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Castolin Eutectic

SOUTH EASTERN EUROPE

Castolin... past foundations, building for the future

A CENTURY OF HISTORY

1906: 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, his 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. 1960'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

Today MEC - Messer Eutectic Castolin is: A world-wide group with over 2300 collaborators Established in all industrialised countries through subsidiaries 4 production plants in Europe 4 production plants on the American continent 2 production plants in Asia 4 complementary technologies: welding, brazing, cutting, thermal spraying Continuous evolution and progress The traditional core competence for Castolin is the constant fight against industrial wear and tear using maintenance fusion technologies. Our long experience in research and development has created numerous patents and progress in the field of industrial materials and metallurgy, surface engineered protective coatings and associated processes. Throughout our hundred year history, Castolin has pioneered product developments at the leading edge of technology with exceptional performance qualities for practical industrial applications leading to conservation of valuable raw material and energy resources.

Castolin Eutectic is a registered BS EN ISO 9001:2000 Company.

Whilst every care has been taken in the preparation of the technical information contained in the publication, it is provided for guidance only and Castolin Eutectic will not accept any liability resulting from its use. Tel:+43 1 869 45 41

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YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS

Castolin Gesellschaft m.b.H. Brunner Strasse 69 1235 Vienna, Austria Phone: +43 - (0)1 - 869 45 41 - 0 Fax: +43 - (0)1 - 869 45 41 - 10 email: [email protected] homepage: www.castolin.at

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TABLE OF CONTENTS

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11

11.10 11.20 11.23 11.26 11.30 11.35 11.40 11.50 11.53 11.56

LOW HEAT INPUT WELDING ALLOYS

EUTECTRODE MANUAL ELECTRODES

Welding Cast Irons Welding Steels Welding Stainless Steels Welding Structural Steels Welding Copper Alloys Welding Aluminium Alloys Gouging, Chamfering, Cutting Carbide Alloy Coatings Alloy Steel Coatings Nickel Alloy and Cobalt Alloy Coatings

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6 7 8 9 9 9 9 10 11 11

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12.23 12.26 12.30 12.35 12.53 12.56

CASTOMIG-MAG WELDING WIRES

Welding Stainless Steels Welding Structural Steels Welding Copper Alloys Welding Aluminium Alloys Alloy Steel Coatings Nickel Alloy Coatings

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12 13 13 14 14 14

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13.20 13.23 13.26 13.30 13.35 13.53 13.56

CASTOTIG WELDING RODS

Welding Special Steels Welding Stainless Steels Welding Structural Steels Welding Copper Alloys Welding Aluminium Alloys Alloy Steel Coatings Nickel Alloy and Cobalt Alloy Coatings

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15 15 15 16 16 16 17

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14.10 14.20 14.23 14.50 14.53 14.56

ENDOTEC CORED WIRES (GAS SHIELDED)

Welding Cast Irons Welding Steels Welding Stainless Steels Carbide Alloy Coatings Alloy Steel Coatings Nickel Alloy and Cobalt Alloy Coatings

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18 18 18 18 19 20

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15.50 15.53

TEROMATEC CORED WIRES (SELF SHIELDED)

Carbide Alloy Coatings Alloy Steel Coatings

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21 21 24

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21.10 22.10 23.10 23.20 24.10 27.10 28.10

LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS

ECOBRAZ RANGES

Capillary Soldering Brazing Alloys Self-Fluxing Brazing Alloys for Copper Gas Welding and Brazing Alloys Wearfacing Alloys Soldering Alloys Fluxes Brazing Light Metal Alloy and Soldering Pastes

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24 25 25 26 27 28 31

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31.10 31.20 31.30 31.40 31.50 31.60 31.70 31.80

POWDERS AND WIRES FOR THERMAL SPRAYING

POWDERS FOR THERMAL SPRAYING

RotoTec ­ Alloy powders for "cold" spray process ProXon ­ One-step alloy powders for "cold" spray process Eutalloy ­ Self-fluxing powders for spraying with simultaneous fusion Eutalloy SF ­ Self-fluxing powders for spraying with simultaneous fusion Eutalloy RW ­ Self-fluxing powders for spraying with subsequent fusion CastoPlast ­ Polymer powders for thermal spray process MetaCeram ­ Ceramic and refractory powders for "cold" thermal spray process EuTroLoy ­ Alloy powders for PTA (Plasma Transferred Arc) process

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36 37 38 38 39 39 40 40

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32.10

WIRES FOR THERMAL SPRAYING

EuTronic Arc spray wires ­ Alloy wires for arc spraying

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4

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COMPOSITE WEAR FACING MATERIALS

MECATEC - COLD SURFACING TECHNOLOGY POLYMERS

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42

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91 92 93

CASTODUR DIAMOND PLATES

WELD CLADDED PLATES POWDER COATED PLATES CASTOTUBES

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44 45 45

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11 EUTECTRODE MANUAL ELECTRODES 11.10 WELDING CAST IRONS

2-44 Ø 2.5 - 3.2 - 4.0 Special electrode with high nickel content for contaminated cast irons. This electrode is highly recommended for welding without preheating old and oil-soaked cast irons, whetever for joining or overlaying, as well as for buttering before welding with bronze electrodes. Rm: 330 MPa Rp0.2: 300 MPa Nickel iron electrode with bimetallic core wire developed for welding grey cast iron to steel or engineering cast iron grades with spheroidal graphite. Deposits have highest mechanical properties and exceptional crack resistance. Rm: 490 MPa Rp0.2: 330 MPa A5: 13.5% Nickel based electrode developed for welding and repair of grey cast iron. Regular deposits. Increased crack resistance. Rm: 320 MPa Nickel iron electrode developed for welding grey cast iron and ductile cast iron. High crack resistance. Rm: 325 MPa Rp0.2: 310 MPa Nickel based electrode developed for welding grey cast iron with soft, machinable deposits. Very easy to use. Rm: 480 MPa Rp0.2: 230 MPa Nickel iron electrode with bimetallic core wire developed for welding cast iron in all positions. High mechanical properties and crack resistance. Rm: 345 MPa Rp0.2: 305 MPa

