government funded R&D projects in all of these sectors.
What is the added-value for clients from the Castolin Eutectic /Monitor Coatings union? Monitor Coatings technology can be rolled out through the ex-
panded Castolin Eutectic network to complement solutions already provided by the latter. An example: Castolin Eutectic is already familiar with HVOF technology but with the addition of our densification technology, we can offer an enhanced coating system on a cost effective basis which will prolong the life of customer products. Monitor Coatings also gains access to an expert sales team and complementary technology to enhance the offer to existing customers.
2013 Castolin Eutectic acquires Monitor Coatings.
2006
2003 Management buyout of Monitor Coatings by Bryan and Rebecca Allcock.
1970s Monitor Coatings moves into the aerospace sector.
Monitor Coatings relocates to new, purpose built factory in North Shields.
1999 Bryan Allcock appointed Managing Director.
1927 Monitor Coatings founded. The company made its reputation by providing coatings for the mining industry.
The British Armed Forces’ Royal Navy recently asked Monitor Coatings to coat a rather large surface. A glimpse of the project underway... An artist's impression of HMS Queen Elizabeth and HMS Prince of Wales.
In May 2012, the UK government, in association with the Aircraft Carrier Alliance engaged Monitor Coatings Ltd to investigate and deliver a suitable deck coating that would withstand the aero thermal environment and gas wash exhaust of the F35 engine on JSF and Eurofighter when conducting a hover transition and vertical landing. The scope of activities to be delivered included : the development of techniques required for large scale preparation and application of a Thermal Metal Spray coating (TMS), over an area in excess of 19,500m² and the development of process-technology readiness and manufacturing capability levels acceptable for large scale application and long term support of the HMS Queen Elizabeth and HMS Prince of Wales carrier deck, both future vessels of the Royal Navy.
Pivotal to this scope of work was the requirement to demonstrate the application of a TMS on a test area of the flight deck. In order to achieve this, a representative test bed providing 84 m² of flight decking plate was installed at Monitor Coatings’ site, in North Shields. The enclosed area at Monitor Coatings provides a suitable working environment for experimentation and testing and contains both a bespoke automated system (fully robotised) and a custom built arc spray system to deliver a triple layer coating system.
...a coating that would withstand the exhaust of the F35 engine...
The new coating system represents a significant departure from the traditional materials used to provide the non-skid requirements of a carrier deck coating. The outside workshop (right) housing the Royal Navy project.
>> COATINGS
Decked out
11
>> COATINGS 12
The aft island goes to be assembled with other sections of the Queen Elizabeth flight deck, currently in construction.
Monitor Coatings, North Shields, Newcastle
Global Coatings Manager To confirm the emphasis placed on the development of its coatings offer to its customers, Castolin Eutectic has appointed a Global Coatings Manager, Mr Stewart Gibson. Mr Gibson is a mechanical engineer and has many years’ experience in the surface coatings industry, having led sales & marketing and operations departments. He started his career with the Hawker Sidley Group as a produc-
Trials have included : surface preparation, surface roughness, surface thickness, porosity, deposition temperatures, deposition rates and the development of an automated process that will ensure all deck edges, deck furniture and deck welds can be accommodated in the final TMS process. The scope of work culminated in a 2-day demonstration to the Aircraft Carrier Alliance and to the stakeholders of the process ap-
plication, quality system and inservice repair programme of the Monitor Coatings Ltd TMS system . The demonstration day was very well received by both senior ranking naval officers and civilians from the marine engineering community. Now, in the final stages of the test programme, project costs and reports are being finalised for submission and consideration.
tion engineer, later moving to sales with Praxair Surface Technologies. He has held a number of key management and executive positions with Bristol Aero Jet Vickers, Renold Power Transmission and latterly Bodycote Surface Technology. His role at Bodycote was that of Business Development Director for innovative coating processes tailored for extreme environments.
plications for the oil, steel, chemical and gas turbine industries.
