TeroMatec. Enduring Performance. Stronger, with Castolin Eutectic. Self shielding peripheric arc system ensures :

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1 TeroMatec Self shielding, welding cored wire technology for wear protection, rebuilding & repair Enduring Performance Stronger, with Castolin Eutectic Self shielding peripheric arc system ensures : Fastest weld deposition rates Higher welding duty cycles On site capability without shielding gas supplies Optimised alloy weld properties for longer service life Maximum cost savings & productivity

2 TeroMatec TEROMATEC CORED WELDING WIRES TeroMatec is a self shielded arc welding process (Open Arc/FCAW) using specially formulated flux cored wire electrodes. The self shielded peripheric arc conception includes a wide range of custom made alloys optimised for industrial wearfacing, rebuilding and repair solutions with many advantages : No shielding gas requirements Fastest weld deposition rates Higher welding duty cycles Efficient weld metal recovery Stock reduction opportunities Ease of use by semi skilled operators Maximum savings & productivity Solidified slag Molten slag Wire guide / contact tube Cored wire Particles-elements/compounds Gas shield created by compounds Arc and Metal transfer NO SHIELDING GAS REQUIREMENTS Solidified weld metal Weld pool Self shielding peripheric arc The TeroMatec process requires no costly investments or complicated manipulation of heavy gas cylinders, regulators, flowmeters, mixers, hoses etc. TeroMatec s autonomous self shielding peripheric arc is designed for outdoor use where on-site wind or draught conditions would simply blow away any external protective gas (GMAW) causing porous, defective welds. FASTEST WELD DEPOSITION RATES HIGHER WELDING DUTY CYCLES The deposition rate of TeroMatec flux cored electrodes is remarkable reaching 4 kg/h with the Ø1.6 mm and almost 10 kg/h with the Ø2.8 mm due to peripheric arc current density effects. Furthermore, by increasing the electrode stick out (distance between the contact tube tip and the workpiece) from 50mm to 75mm, the deposition rate can be boosted over 12 kg/h due to electrical resistance heating effects whilst reducing heat input and dilution with the base metal. The welding duty cycle (X) is simply the % relationship between the effective arc welding time (t1) and the total time involved (t1 + t2) where t2 is the non productive time between the arc welding cycles. Thus TeroMatec duty cycles easily reach over 90% in automatic mode compared with MMA stick electrodes which peak around 40%. The higher duty cycle for TeroMatec is due to : no need to keep stopping & changing electrodes repetitive striking & restriking eliminated less post weld slag cleaning required fewer stop-start weld crater defects to grind Deposition rate (kg/h) 400% extra 300% extra Arc On t1 X = x 100 % t1 + t2 Arc Off Time High efficiency manual electrode Current (A) TeroMatec X 80-90% Manual electrode X 40% 2

3 EFFICIENT WELD METAL RECOVERY ( %) The weld metal recovery (sometimes called yield or efficiency) is simply the ratio of the mass of weld deposited to the total mass of the original welding electrode. Thus TeroMatec cored wires have an excellent weld metal recovery ratio reaching 95% whilst MMA stick electrodes only reach around 65% due to higher slag volumes and repetitive stub end losses. In other words, TeroMatec ensures that virtually all the weight of purchased cored wire ends up as a useful weld deposit thus reducing consumable costs. = 1000g = 1000g 650 g 950 g MMA - 65% TeroMatec - 95% STOCK REDUCTION OPPORTUNITIES As a 15kg TeroMatec spool represents around 22kg of MMA stick electrodes for the same quantity of required weld deposit, this represents a potential to cut welding consumable stocks by over 30%! Additionally, when a single spool Ø 1.2 or 1.6 mm TeroMatec is considered, its all round application welding capabilities can eliminate the need to stock separate packs of stick electrodes in 2.4mm, 3.2mm, 4.0mm & 5.0mm sizes thus further reducing inventory costs. EASE OF USE BY SEMI SKILLED OPERATORS Relatively little training is required for the TeroMatec process (compared with MMA) which makes it easy to learn by semi-skilled operators due to the self regulating nature of the arc, variable stick out capability, better visibility and absence of external shielding gases. Furthermore, powerful flux deoxidisers in the TeroMatec cored wire enable direct welding on rusty or oxidised steel surfaces without the meticulous precleaning needed for the GMAW process, especially when access is limited. MAXIMUM SAVINGS & PRODUCTIVITY Numerous studies by industry show that labour costs are the biggest single expense in welding. As skilled labour rates continue to rise inexorably, cut and control your welding costs with TeroMatec. TeroMatec systems significantly increase cost savings and productivity over both Mig / Mag & MMA processes due to the ease of use by semi skilled operators, the incomparable weld deposition rates giving superior performance and service life. 3