XHD 2230 Ø 2.5 - 3.2 - 4.0

XHD 2480 Ø 2.5 - 3.2 2-23 Ø 2.5 - 3.2 - 4.0 2-24 Ø 2.5 - 3.2 - 4.0 2240 Ø 2.5 - 3.2 - 4.0

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11.20 WELDING STEELS

Designations 640 Ø 2.5 - 3.2 - 4.0 Properties Electrode for fully austenitic steel deposits with exceptional hot crack resistance. This alloy is developed for repair and assembly of high alloy and carbon steels. Rm: 650 MPa Rp0.2: 450 MPa A5: 38% Work hardened: 400 HV30 High impact resistance. Rebuilding worn parts in 14% manganese steel. Buttering layer before wear facing. Rm: 680 MPa Rp0.2: 510 MPa A5: 32% Work hardened: 400 HV30 High alloy tool & die repairs and joining dissimilar steels. Highest tensile strength and crack resistance. Exceptionally easy weldability. Rm: 860 Mpa Rp0.2: 690 MPa A5: 20% Specifically designed for joining and buttering a wide range of steels which are either of unknown composition or considered 'difficult - to weld' and where matching electrodes do not exist. Rm: 820 MPa Rp0.2: 620 MPa A5: 25% Assembly, rebuilding, buttering layer for alloyed and hardenable steels before wear facing. High resistance to cracking. Rm: 675 MPa Rp0.2: 550 MPa A5: 40% Electrode deposits a high nickel alloy with an austenitic structure for welding all kinds of steel and steel castings in thick sections. Welding nickel alloys and Inconel 600®TM. Working temperature: from cryogenic up to 980°C. Rm: 670 MPa Rp0.2: 420 MPa A5: 45% High nickel alloy electrode producing deposits with excellent toughness, capable of withstanding high stress even under impact loading. Rm: 590 MPa Rp0.2: 420 MPa A5: 30% Electrode developed for high speed welding of difficult-to-weld, galvanised or dissimilar steels. Rebuilding and buttering layers before wear facing. High metal recovery (170%). Rm: 800 MPa Rp0.2: 670 MPa A5: 17.5%

XHD 646 Ø 2.5 - 3.2 Ø 4.0 - 5.0 Xuper 680S Ø 1.6 - 2.0 - 2.5 Ø 3.2 - 4.0 690 SF Ø 2.5 - 3.2

Xuper 690 Ø 2.5 - 3.2 - 4.0 Xuper 2222 Ø 2.5 - 3.2 Ø 4.0 - 5.0

XHD 2222 Ø 2.5 - 3.2 - 4.0 XHD 6868 Ø 2.5 - 3.2 - 4.0

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11.23 WELDING STAINLESS STEELS

Designations E 307-17 Ø 2.5 - 3.2 - 4.0 Properties Rutile electrode depositing a corrosion-resistant austenitic stainless steel. The deposited metal can be work hardened combining good ductility and toughness properties. Rm: 610 MPa Rp0.2: 445 MPa A5: 40% AWS A 5.4: E 307-17 Electrode developed for assembly and repair of AISI 304 type stainless steel. Rm: 590 MPa Rp0.2: 430 MPa A5: 40% AWS A 5.4: E 308 L-17 Rutile type electrode depositing low carbon austenitic-ferritic stainless steel. It has increased corrosion resistance, notably to intercrystalline corrosion up to 350°C and in air oxidation up to 1050°C. Rm: 640 MPa Rp0.2: 480 MPa A5: 30% AWS A 5.4: E 309 MoL-17 Electrode developed for assembly and repair of AISI 309 (25/12), 310 (25/20), and 314 type refractory steel. Excellent resistance to heat (up to 1050 °C) and corrosion. Rm: 600 MPa Rp0.2: 400 MPa A5: 35% AWS A 5.4: E 310-17 Electrode developed for assembly and repair of AISI 316 type stainless steel. Rm: 590 MPa Rp0.2: 440 MPa A5: 40% AWS A 5.4: E 316 L-17. Rutile type electrode depositing austenitic stainless steel stabilized with niobium. It has increased corrosion resistance, notably to intercrystalline corrosion and pitting up to 400°C and in air oxidation up to 800°C. Rm: 620 MPa Rp0.2: 470 MPa A5: 35 % AWS A 5.4: E 318-17 Electrode developed for homogeneous welding of Z2 NCDU 25-20 (Uranus B6 ®TM) type stainless steels. Assembly and repair of corrosion resistant steel (sulphuric or phosphoric environments) or refractory steel (up to 1000°C) Rm: 590 MPa Rp0.2: 410 MPa A5: 40 % AWS A 5.4: E 385-17

E 308L-17 Ø 2.5 - 3.2 - 4.0 E309MoL-17 Ø 3.2 - 4.0

E 310-17 Ø 2.5 - 3.2 - 4.0

E 316L-17 Ø 2.0 - 2.5 Ø 3.2 - 4.0 E 318-17 Ø 2.5 - 3.2 - 4.0

E 385-17 Ø 2.5 - 3.2 - 4.0

Especially for Maintenance Welding of Stainless Steels

Designations 33000 Ø 2.0 - 2.5 - 3.2 33300 Ø 2.5 - 3.2 Properties Electrode developed for assembly and repair of AISI 304 type stainless steel. Rm: 615 MPa Rp0.2: 450 MPa A5: 42 % AWS A 5.4: E 308L -17 Electrode developed for assembly and repair of AISI 309 (25/12), 310 (25/20), and 314 type refractory steel. Excellent resistance to heat (up to 1050 °C) and corrosion. Rm: 565 MPa Rp0.2: 395 MPa A5: 36 % AWS A 5.4: E 310-16 Electrode developed for assembly and repair of AISI 316 type stainless steel. Rm: 700 MPa Rp0.2: 535 MPa A5: 30 % AWS A 5.4: E 316L -17

33500 Ø 2.0 - 2.5 - 3.2

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Especially for Maintenance Welding of Stainless Steels - Continued

Designations Castinox D Ø 2.5 - 3.2 Properties Electrode developed for assembly and repair of AISI 309 (25/12), 310 (25/20), and 314 type refractory steel. Excellent resistance to heat (up to 1200 °C) and corrosion. Rm: 555 MPa Rp0.2: 399 MPa A5: 33 %

11.26 WELDING STRUCTURAL STEELS

Designations 6601 Ø 2.5 - 3.2 6666 Ø 2.5 - 3.2 - 4.0 Properties Rutile electrode for welding usual structural steels in all positions. Rm: 570 MPa Re: 480 MPa A5: 21 % AWS A 5.1: E 6013 Basic double extruded flux coated electrode for welding low alloy steel. Rm: 570 MPa Re: 420 MPa A5: 20 % AWS A 5.5: E 8018 G

11.30 WELDING COPPER ALLOYS

Designations 285 Ø 3.2 - 4.0 XHD 1855 Ø 3.2 Properties Bronze electrode developed for assembly and repair of copper based alloys and resurfacing of steel or cast iron parts subject to frictional wear. Rm: 380 MPa A5: 18 % Hardness: 125 HB Complex bronze electrode developed for marine applications needing high strength / ductility properties and resistance to wear by cavitiation, corrosion, friction. Rm: 705 Mpa A5: 24% Hardness: 175 HV30

11.35 WELDING ALUMINIUM ALLOYS

Designations 2101S Ø 2.5 - 3.2 XHD 2100 Ø 3.2 Properties Electrode developed for the assembly and repair of aluminium alloy castings. Rm: 170 MPa Rp0.2: 95 MPa A5: 5 % Electrode developed for welding wrought aluminium alloys particularly when anodisation is required .