Mr Gibson has also been responsible for setting up coating workshop operations in Dubai, Singapore and Canada and has in-depth experience of coating ap-
sgibson@castolin.com
Strategically placed CastoLabs® across Europe are developing the technology and skills to significantly reduce the down time on Vertical Roller Mill and Roller Press repairs. Whilst Castolin Eutectic formally created its dedicated Business Unit “Heavy Duty/Vertical Roller Mill and Roller Press” (VRM & RP) in January 2012, the specialisation and the skills developed across the global network of CastoLabs® go back several decades.
tract - the coating of the largest of Loesche VRM models at the HeidelbergCement plant, in Tula. Four rollers and one table were welded in 92 hours. The solution involved 2,700 kg of 8338 and 8355 TeroMatec self-shielding wire.
Trained by the Wiener Neudorf CastoLab®, the Russian team gained high praise from the Technical Management of Loesche : “(Castolin) performed the job in an excellent way.
In late 2009, Castolin Europe's VRM Mobile Service Unit was awarded its first contract, for the on-site welding of a VRM, in Albania. Thanks to the enthusiasm and professionalism of all those involved (from the Wiener Neudorf CastoLab®), the project was an outstanding success. As the first such contract of many to follow, it soon became clear that the VRM Mobile Service Units - then based solely in Castolin Austria - would no longer be able to cater to the entire European market’s needs. Castolin Eutectic anticipated this demand and invested the matching resources for expansion of the service offer, to both Russia and Spain. Whilst scrupulously adhering to Quality Standards, the sourcing of equipment and training of staff was so efficient that, before the Business Unit had even run out its first year, Castolin Russia had clinched the award of its first con-
Roller Press at Holcim’s plant (Bulgaria).
CastoLab Team on site at Heidelberg Cement, Tula (Russia).
>> CASTOLAB® SERVICES >CEMENT
Cement giants benefit from growing CastoLab® Services network
13
>> CASTOLAB® SERVICES >CEMENT 14
The team was highly professional and the equipment outstanding. The work was executed in time.” By the end of March 2013, Castolin Spain had also taken delivery of its own VRM Mobile Service Units. The established Castolin Eutectic global network and the CemTec Team ensured perfect technology transfer and Spain has already taken on the Teruel UPT power plant service (on site) as well as carrying out the recent refurbishment of a VRM table from a Lafarge cement factory, at the CastoLab® itself. At Castolin Austria, the direct collaboration with Original Equipment Manufacturers (OEM) enables deep understanding of guiding principles and performance optimisation. Results speak for themselves with jobs such as that performed in Beli Izvor, Bulgaria for Holcim, where 2 KHD Roller Presses were repaired with a total of 1,900 kg of 5 different wire types. Whilst Castolin Eutectic had indicated 14 days’ down-time to the customer, the team managed to finish two days ahead of schedule. The latest project to be completed was the resurfacing of two identical rollers, sent from Croatia. Since the 1990s, specialists of the Global Heavy Duty/VRM & RP Business Unit have repaired over 40 different VRM models for a client list of over 30 cement manufacturers, the world over.
Mounting equipment at HeidelbergCement plant (Russia).
Client carrying out final checks (Bulgaria).
Further reading | International Cement Review | July 2013 issue, page 88 - “Reducing VRM repair downtime”, by Castolin Eutectic, (M.Trenk)
Castolin Eutectic VRM & RP brochure
The VRM Mobile Service Unit (Russia).
In Europe alone, some 50 sintering plants deal daily with problematic issues of equipment service-life length and related productivity levels. Castolin Eutectic’s E3 Technology optimises performance and offers impressive results.
>> CASTOLAB® SERVICES > STEEL
E3 Technology at the service of steel
15
A completely mounted rotor with 12 stars, fully protected by E3 technology and ready for installation.