4 TeroMatec TEROMATEC MANUFACTURING FACILITIES The TeroMatec range of high performance cored electrodes are formulated, developed and manufactured in Castolin Eutectic s own modern plants using specially designed production equipment and procedures in accordance with ISO 9001 and EN quality assurance standards. Each TeroMatec batch after wire drawing and baking, is weld tested for consistent chemistry, properties & operability before precision spiral spooling and protective packaging for stock. metal strip pre-forming roll flux finishing rolls core wire ø 1,2 mm ø 1,6 mm ø 2,4 mm ø 2,8 mm Self shielding flux ingredients, arc ionising stabilisers, fine grain inoculants, powerful deoxidisers, metallurgical refining agents, selected alloying elements, carbide compounds, etc. Steel strip SELF SHIELDED PERIPHERIC ARC UNIQUE ANTI-WEAR ALLOYS Solid Mag wires can only be manufactured in metallurgical alloys which can be cast and easily drawn down to final diameters. The TeroMatec cored electrode concept completely overcomes such limitations and unique metallurgical alloys have been formulated with high density, ultra-hard micro constituants in Fe matrices. Thus the wide TeroMatec alloy range provides cost effective solutions for most wear problems found in industry. Thanks to TeroMatec s self shielding and high current density characteristics, it can be welded at lower welding currents than a solid wire whilst keeping a stable metal transfer across the arc due to ionising elements in the core. Additionally, the lower heat input and presence of powerful deoxidising fluxes means that TeroMatec weld deposits have better bonding, lower dilution, superior microstructure properties and minimal heat affected zones for maximum service performance. 4

5 WEAR PROTECTIVE COATINGS TO PROLONG SERVICE LIFE Abrasion Erosion Classic wear types that occur in industry are: Abrasion Impact Heat & Corrosion Erosion Friction Cavitation At Castolin Eutectic we take the time to study industry specific types of wear because until the nature of the wear is fully understood, the correct solution cannot be identified. Damage caused by these wear groups costs money, especially in downtime and lost production, replacement parts, repair and ongoing maintenance. Impact Heat & Corrosion Friction Cavitation Castolin Eutectic has proved for more than a century that a preventive maintenance welding program can extend the life of critical machine parts by as much as 500%. Castolin Eutectic has the «knowhow» to identify the most serious wear problems and «show how» to avoid them. Castolin Eutectic can greatly increase your plant efficiency and profits. PROVEN WEARFACING APPLICATIONS Wearfacing a worn VRM segmented roller Wearfaced teeth of a sugar cane crusher Wearfacing repair of damaged roller press Wearfacing using TeroMatec and Submerged Arc process 5