11.40 GOUGING, CHAMFERING, CUTTING

Designations CutTrode 01 Ø 3.2 - 4.0 - 5.0 ChamferTrode 03 / 04 Ø 3.2 - 4.0 Properties Electrode developed for gas free, high speed cutting and piercing work on all metals in all positions. Electrode developed for fast metal removal and surface preparation by chamfering, grooving and gouging. Elimination of worn and cracked surfaces.

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11.50 CARBIDE ALLOY COATINGS

Designations N 700 Ø 3.2 XHD 6710 Ø 3.2 - 4.0 XHD 6715 Ø 3.2 Properties Electrode depositing chromium carbides for wear protection against abrasion combined with pressure and moderate impact. Hardness: 59-64 HRC. High metal recovery (215%) electrode developed for protection against wear by abrasion and erosion. The hardness is obtained in a single pass. Hardness: 63-68 HRC. High metal recovery (255%) electrode developed for protection against wear by abrasion and erosion. Maximum hot abrasion resistance up to 650°C. The hardness is obtained in a single pass. Hardness: 65 HRC. High metal recovery (170%) electrode developed for anti-wear resurfacing of parts subject to combined stresses: abrasion, pressure and moderate impact by medium to fine particles. Hardness: 55-60 HRC. High metal recovery (250%) electrode developed for protective coatings against wear by abrasion in the presence of very fine and very hard abrasive materials. Maximum hot abrasion resistance up to 650°C. Hardness: 900-1100 HV30 Thanks to high density and good distribution of hard DIAMAX particles in a hard nickel based matrix, the deposit obtained with this electrode is highly resistant to abrasion, erosion and corrosion at high temperatures. Hardness: 56 HRC

5006 Ø 2.5 - 3.2 Ø 4.0 - 5.0 N 6070 Ø 4.0

6088 Ø 5.0

TECHNICAL NOTE

Microstructures of the primary EutecTrode alloys from the 11.50 carbide alloy coatings.

XHD 6715 5006

N 6070

N 700

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11.53 ALLOY STEEL COATINGS

Designations 2 Ø 2.5 - 3.2 6 Ø 2.5 - 3.2 Properties Electrode deposits a chromium, molybdenum, manganese alloy steel developed for anti-wear coating of parts to resist impact, pressure and abrasion. Hardness: 55-60 HRC Electrode for High Speed Steel type deposits developed for fabrication or repair of damaged tools. Increased resistance to shock, pressure, cracking and oxidation at high temperature. Hardness: 62 HRC High metal recovery (150%) electrode developed for anti-wear coatings on parts or tools to resist high pressures, impacts and wear. Hardness: 53-58 HRC High metal recovery (150%) electrode developed for protective coatings on parts subject to wear by fatigue (cutting tools), metal-to-metal friction and by impacts with abrasion. Hardness: 53-57 HRC High metal recovery (135%) electrode developed for protective coatings on parts subject to elevated temperatures in combined wear regimes: heat ­ corrosion ­ friction. Hardness as welded: 470 HV30 Work hardened: 530 HV30 Electrode deposits a low temperature precipitation hardening martensitic steel (maraging steel) for making composite tools suitable for cold working and cutting operations. Hardness as welded: 36 HRC. Hardness after heat treatment 480 °C for 4 hours: 52 HRC Electrode developed for coating parts to resist deformation and wear by high pressure loading. Rebuilding and buttering layers before wear facing. Rm : 960 MPa Rp0.2 : 810 MPa A5: 13 % Hardness: 320 HV30

N 102 Ø 3.2 - 4.0 EC 3292 Ø 2.5 - 3.2

XHD 6804 Ø 2.5 - 3.2 - 4.0

6055 Ø 3.2 - 4.0

35200 Ø 3.2 - 4.0

11.56 NICKEL ALLOY AND COBALT ALLOY COATINGS

Designations XHD 6865 Ø 2.5 - 3.2 Properties High metal recovery (150%) electrode depositing a special nickel alloy, developed for wear protective coatings on hot working tools and dies Working temperature: up to 950°C. Hardness as welded: 240 HB Work hardened: 360-380 HB. High metal recovery (170%) electrode depositing a special nickel alloy, developed for wear protective, creep resistant coatings on hot working tools and dies. Working temperature: up to 1100°C. Hardness as welded: 200 HB Work hardened: 350 HB.

XHD 6817 Ø 3.2

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11.56 NICKEL ALLOY AND COBALT ALLOY COATINGS - CONTINUED

Designations N 9025 Ø 3.2 Properties Electrode deposits a cobalt based, work hardening alloy (Grade 25 type) having high hot crack resistant mechanical properties and a superior resistance to metal-to-metal friction, oxidation, pressure and thermal fatigue. Hardness as welded: 250 HV30 Work hardened: 440 HV30 Electrode deposits a cobalt based alloy with lower hardness (Grade 6 type), intended for resurfacing for protection against wear combined with corrosion, heat and abrasion. The deposited metal retains its hardness at high temperature. High resistance to impact and hot cracking. Hardness: 40-45 HRC Electrode deposits a work hardening cobalt based alloy (Grade 21 type), intended for resurfacing for protection against wear combined with corrosion, heat and impact. The deposited alloy retains its properties at high temperature. Hardness as welded: 320 HV30 Work hardened: 525 HV30

N 9060 Ø 3.2

N 9080 Ø 3.2 - 4.0

12 CASTOMIG-MAG WELDING WIRES 12.23 WELDING STAINLESS STEELS

Designations 45500 S (ER 316LSi) Ø 0.8 - 1.2 - 1.6 15 Kg 45503 S (ER 308LSi) Ø 0.8 -1.0 Ø 1.2 - 1.6 15 Kg 45513 S (ER 310) Ø 1.0 - 1.2 15 Kg 45516 S (ER 309LSi) Ø 1.0 15 Kg Properties MAG wire for assembly and repair of AISI 316 type stainless steel. Rm: 560 MPa Rp0.2: 370 MPa A5: 35 % AWS SFA 5.9: ER 316 LSI