The extreme temperatures generated in the sinter-making process dramatically wear the rotor and breaker bars of the sinter crusher. In terms of cost efficiency and ecological impact, it is therefore critical that the sintering and crushing process be optimised. Castolin Eutectic’s E3 Technology offers the crushing components protection from both the abrasionand temperature-induced wear. Rotor teeth and breakers bars are exposed to severe abrasion. After its progression along the sinter belt, the sinter enters the crushing area at a temperature of around 900°C. This brings the equipment temperature itself up to a minimum of 400°C. In 2008, Castolin Eutectic was awarded its first contract by a large steel manufacturer, to address sinter crusher issues at its plants. The customer had turned to Castolin Eutectic after the wear resistance of all competitors’ solutions was considered insufficient. Working in tandem with the customer and the Austrian Competence Centre for Tribology (AC²T), Castolin Eutectic
undertook research to develop the optimum solution. The Research & Development Team studied the hardness and the wear resistant properties at high temperatures of various alloys.
2. a very specific 3-D welding pattern.
After several years’ research and onsite tests, the E3 Solution was finalised. As its name suggests, this solution offers 3-dimensional protection to customers’ equipment.
This solution can be provided either as parts or applied to the manufacture of a complete rotor system, from engineering to the finished unit. Since those early beginnings, measurements are consistently carried out at two test-plants.
Such results come from a combination of two factors : 1. a unique high temperature wear resistant alloy
The E3 Technology addresses the highest wear positions on the sinter crushing equipment; the rotor discs, rotor teeth and the breaker bars.
Specific trials have been carried out to compare E3 Technology’s performance with that of a carbide liner
Comparative test on breaker bars : (A) standard wear solution; (B) E3 solution.
> STEEL >> CASTOLAB® SERVICES 16
on the rotor. Results obtained with E3 Technology, on a single tooth, show that after 85 weeks the E3 Technology coated tooth remains in good condition, whilst the carbide liner teeth are completely worn down.
For the customer, this brings clear economical advantages : - Longer wear-resistance of the rotor parts which significantly reduce maintenance down-times - The complexities and risks of watercooled parts, often used to maintain lower operating temperatures, are avoided, and
Similarly, tests on a complete rotor system delivered overwhelming results in favour of the E3 Technology solution; the carbide liner solution was worn after 10 months (2.4 million tons of sinter processed); the E3 Technology coated system was still in good condition after 37 months (9 million tons of sinter processed).
- Preserving the crushing equipment enables the optimum sinter grain size to be obtained which, in turn, ensures an economic operation of blast furnaces. Currently, Castolin Eutectic is studying future uses of the E3 Technology solution on new extreme high temperature environments.
As regards the breaker bar resistance, it showed a 6-fold improvement over standard wearplate solutions (<< photo comparative test on breaker bars).
The E3 Technology Solution is available exclusively from CastoLab® Services.
Distribution
Castolin Eutectic Distribution catalogue
Welding Equipment : Title MIG/MAG Processes
Welding equipment: Title MMA Process
28
DERBY 161 & DERBY 305 & DERBY 425 DSII DERBY 161
DERBY 305
DERBY 425 DS II
ARC 1250
ARC 1450
ARC 1650
Power supply
230V single phase 50/60 Hz
230V single phase 50/60 Hz
230V single phase 50/60 Hz
Power supply
230V single phase 50/60 Hz
3x 230V/400V 50/60 Hz
3x 230V/400V 50/60 Hz
Weight
2.5 kg
3 kg
3.5 kg
Size
40 x 62 x 54 cm
88 x 50 x 74 cm
100 x 55,5 x 134 cm
Duty cycle
100A (10%)
130A (10%)
150A (10%)
Weight
37 Kg
90 Kg
144 kg
IP 21
IP 21
Duty cycle
140A (20%) 80A (50%)
290A (35%) 225A (60%)
400 A (40%) 326 A (60%)
IP index
IP 22
IP 22
IP 23
Item code
600120 (No torch, no cable)
754454
757500
IP index
IP 21
Standard
60974-1; 6097410
60974-1; 6097410
60974-1; 6097410
Item code
662754
662755
662756
Description • User friendly • Easy to transport (from 2.5 to 3.5kg) • Excellent weldability for all electrode types : rutile, stainless steel, cast iron and basics.