6 TeroMatec THE COMPLETELY MOBILE TEROMATEC SYSTEM Weighing only 24kg, the TeroMatec Wire Feeder 400 is designed to be easily moved by the welder around the workshop or for on-site applications. The process is much easier to use than traditional MMA stick electrodes because of the self regulating nature of the arc length which is directly controlled by the variable speed wire feeder. CastoMatec 655 power source TeroMatec Wire Feeder 400 Welding torch Wire feeder auxiliary ground cable Power source welding cable Technical data Power source ground cable & clamp Nominal motor supply 28 VDC max Power 98 W Welding current range A Nominal welding current 400 A Open Circuit Voltage 80 V max Duty cycle 100% Wire feed speed 12 m/min Wire diameters 1.6/2.4/2.8 Weight 24 Kg Wire feeding system specially developed for wearfacing thick, heavy components Designed for cored wire Ø 1.6, 2.4, 2.8mm. Powerful wire feeding thanks to the gearing of two guide rolls Easy maintenance (minimal electronics & no gas) Easy to transport for working in extreme conditions Automatic regulation of wire feed speed. Exclusive wire feeding system The TeroMatec Wire Feeder 400 ensures smooth push feeding speeds for Tero- Matec flux cored electrodes. Remote on-off control. 6

7 688 Fe 690 Fe 2010 Fe 4226 Fe TeroMatec Applications Technical Data For Joining, Buttering and Rebuilding Repair of chassis and large parts in cast steel, Tensile strength : N/mm² grab arms, buckets, machine bases. Elongation (l=d) : % Hardness : HV Bucket blades, grabs, leveller blades, toothholders on mechanical shovels Foundry defects in cast steel, shrinkage cavities or blowholes in semihard or cast steel. Repair of foundry defects in nodular or spheroidal graphite grades of cast iron - porosity, blow holes or shrinkage cavities. Tensile strength : N/mm² Elongation (l=d) : % Hardness : HV Tensile strength : N/mm² Hardness : HV Tensile strength ~475 N/mm2 Hardness ~50 HRC Annealed ~24 HRC For anti-wear Coatings high resistant to Impact, metal/metal Friction, and slight Abrasion 3110 Fe 3205 Fe 3206 Fe 3220 Fe 3302 Fe ES 4530 Abrasion Erosion Impact Friction Heat Corrosion Cavitation Rebuilding Fe Base Metal Guides and rolls, rebuilding missing sections on large, very worn parts Caterpillar track vehicle wear plates.. Rolling mill slide rods, shovel buckets, mobile crane wheels, rails. Crusher hammers, rolls, cranes, jaws, power shovel or dredge buckets, pump parts. Mechanical shovel teeth, crusher hammers and rolls, grab edges. For intermediate layers and multi-pass antiwear coatings, joining of large parts of dissimilar composition, rail points, crusher bars and jaws, drive sprockets. Railway retarder beams and wagon brakes, outside parts in hydroelectric power stations, defects in chromium cast steel. For submerged arc welding. Tensile strength : N/mm² Hardness : HV Tensile strength : N/mm² Elongation (l=d) : % Hardness : HV Hardness after workhardening : 400HV Hardness ~300 HV Work hardened ~45 HRC Hardness : HV Tensile strength : N/mm² Elongation (l=d) : % Hardness : HV Tensile strength : N/mm² Hardness : HV Hardness after welding : HV For anti-wear Coatings resistant to moderate Abrasion combined with Impact and Pressure 4327 Fe 4415 Fe 4625 Fe Crusher hammers, bars, anvils, casings, mechanical shovel bucket teeth & lips, dragline grab teeth, scraper blades. Ground augers, percussion grabs, dragline teeth and leading edges, gravel pumps, conveyor screws. Crusher bars and cylinders, feed screws, clay crushers, conveyor belts, waste disposal crusher hammers. Hardness ~59 HRC Hardness : HV Hardness : HV 4923 Fe Crusher hammers and bars, impact and casing screens, bucket teeth and lips, scraper blades. Hardness : HV New Product 3952 Fe 4395N For anti-wear Coatings resistant to high Abrasion and Erosion Fe 4601 Fe 4630 Fe Sinter crushers and fans, hot sieves, screens and bells. Unique NanoAlloy for transport screws, furnace chutes, exhaust fans, cyclones, conveyor, mixers, scrapers, screws, screens. Conveyor screws, rolls, crusher pinions and grinders, dragline and pump parts. Press spindle segment heads, mixer segments, blades and scraper, wear plates, induction fans, drag chains. Hardness : HV Hardness ~70 HRC Hardness : HV Hardness : HV 4660 Fe Jaw crushers, mixer paddles, pump wheels, mould screws. Hardness : HV Main application Secondary application 7