MAG wire for assembly and repair of AISI 304 type stainless steel. Rm 600 MPa Rp0.2: 360 MPa A5: 40 % AWS SFA 5.9: ER 308 LSI

MAG wire for assembly and repair of refractory (AISI type 310) stainless steel that needs to resist corrosion and oxidation in air up to 1150°C. Rm: 580 Mpa Rp0.2: 380 Mpa A5: 42 % AWS SFA 5.9: ER 310 MAG wire for heterogeneous welding of steels that are difficult to weld and for welding 309 type stainless steel. Rm: 600 MPa Rp0.2: 400 MPa A5: 40 % AWS SFA 5.9: ER 309LSi

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12.23 WELDING STAINLESS STEELS - CONTINUED

Designations 45552 S (ER 347) Ø 0.8 - 1.0 - 1.2 15 Kg 45554 S (ER 307 Si) Ø 0.8 - 1.0 Ø 1.2 - 1.6 15 Kg Properties MAG wire for welding 304 type stainless steels stabilized with Ti or Nb (321 and 347). Rm: 660 MPa Rp0.2: 460 MPa A5: 42 % AWS A 5.9: ER 347 MAG wire for welding austenitic steels with manganese and welding steels that are difficult to weld or with thick sections. Rm: 620 MPa Rp0.2: 420 MPa A5: 40 %

12.26 WELDING STRUCTURAL STEELS

Designations 45250 Ø 0.8 - 1.0 - 1.2 15 Kg 45252 Ø 0.8 - 1.0 - 1.2 15 Kg 45257 Ø 0.8 - 1.0 - 1.2 15 Kg Properties MAG wire for welding non-alloyed or low alloyed steel in general use. Rm: >570 MPa Rp0.2: >420 Mpa A5: >19 % EN 440: G4Si1 MAG wire for welding steel resistant to heat and creep up to 570 °C. Rm: >600 MPa Rp0.2: >500 MPa A5: >20% MAG wire for welding high yield strength steel (up to 700MPa) used in highly stressed parts of fabrication-welded structures. Rm: 830 MPa Rp0.2: 760 MPa A5: 18 % AWS A 5.28: ER 100S-G

12.30 WELDING COPPER ALLOYS

Designations 45703 Ø 1.0 - 1.2 15 Kg 45706 Ø 1.0 - 1.2 15 Kg 45751 Ø 0.8 - 1.0 Ø 1.2 - 1.6 15 Kg Properties MIG wire for assembly and coating of plain bronze (copper-tin) parts. Rm: 260 MPa A: 20 % DIN 1733 SG-CuSn6 MIG wire for assembly and coating of copper and its alloys. Copper-Silicon alloy (3%). Rm: 350 MPa Rp0.2: 150 MPa A5: 40 % DIN 1733: SG Cu Si 3 MIG wire for welding copper-aluminum alloys and coating parts subject to wear by metal-to-metal friction. Very good resistance to corrosion by sea water. Rm: 430 MPa A: 40 % Hardness: 100 HB

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12.35 WELDING ALUMINIUM ALLOYS

Designations 45802 Ø 0.8 - 1.0 - 1.2 7.5 Kg 45803 Ø 1.0 - 1.2 - 1.6 7.5 Kg 45806 Ø 1.0 - 1.2 7.5 Kg Properties MIG wire (type AG5, 5356) for welding aluminium alloys. Homogeneous welding of aluminum-magnesium alloys with 5% Mg. Rm: >235 MPa Rp0.2: >110 MPa A5: >17 % EN: AW­AlMg5(A) MIG wire (type AS5, 4043) for welding aluminum-magnesium alloys and reclamation of defective foundry castings. Rm: >120 MPa Rp0.2: >40MPa A5: >8 % EN: AW-AlSi5(A) MIG wire (type AG4MC, 5183) for welding aluminum-magnesium alloys. Rm: >275 MPa Rp0.2: >125 MPa A5: >17 % EN: AW-AlMg5Mn1(A)

12.53 ALLOY STEEL COATINGS

Designations 45351 Ø 0.8 - 1.0 Ø 1.2 - 1.6 15 Kg 45365 Ø 1.0 - 1.2 15 Kg Properties MIG wire for producing anti-wear coatings on parts subject to combined pressure, moderate abrasion and significant impacts. Hardness: 60 HRC DIN 8555: SG 6-60-GTZ MIG wire for producing anti-wear coatings on parts subject to combined pressure and abrasion, which is only machineable by grinding. Hardness: 58 HRC MSG 3-GZ-60

12.56 NICKEL ALLOY COATINGS

Designations 45654 Ø 1.0 - 1.2 15 Kg Properties MIG wire for welding Inconel 625 ® and nickel based alloys. Austenitic alloy for assembly of dissimilar steels. Rm: > 700 Mpa Rp0.2: > 420 Mpa A5: >25 % AWS 5.4 14: ER NiCrMo-3

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13 CASTOTIG WELDING RODS 13.20 WELDING SPECIAL STEELS

Designations 45507 WS (ER 312) Ø 1.0 - 2.0 Ø 2.4 - 3.2 45612W Ø 1.0 - 1.6 Ø 2.0 - 2.4 Properties TIG rod for assembling or coating tool steel or dissimilar steels. Buttering layer before surfacing. Rm: 750 Mpa Rp0.2: 530 Mpa A5: 25 % AWS SFA 5.9: ER 312 TIG rod for welding Inconel 600 ®, nickel based alloys and tool steels or low to highly alloyed steels that are difficult to weld. Assembly of copper with steel. Rm: >620 Mpa Rp0.2: >380 Mpa A5: >35 % AWS SFA 5.14: ER NiCr­3 TIG rod for welding Inconel 625 ® and nickel based alloys. Austenitic alloy for assembly of dissimilar steels. Rm: > 700 Mpa Rp0.2: > 420 Mpa A5: >25 % AWS 5.4 14: ER NiCrMo-3