• Range of 3 equipment, welds all electrode diameters up to 4mm. • Standard single phase 230V • Reinforced insulation • Robust and reliable • Latest inverter technology, outstanding arc precision • CE compliant
W180
W210GE
230V single phase 50/60 Hz
230V single phase 50/60 Hz
230V single phase 50/60 Hz
Amperage range
5 - 150A
W150
5 - 180A
5 - 210A
Open circuit voltage
80V
80V
80V
Duty cycle : 40% 60%
130A
170A IP 23
IP 23
29
Description Semi-automatic welding technology with wire for automated MIG / MAG welding. The principle of polarity reversal allows the use of Castolin cored wire coils without the use of shielding gas. The Derby can also be used with shielding gas. CE compliant.
DERBY 305
W RANGE Dedicated range for the PRO Inverter Power supply
High temperature cyclic abrasion test apparatus, used for Castolin Eutectic R&D at AC²T in Vienna.
tradition ARC RANGE Ventilated MMA Inverter
Castolin Eutectic Sinter Crusher brochure
DERBY 425 DS II
DERBY 161
210A
IP index
IP 23
Weight
5 kg
5 kg
8.5 kg
Size
12x31x27
12x31x27
18x25x40
Item code
600834
662757
662758
Description • User friendly • Easy to transport (from 5 to 8.5kg) • Excellent weldability for all electrode types : basic, rutile, stainless steel, cast iron and also wearfacing • Powerful equipments (130A up to 190A) • Range of 3 equipment, weld all electrode diameters up to 5mm.
• Can be connected to a power generator • Delivered complete with earth cable, welding cable and operating manual. • Standard single phase 230V • Reinforced insulation • Robust and reliable • Latest inverter technology, outstanding arc precision • CE compliant
For more information about our complete welding equipment offer, please read our specific catalogue.
Castolin Eutectic has built up its reputation by solving industrial problems - its technicians work directly with the enduser and directly on the problem. Many of Castolin Eutectic’s customers are tradesmen or professional handymen who want to buy their favourite products through a
«Distributor», close to where they work. For these customers and for the re-sellers of its products, Castolin Eutectic created a Distribution range, «Castolin Pro», in parallel to its Industrial range. The new “Distribution” website is now online.
All Distribution products used by tradesmen and available via local distributors can be found on this new site. CastoTape, Disks Zirco, Torch CT27, cutting tools, soldering irons, to name but a few, all feature, with recent pictures and up-to-date product information. www.castolin-pro.com
Castolin Eutectic Since the last edition of Solutions, Castolin Eutectic has been working on bringing information to its customers - better and faster.
>> MEDIA
world wide web
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Simona Serban, Group Web Manager.
One year ago, Castolin Eutectic hired a bright young web manager, Simona Serban. Today, the company’s internet site has been brought alive and rendered accessible to each and every customer, from Cuautitlán Izcalli (Mexico offices) to Hokkaido (Japan). In a short period of time, all of the principal Castolin Eutectic national sites (16) have been brought under one corporate banner and - more importantly - up to the same level of information for all Castolin Eutectic customers, worldwide. If you haven’t tried the new internet site, here are a few reasons you should.
Features of castolin.com : • Contacts for fast and instant access to all of Castolin Eutectic offices (http://www.castolin.com/ contact)
• Regular updates of news, events, new services/products, job vacancies • Focus Applications (with countryspecific news)
• Google Translate for automatic translation of languages not offered as yet (Arabic, Thai, Vietnamese etc)
• Videos, images & brochures to be downloaded
•
All Material Safety Data Sheet (MSDS) for free download with simple subscription facilities to automatically receive the latest versions by email (http://castolin.com/msds-portal)
• Social media sharing functionality (feel free to use the “share” buttons to forward to colleagues!)