8 CastoDur Diamond Plates Self shielding TeroMatec flux cored wires also form the basis for our developments of wearfaced parts such as wearplates (CastoDur Diamond Plate) and weartubes (CastoTube).These composite material parts consist of an easy-to-weld steel plate or tube cladded with abrasion and erosion resistant alloys using either arc welding or plasma coating or vacuum furnace fusion systems. They are suitable not only for the protection of extensive surfaces against wear but also for fabricating complex machinery and equipment with longer service life and lower maintenance costs. CDP and CastoTube production plants have invested in fully automated robotics and state-of-the-art manufacturing technology to guarantee highest quality, exchangeable wearfaced parts which increase industrial productivity and protect the environment by conserving scarce raw material resources. CastoDur Diamond Plates CDP The better quality! CDP 4666 is the High Load wearplate for extreme abrasion and erosion resistance. Its complex carbide structure contains a high density of hard particles. The extremely hard boron and niobium particles are finely dispersed in between the chromium carbides, reducing their spacing and ensuring the best protection from abrasive and erosive media of finer size. Type of wearfacing: C, Cr, Nb, B Hardness: HRC Carbide content: > 50 % CDP 4624 DXW - The best ratio cost/performance CDP XuperWave 4624 is the ideal wearplate for applications where the right balance between price and service life is required, thus maintaining the Castolin high standard welding quality and smooth surface. Type of wearfacing: C, Cr Hardness: HRC Carbide content: > 30 % CDP 4666 application in a cement plant Base material (mm) Wearfacing (mm) CDP 4666 DP and 4624 DXW CDP 4666 DP and 4624 DXW CDP 4666 DP and 4624 DXW CDP 4666 DP and 4624 DXW CDP 4666 DP and 4624 DXW CDP 4666 DP and 4624 DXW Other dimensions available on request CDP 4624 DXW applications CastoTube CastoTubes - the latest addition to our expanding range of semi-finished, anti-wear solutions for industry. Basically it consists of easy-to-weld mild steel tubes which have been internally wearface-welded with TeroMatec 4666 alloy thus maintaining the exceptional wear resistance of our well known 4666 CastoDur Diamond Plates. Furthermore, by avoiding expensive forming operations of flat plates into tubes, seamless small diameter. CastoTubes offer many advantages: Highly cost effective Absence of harmful linear weld joints Exceptional wear resistance Perfectly round cross section Spiral welding minimises distortion Lightweight for handling Easy-to-join by welding or mechanical means CastoTube Parts 100 mm diameter CastoTube Article code Internal Diameter (mm) External Diameter Do (mm) Base Tube Wall TB (mm) Wearfacing TH (mm) 0150 CT ,8 7,1 3, CT ,7 5,6 3, CT ,0 6,3 3, CT ,0 8,0 3, CT ,50 8,80 3,00 Other dimensions available on request 8

9 CastoLab Our mission is to develop applications and solve customer problems. Depending on the customer s wish, we can transfer this knowledge to him or perform the work for him in our approved CastoLab workshops. CastoLabs can develop advanced procedures to allow transfer of complete solutions to end users. Casto- Labs offer a complete and comprehensive service for the maintenance of machine parts and major components subject to extensive service wear or needing repair. Work can either be undertaken in the Casto- Lab or alternatively on site. Often the parts being repaired or protected need to be produced on a regular basis, and here specialist prepared parts can be produced in unique manufacturing environment, from 10's of parts to 100,000 parts per year Large CastoLab for major repairs On site Boiler Coating Precision working Fan built with wear resistant CDP Rebuilding Crusher teeth ready for wearfacing YOUR 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 steel, cement, automotive, power, oil, waste & recycling, etc. Fan Protected with Powder Coated Wear Plates Arc Wire Spraying 9