45654W Ø 1.6 - 2.0 - 2.5

13.23 WELDING STAINLESS STEELS

Designations 45500 WS (ER 316L) Ø 1.6 - 2.0 - 2.4 45503 WS (ER 308L) Ø 1.0 - 1.6 - 2.0 Ø 2.4 - 3.2 45513 WS (ER 310) Ø 1.6 - 2.0 45552W (ER 347) Ø 1.0 - 2.0 Ø 2.4 - 3.2 Properties TIG rod for assembly and repair of AISI 316 type stainless steel. Rm: 560 Mpa Rp0.2: 370 Mpa A5: 35 % AWS SFA 5.9: ER 316 L TIG rod for assembly and repair of AISI 304 type stainless steel. Rm: 600 MPa Rp0.2: 360 MPa A5: 40 % AWS SFA 5.9: ER 308 L

TIG rod for welding refractory stainless steel (AISI type 310) that needs to resist corrosion and oxidation in air up to 1150°C. Rm: 580 MPa Rp0.2: 380 MPa A5: 42 % AWS SFA 5.9: ER 310 TIG rod for welding 304 type stainless steel stabilized with Ti or Nb (321 and 347). Rm: 660 MPa Rp0.2: 460 MPa A5: 42 % AWS SFA 5.9: ER 347

13.26 WELDING STRUCTURAL STEELS

Designations 45252W Ø 2.0 - 3.0 45255W Ø 2.0 - 2.4 - 3.0 Properties TIG rod for the assembly and resurfacing of 15 CD 4 type steel. Resists heat up to temperatures of 550°C. Rm : >510 MPa Rp0.2: >355 MPa A5: >20 % AWS A 5.28-29 : ER80 S-G TIG rod for fabrication welding mechanical structural steel assemblies. Rm : > 530 MPa Rp0.2: > 385 MPa A5: > 20 % AWS A 5.18 : ER 70 S 6

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13.30 WELDING COPPER ALLOYS

Designations 45701W Ø 2.0 45703W Ø 2.0 - 2.5 45704W Ø 2.0 - 3.0 Properties TIG rod for assembly and coating of parts subject to marine corrosion and notably the 70/30 or 90/10 copper-nickel alloys. Rm: 420 MPa Rp0.2: 240 MPa A5: 36 % DIN 1733: SG-Cu Ni 30 Fe TIG rod for assembly and coating of plain bronze (copper-tin) parts. Fights against wear by metal-to-metal friction. Rm: 260 MPa Hardness: 80 HB A: 20 % DIN 1733: SG-Cu Sn 6 TIG rod for assembly and coating of pure copper. The deposited metal provides high electrical conductivity. Particularly recommended for copper that is difficult to weld. Rm: 200 Mpa Hardness: 60 HB A: 30 % DIN 1733: SG-Cu Ag TIG rod for assembly and coating of copper and its alloys. Copper-silicon alloy (3%). Rm: 350 MPa Hardness: 80 HB Din 1733: SG Cu Si 3

45706W Ø 2.0

13.35 WELDING ALUMINUM ALLOYS

Designations 45801W Ø 2.0 - 3.2 45802W Ø 2.0 - 2.5 Ø 3.2 - 4.0 45806W Ø 2.0 Properties TIG rod for welding aluminum (up to 99.5%) and its alloys. Rm : >65 MPa Rp0.2: >20 MPa A5: >35 % AWS A 5.10: ER 1100 DIN 1732 : SG Al99.5Ti TIG rod for welding aluminum-magnesium alloys and similar types of aluminum alloys. Rm: >235 MPa Rp0.2: >110 MPa A5: >17 % AWS A 5.10: ER 5356 DIN 1732 : SG Al Mg 5 TIG rod for welding aluminum-magnesium alloys. Excellent mechanical properties. Rm: >275 MPa Rp0.2: >125 MPa A5: 17 % AWS A 5.10: ER 5183 DIN 1732: SG AlMg 4.5 Mn

13.53 ALLOY STEEL COATINGS

Designations 45301W Ø 1.0 - 1.6 Ø 2.0 - 2.4 45303W Ø 1.0 - 1.6 Ø 2.0 - 2.5 Properties TIG rod for coating parts subject to heat, thermal shock and plastic deformation. Hardness as welded: 46 HRC TIG rod for HSS coating of parts subject to combined mechanical wear: adhesion, friction, shock or contact fatigue at elevated temperatures. Hardness as welded: 63 HRC

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13.53 ALLOY STEEL COATINGS - CONTINUED

Designations 45305W Ø 1.0 - 1.6 45351 W Ø 1.0 - 1.6 45355 W Ø 1.0 - 1.6 - 2.0 Properties TIG rod for preventive and repair coating of hot working tools. Hardness as welded: 53 HRC TIG rod for coating parts subject to heat, impact, sliding and rolling abrasion. Hardness as welded: 60 HRC TIG rod Maraging type. Martensitic precipitation hardening Ni-Co-Mo steel for cold metal working applications. Hardness as welded: 34 HRC Hardness after heat treatment 480°C for 4 hours: 51 HRC

13.56 NICKEL ALLOY AND COBALT ALLOY COATINGS

Designations 45406W Ø 3.0 - 4.0 45412W Ø 3.0 45421W Ø 3.0 45612W Ø 1.0 - 1.6 Ø 2.0 - 2.4 Properties TIG rod cobalt based alloy (Grade 6 type). Excellent resistance to heat, corrosion, wear, cavitation and metal-to-metal friction. Hardness as welded: 41 HRC TIG rod cobalt based alloy (Grade 12 type). Excellent resistance to heat, corrosion, wear, cavitation and metal-to-metal friction. Hardness as welded: 48 HRC TIG rod cobalt based alloy (Grade 21 type). Excellent resistance to heat, corrosion, wear, cavitation and metal-to-metal friction. Hardness as welded: 330 HV30 Work hardened: 450 HV30 TIG rod for welding Inconel 600 ®TM, nickel based alloys and tool steels or low to highly alloyed steels that are difficult to weld. Assembly of copper with steel. Rm: >620 Mpa Rp0.2: >380 MPa A5: >35 % AWS A 5.14: ER NiCr­3 TIG rod for welding Inconel 625 ®TM and nickel based alloys. Austenitic alloy for assembly of dissimilar steels. Rm: > 700 Mpa Rp0.2: > 420 Mpa A5: >25 % AWS A 5.14: ER

45654W Ø 1.6 - 2.0 - 2.5

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14 ENDOTEC CORED WIRES (GAS SHIELDED) 14.10 WELDING CAST IRONS

Designations DO*23 Ø 1.0 - 1.2 15 Kg Properties Metal cored nickel-iron wire developed for welding cast iron assemblies or rebuilding. Joining cast iron to steel. Hardness: 200 HV30