•
A powerful search engine for customers to find every Castolin Eutectic product or service, in a maximum of 3 clicks
All of this information has been optimised for mobile devices (no Flash included) and modern browsers (Google Chrome, FireFox, Explorer, Opera etc.)
>> PRODUCTS
What’s new
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A selection of the latest Castolin Eutectic products. Product information (flyers, brochures, data sheets) and all related reading are available on www.castolin.com or from local market centres.
Castolin Eutectic Hardbanding brochure
OilTec >> OTW 10SS | 16XS | 12Ti Related reading >>
The Oil & Gas industry has never been more a part of Castolin Eutectic's landscape. Today, the company offers services and products to the industry. The Services sector has been reinforced by the investments in Trio, Norway and Monitor Coatings, UK and the OilTec Products range is also well established and growing. The first product - hardbanding wire OTW 12Ti - was developed and manufactured internally. This range has now been expanded to OTW 10SS and OTW 16XS. The full range can be viewed on-line and in the Castolin Eutectic Hardbanding Brochure.
OTW 12Ti actively protects against wear in the most extreme drilling conditions, as demonstrated by its performance in highly deviated well & open hole applications. OTW 12Ti's hardness scale (61.5 HRC), combined with Non-Cracking- (NCD) and Flexible Application Designs (FAD), enables high load, open hole performance, while simultaneously meeting all casing friendly requirements.
www.otw-hardbanding.com
Hardbanding ED & TEST VED O APPR
For Oil and Gas drilling
Key Industry Program
OilTec Stronger… with Castolin Eutectic
Optimized Performance • Crack Free Design • Casing Friendly • Optimized Tool Wear Resistance • Flexible Rebuild Design
OTW 10SS is an exclusive gas shielded, metal cored alloy wire, specifically designed for use in severe sour (SS) environments and is fully compatible with all drillpipe sour service grades. OTW 10SS is formulated to produce a unique, hard tool-steel microstructure with numerous ultrafine/ultra-hard phases, dispersed in a tough tempered martensitic matrix.
OTW 16XS was specifically designed for use in Ultra Deepwater applications where most wells are highly deviated and extremely deep. Such wells require the highest level of strength and prolonged performance. OTW 16XS contains superior casing friendly properties and demonstrates a unique ability to offer the best wear-resistant materials in open hole and cased-hole environments.
Equipment > Micro GAP50
Micro GAP 50 DC is ideal for welding applications that require precision, high deposit quality and low dilution especially when fully automatic welding is impractical such as for one-off applications or multiple processes.
>> PRODUCTS
For all manual applications with low welding currents : plasma welding, plasma spot welding, TIG welding. Welding with the Micro GAP 50 DC.
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The welding units are available with various features. The operation is carried out via the touch display. Micro GAP 50 DC is designed for manual and semiautomatic welding tasks in which frequent parameter changes are required. All the settings are displayed on the LCD display in plain text, and up to 1,000 memory locations are available for storing the welding parameters.
Castolin Eutectic Micro GAP50 DC brochure
Features
The extremely powerful inverter delivers 33 A at a 100% duty cycle, which is also sufficient for microplasma welding. It also goes as low as o.5 A for delicate, precision work.
> Clearly laid-out control panel > Simple pre-selection of welding parameters > Compact design
Consumables > Laser Powders In addition to recent investments in laser cladding facilities in Norway and South Korea, Castolin Eutectic has developed a range of consumables specifically tailored for the laser cladding process. These powders are all gas-atomised and quality-controlled at the Castolin Eutectic Production Centre, in Dublin (CEIL). CEIL is fully accredited by ISO/TÜV and Lloyds of London and there are currently numerous different powders avail-
Laser powder coating technology Enduring Performance…
Stronger, with
Castolin Eutectic
Courtesy of Trumpf
able, ranging from Cobalt, Nickel and Tungsten containing alloys. The full range of powders are presented in the Laser Powder Coating Technology Brochure, available on-line.
Precise coatings with fine wear resistant microstructure, metallurgical bonding and lowest heat input
Stronger, with... Castolin Eutectic
www.castolin.com