10 TeroMatec CASTOLIN EUTECTIC Training Castolin Eutectic Locations The unique Terolink database of Castolin Eutectic contains more than 8,000 fully documented approved applications from around the globe. The case studies include photographs, technical data, detailed descriptions and cost-saving analyses. To increase customer knowhow in wear technology and repair techniques, we have developed a full line of seminars and training programs, teaching all relevant personnel from welders and engineers to sales teams and managing directors. Manufacturing R&D-Wear Test Laboratory Product Portfolio - Widest in the Industry Together with our sister company, the Messer Group, we can offer our customers a very powerful range of products and services. Being «Part of the Messer World» means: Investment of over 420 million More than 6,000 motivated employees Over 100 factories to meet customer needs Technical sales support in over 120 countries 2,000 technical sales people in the field with our customers every day Metallurgical Laboratory Micrograph of Wear Phenomena 10

11 HISTORY OF CASTOLIN EUTECTIC ADDRESSES OF CASTOLIN EUTECTIC COMPANIES IN EUROPE Austria, Hungary, South East Europe Castolin GmbH Brunner Strasse Wien +43-(0) Belgium s.a. Castolin Benelux n.v , Blvd de l Humanité 1190 Bruxelles +32-(0) Czech Republic Castolin pol.s.r.o. Trojska 18/ Praha (0) France Castolin France S.A. 22, Av. du Québec BP 325 Z.A. Courtaboeuf 1- Villebon Courtaboeuf Cedex +33-(0) Germany Castolin GmbH Gutenbergstrasse Kriftel +49-(0) Portugal Castolin Portugal Rua Maestro Ferrer Trindade, 4B Paco de Arcos : Foundation of Castolin in Lausanne, Switzerland by Jean-Pierre Wasserman. His stroke of genius: to discover a way of welding cast iron at low temperature; in the following years, this innovation was further developed for all industrial metals including aluminium alloys. 1940: Foundation of Eutectic Welding Alloys Corporation in New York 1952: Foundation of Castolin France 1959: Foundation of Eutectic Japan Ltd 1962: Foundation of Eutectic India Ltd s: International consolidation under Castolin Eutectic 1970 s: Creation of training centers for Maintenance & Repair technologies 1978: Establishment of World Head Quarters in St-Sulpice, Switzerland 2000: Merger with Messer Cutting & Welding and creation of the MEC Group - Messer Eutectic Castolin 2005: Part of the Messer World 2006: 100 years of innovation, service and quality. Netherlands Castolin Benelux N.V. Rotterdamseweg HH Delft +31-(0) Norway Castolin Scandinavia Teknologiparken, Akersvn. 24 C 0177 Oslo Poland Castolin Sp.z.o.o. P.O. Box 502, ul. Robotnicza Gliwice +48-(0) Spain, Portugal Castolin Iberica S.A. P. I. de Alcobendas c/ San Rafael, Alcobendas (Madrid) Sweden, Denmark Castolin Scandinavia AB Transportgatan Hisings-Backa +46-(0) Lithuania Castolin Sp.z.o.o. filialas V. Nageviciaus Vilnius Switzerland Castolin Eutectic Int. SA Swiss Market Centre Ch. de la Venoge St. Sulpice +41-(0) Russia Castolin Moscow Zemlanoy val st. 60/22, of 5D Moscow Turkey Castolin Kaynak Ltd. Yukari Dudullu Mahallesi Bostanci Yolu Sehit Sokak Istanbul United Kingdom & Ireland Eutectic Company Ltd. Merse Road North Moons Moat Redditch B98 9NZ +44-(0) For all others Countries please contact: Castolin Eutectic Int. S.A. Export Market Center P.O. Box 360 CH-1001 Lausanne, Switzerland +41-(0) Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggest 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 Castolin Eutectic and its affiliates shall have no liability in respect there of. Your resource for protection, repair and joining solutions 11

12 Stronger with... Castolin Eutectic WEAR & FUSION TECHNOLOGY Ask for a demonstration from our Application Specialists. -> <<< -> <<<