14.20 WELDING STEELS

Designations DO*02 Ø 1.2 - 1.6 15 Kg DO*22 Ø 1.6 15 Kg DO*266 S Ø 1.6 15 Kg Properties Metal cored wire developed for welding difficult-to-weld steels, armour plate and manganese steel. Rm: 650 Mpa Rp0.2: 390 Mpa A 35 % Hardness as welded: 170 HV30 Work hardened: 310 HV30 Inconel 600®TM type metal cored wire developed for weld surfacing nickel alloys, low or high alloy steel, and refractory steel and alloys. Rm: 650 Mpa Rp0.2: 370 Mpa A5: 40% Hardness as welded: 165 HV30 Work hardened: 320 HV30 Copper-coated cored wire electrode providing fast solidification, rutiletype slag characteristics. Rm: 510 Mpa A5: 22%

14.23 WELDING STAINLESS STEELS

Designations DO*28 S Ø 1.2 15 Kg Properties Metal-flux cored wire intended for welding AISI 316 L type steel. Rm: 500-600 Mpa Rp0.2: 380-450 Mpa A5: 35-45 % AWS A 5.9: E 316 LT-1

14.50 CARBIDE ALLOY COATINGS

Designations DO*11 Ø 1.6 15 Kg DO*48 Ø 1.6 15 Kg Properties Metal cored wire developed for producing anti-wear coatings (tungsten carbides in a nickel based matrix) on parts subject to severe abrasion in combination with heat and corrosion. Hardness (matrix): 55 HRC Hardness (carbides): 2400 HV0.4 Metal cored wire developed for producing anti-wear coatings (tungsten carbides in an iron base matrix) on parts subject to severe abrasion or erosion combined with moderate pressure and impacts. Hardness (matrix): 55 HRC Hardness (carbides): 2300 HV0.3

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14.50 CARBIDE ALLOY COATINGS - CONTINUED

Designations DO*390 N Ø 1.6 15 Kg DO*395 N Ø 1.2 15 Kg Properties NanoAlloy patended, gas shielded, metal cored alloy wire, ideal for maintenance and repair applications or batch manufacturing where highest integrity welding, efficiency and productivity are required. Hardness (one layer): 70 HRC The slag-free deposit contains a high volume fraction of ultra-hard phases which ensures an excellent performance against abrasion, erosion combined with moderate impact. Hardness (one layer): 69 HRC

14.53 ALLOY STEEL COATINGS

Designations DO*04 Ø 1.2 - 1.6 15 Kg DO*05 Ø 1.6 15 Kg DO*06 Ø 1.6 15 Kg DO*13 Ø 1.2 - 1.6 15 Kg DO*15 Ø 1.2 - 1.6 15 Kg DO*16 Ø 1.6 15 Kg DO*30 Ø 1.2 - 1.6 15 Kg DO*33 Ø 1.6 15 Kg DO*55 Ø 1.6 15 Kg Properties Metal cored wire develped for producing anti-wear coating depositing steel alloyed with chromium, cobalt and molybdenum. Excellent resistance to wear by metal-to-metal friction, mechanical properties stable up to 500°C. Hardness: 48 HRC Metal cored wire developed for producing work hardening anti-wear coatings, having an excellent resistance to impacts, pressure and high stress abrasion. Hardness as welded: 250 HV30 Work hardened: 380 HV30 Metal cored wire developed for producing anti-wear coatings with High Speed Steel properties for fabrication or repair of damaged tools. Increased resistance to shock, pressure, cracking and oxidation at high temperature. Hardness: 63 HRC Metal cored wire developed for producing anti-wear coatings, having a high resistance to pressure, impacts and moderate abrasion. Hardness: 58 HRC Metal cored wire developed for producing anti-wear coatings on parts subject to impact, abrasion and contact fatigue. Hardness: 58 HRC Metal cored wire developed for producing anti-wear coatings having excellent resistance to shocks and to pressures up to 550°C. Hardness: 48 HRC. Metal cored wire developed for producing single pass, anti-wear coatings on parts subject to abrasion and erosion by small particles. Hardness: 67 HRC Metal cored wire developed for producing anti-wear coatings having excellent resistance to abrasion and erosion at high temperatures up to 650°C. Hardness: 68 HRC Metal cored wire Maraging type (Martensitic Ni-Co-Mo steel with precipitation hardening) developed for producing anti-wear coatings on parts subject to compression, creep and cold cutting. Hardness as welded: 35 HRC Hardness after heat treatment 480°C for 3 to 7 hours: 58 HRC

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14.53 ALLOY STEEL COATINGS - CONTINUED

Designations DO*322 Ø 1.6 15 Kg DO*327 Ø 1.6 15 Kg DO*332 Ø 1.6 15 Kg CaviTec GMA Ø 1.2 - 1.6 15 Kg Properties Metal cored wire developed for producing multi pass, anti-wear coatings on parts subject to abrasion and erosion by small particles. Hardness: 65 HRC Metal cored wire developed for producing multi pass, crack-free coating of parts subject to wear by combined abrasion and impact with high pressures. Hardness: 58 HRC Metal cored wire developed for multi pass, anti-wear coatings having excellent resistance to abrasion and moderate impact. Hardness: 60 HRC Metal cored wire developed with a patented alloy system producing anti-wear coatings with outstanding cavitation resistance on hydraulic turbines and pumping equipment. Hardness as welded: 280 HV30 Work hardened: 390 HV30

14.56 NICKEL ALLOY AND COBALT ALLOY COATINGS

Designations DO*60 Ø 1.2 - 1.6 15 Kg DO*70 Ø 1.6 15 Kg DO*80 Ø 1.6 15 Kg DO*85 Ø 1.6 15 Kg Properties Metal cored wire depositing a Grade 6 type cobalt base alloy. Excellent resistance to heat, corrosion, wear, cavitation and metal-to-metal friction. Hardness: 41 HRC Metal cored wire depositing a Grade 12 type cobalt base alloy. Excellent resistance to heat, corrosion, abrasion, cavitation and metal-to-metal friction Hardness: 48 HRC Metal cored wire depositing a Grade 21 type cobalt base alloy. Excellent resistance to heat, corrosion, wear, cavitation and metal-to-metal friction. Hardness as welded: 330 HV30 Work hardened: 450 HV30 Metal cored wire depositing a Grade 25 type cobalt base alloy. Excellent resistance to thermal shocks and pressures, as well as abrasion at temperatures up to 950°C and oxidation up to 1200°C. Hardness as welded: 250 HV30 Work hardened: 380 HV30

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15 TEROMATEC CORED WIRES (SELF SHIELDED) 15.50 CARBIDE ALLOY COATINGS

Designations 3952 Ø 1.6 - 2.8 15 kg 4395 N Ø 2.8 15 Kg 4601 Ø 1.2 - 1.6 - 2.8 15 Kg 4660 Ø 1.2 - 1.6 - 2.8 15 Kg Properties Self shielded cored wire developed for coating parts subject to hot abrasion up to service temperature of 600°C. Hardness: 65 HRC Self shielded cored wire developed for coating parts subject to abrasion and erosion combined with moderate impact. Hardness: 69 HRC Self shielded cored wire developed for coating parts subject to abrasion without impact. Hardness: 60 HRC Self shielded cored wire developed for coating parts subject to abrasion by medium and large bodies Hardness: 63 HRC

15.53 ALLOY STEEL COATINGS

Designations 3205 Ø 1.6 - 2.4 - 2.8 15 Kg 4415 Ø 1.6 - 2.8 15 Kg 4630 Ø 2.8 15 Kg 4923 Ø 1.2 - 1.6 - 2.8 15 Kg Properties Self shielded cored wire developed for anti-wear coating of low or alloy steel parts with work hardening properties against heavy impact, pressure and friction. Hardness as welded: 250 HV30 Work hardened: 390 HV30 Self shielded cored wire developed for anti-wear coating of low or alloy steel parts to resist impact and abrasion up to service temperature of 500°C. Hardness: 55 HRC Self shielded cored wire developed for anti-wear coating of low or alloy steel parts in single pass to resist severe abrasion and erosion by fine particles. Hardness: 67 HRC Self shielded cored wire developed for crack-free coating of parts subject to wear by combined abrasion and impact with high pressures. Hardness: 57 HRC

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TECHNICAL NOTE

Sample photographs of wearfacing applications using Castolin Maintenance & Repair welding alloys. We have a Terolink technical library describing many application case studies (process, alloy used, context of the part and application, operating procedure, precautions, etc.). This electronic database makes it possible for us to better solve the wear problems encountered and to propose practical solutions as part of our technial service to industry.

CRUSHER ROTOR / QUARRY

CROWN GEAR RING ­ SUGAR REFINERY

TONGS / STEEL INDUSTRY

ROTARY CUTTER / CIVIL ENGINEERING

MOULD / AUTOMOTIVE

ROTOR DISCS / CEMENT PLANT

HAMMERS / WASTE RECYCLING

HYDROPULPER ROTOR / PAPER MILL

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21 ECOBRAZ RANGES 21.10 CAPILLARY SILVER BRAZING ALLOYS

Cadfree® Silver Alloys

Designations 1020 B - T - XFC Properties Castolin 1020 is a CADFREE® quaternary Ag-Cu-Zn-Sn brazing alloy for capillary joining of ferrous metals, plus Cu and Ni alloys. Very high Ag content gives excellent fluidity, low joining temperature and increased mechanical strength in joints. Water/gas-tight sealing of joints. Deposit colour: stainless steel. A high silver-copper-zinc-tin alloy. Formulated for maximum fluidity and wettability on the metals specified. High fluidity, low heat input and very good mechanical properties make this latest silver alloy exceptional. Maximum Safety Margin, thanks to its high silver content: either by capillary attraction, in the case of close-fitting components, or by moulding in the case of large joint gaps. Joints built up with Castolin 181 are especially resistant to impact and vibrations.

1666 1666 XFC 181 - 181 F

Silver Alloys with Cadmium

Designations 1010 XFC Properties Castolin 1010 XFC is a brazing alloy for capillary joining of ferrous metals, plus Cu and Ni alloys. High Ag content plus Cd gives outstanding fluidity, lowest joining temperature and high mechanical strength in joints. Water/gas-tight sealing of joints. The high silver content of this filler alloy promotes joining by capillarity, and makes this product ideal for joining dissimilar metals. 1030 XFC is recommended for all maximum safety margin applications. 1802 is a quaternary Ag-Cd-Cu-Zn brazing alloy for capillary joining of ferrous metals, plus Cu and Ni alloys. High Ag content plus Cd gives outstanding fluidity, lowest joining temperature and high mechanical strength in joints. Water/gas-tight sealing of joints. Versatile and economical, this low temperature brazing alloy is designed for application on copper, brass, bronze and steels. Especially recommended for dissimilar metal combinations such as carbon or alloy steels to copper, brass or bronze.

1030 XFC

1802 - 1802 L 1802 XFC

1810 XFC

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22.10 SELF-FLUXING BRAZING ALLOYS FOR COPPER

Self-Fluxing Copper Alloys

Designations 1803D 1805 RB 5246 Properties Self-fluxing brazing alloy for copper to copper joining. Self-fluxing brazing alloy for copper to copper joining. RB 5246 is a copper-phosphorus brazing alloy in bare rod form, for capillary joining of copper and copper alloy parts. It is designed to deliver low-cost, watertight joints and is particularly for mass production applications. When joining copper to copper with this product, a separate flux is not required. RB 5280 is a Cu P Ag brazing alloy with 2% Ag, designed for joining Cu and Cu alloys. Ag content gives increased fluidity and better penetration of joints, Water/gas-tight sealing of joints. RB 5283 is a Cu Ag P brazing alloy with 15% Ag, for capillary joining of Cu and Cu alloys. Ag content gives improved fluidity and increased mechanical strength in joints. Water/gas-tight sealing of joints. RB 5286 is a Cu P Ag brazing alloy with 5% Ag, designed for joining Cu and Cu alloys. Ag content gives increased fluidity and better penetration of joints. Water/gas-tight sealing of joints. Product form: bare alloy rod Deposit colour: copper (after cleaning)

RB 5280

RB 5283

RB 5286

23.10 GAS WELDING AND BRAZING ALLOYS

Brazing-Brass/Bronze Alloys

Designations Properties

146 MF - 146 XFC 146 is a bronze type alloy for use with cast-iron and carbon steel components, also recommended for galvanised steels and copper base alloys. 16 XFC A silver containing alloy for producing high strength joints by either thin flowing or bead formation on carbon and alloy steel applications, and especially suitable for joining carbide tips. A copper base alloy producing high fluidity or bead forming characteristics by simply controlling the heat input combination. Deposits are of exceptional joint strength and crack resistance, and are fully machinable and will work harden under impact loading conditions.

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Brazing-Brass/Bronze Alloys - CONTINUED

Designations 18 - 18 MF 18 XFC Properties Application designed welding rod for the repair and maintenance of brass, bronze and copper parts. An economical silver bearing brazing type alloy for use on a wide range of brasses and bronzes, and a combination of these, also suitable for dissimilar combinations of copper alloys to ferrous materials. A bronze alloy producing maximum strength and fluidity. The addition of deoxidising elements aid in eliminating zinc oxidation and fuming. Cu-Zn-Ni braze welding alloy for repair and rebuilding of metal components. The Castolin alloy 80 is recommended for high strength joints on tubulars chassis and bronze bearings and excellent frictional resistance overlays on shafts etc.

185 XFC 80 MF 80 XFC

23.20 WEARFACING ALLOYS

Wearfacing with Carbides

Designations CastoDrill 8800 Properties A flux coated bronze/tungsten carbide rod for use with the oxyacetylene process for applications requiring excellent cutting properties along with abrasion and impact resistance in media such as sand, gravel, earth, minerals etc., also recommended for tools to remove drill rods in well drilling. A composite torch rod; consisting of hard carbide particles dispersed through a tough alloy matrix.

TeroCote® 7888 T 7888 T is a high performance anti-wear product in the form of a flexible cord, comprising a nickel core wire, covered with an elastic binder with carbides containing a mixture of carbides and nickel alloy powder. The latter has a uniquely effective self-fluxing action, which gives 7888 T outstanding wetting properties. As a result, a smooth, even protective coat can be deposited quickly and easily, greatly reducing the risk of overheating the base material. Each spool of 7888 T carries one continous length of cord of rigorously consistent diameter and without joints, for improved reliability with automated or robotic feeder systems. 7888 T deposits an extremely durable protective coating comprising a dense mass of ultrahard tungsten carbides embedded in a tough nickel-chromium alloy matrix. This structure offers extremely effective protection against erosive and abrasive attack by a wide variety of materials. The matrix composition helps to absorb moderate impact and improves resistance to corrosion, while the angular profile of the finely crystallised carbides makes them very difficult to dislocate. Ultimium® 8811 A carbide containing rod for producing the ultimate in abrasion resistance due to the high concentration of hard, wear resistant carbides within a self fluxing metallic matrix. For use on steels, stainless steel and cast iron components utilising the Oxyacetylene, TIG and Eutalloy processes. This unique alloy form provides a welded protective coating without dilution of the base material. High density of carbide hard phases. Sound, crack free deposit. No deformation of workpiece. Rod identification: Dark grey coating.

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Wearfacing with Carbides - CONTINUED

Designations Ultimium 8888 Properties Ultimium 8888 is a nickel based composite rod containing a high quantity of tungsten carbides. This functional coating is designed for cutting and drilling applications. The coating thickness of 5-10mm guarantees great wear and corrosion resistance. Castolin 8888 Cutter was specifically designed to be have the «Ultimate Cutting Performance». Only high grade tungsten carbides are used, insuring consistant cutting performance. Castolin 7650 CR has excellent flow and wetting characteristics. It is designed to coat, repair and protect low alloyed steels as well as cast iron parts with up to 0.5% carbon.

Ultimium 8888 Cutter E 7650

Wearfacing without Carbides

Designations CastoDur® N 901 Properties Cobalt base alloy for use with either oxyacetylene or the TIG process, for applications subject to wear by abrasion, impact and pressure in both hot and cold service conditions. Deposits also provide corrosion and heat resistance with excellent hot hardness properties. Excellent resistance to corrosion and abrasion. High hardness properties. Good heat resistance. CastoDur 906 is a cobalt base filler metal. This alloy is used in applications where lower hardness with abrasion and corosion resistance are needed.

CastoDur® N 906

24.10 SOLDERING ALLOYS

Soft Soldering

Designations 157 - 157 T Properties 157 is a solder alloy containing silver but no lead or cadmium, and particularly recommended for applications in the food processing industry. The mechanical properties of assemblies made with 157 are superior to those of any conventional (lead-tin) alloys, making it especially preferable in harsh service conditions. 1827 is a cadmium based soft solder containing silver. It is recommended for joining aluminium to copper.

1827

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Light Metal

Designations 190 - 190 FBK Properties Recommended for good strength joints in sheet and wrought aluminium and some aluminium alloys. Ideal for brazing furniture and fittings, window frames, aluminium utensils and applications within the aircraft and radio industries. Castolin 190 can be used in conjunction with the Oxyacetylene and Tungsten inert gas shielded (TIG) processes. An aluminium silicon alloy producing good strength joints and good resistance to corrosion. Not suitable for parts requiring anodised finishes or aluminium alloys containing more than 1.5% magnesium. 190: Bare rod Mini-flux filler rod for overlays, repairs and fabrication of parts made from copper and its alloys such as York-Albro, cupro-aluminium, and the joining of these to nickel alloys, or cast iron which must have high corrosion resistance. Castolin 1185 MF is recommended particularly for its excellent resistance to corrosion from sea water and mineral and organic acids, such as sulphuric, acetic, hydrofluoric and hydrochloric acid diluted to 5%, saline and alkaline solutions. 1902 is a magnesium aluminium alloy. Specially designed for braze welding of magnesium motor-blocks and castings. An extruded flux coated aluminium alloy for low heat input, high strength welding repairs and fabrication of wrought and cast aluminium and some aluminium alloys. Not suitable for parts requiring an anodised finish. Uniform flux coating. Rapid solidification ideal for butt joints. Soft solder especially suited for joining aluminium to other metals.

1185 MF

1902 21F

AluTin 51

27.10 FLUXES

Brass/Bronze Fluxes

Designations 16 Properties Paste brazing flux for capillary brazing with copper - zinc - nickel based alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. This results in an optimal wetting of the filler metal and increase of the capillary effect in the gap between the two surfaces to be joined. The development of a surface alloy between the filler metal and the base metal ensures the metallic continuity. Paste brazing flux for capillary brazing with copper - zinc - nickel based alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. This results in an optimal wetting of the filler metal and increase of the capillary effect in the gap between the two surfaces to be joined. The development of a surface alloy between the filler metal and the base metal ensures the metallic continuity, eliminating zinc oxidation and fuming.

18

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Brass/Bronze Fluxes - CONTINUED

Designations 185 A Properties Paste brazing flux for braze coating with copper - zinc - nickel based alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. This results in an optimal wetting of the filler metal and increase of the capillary effect in the gap between the two surfaces to be joined. The development of a surface alloy between the filler metal and the base metal ensures the metallic continuity. The brazing flux 185 A is designed for use with the following heating methods: oxyacetylene flame and furnace without gas protection.

Light metal fluxes

Designations 190 Properties Recommended Castolin 190 flux in powder for use with Castolin 190 filler alloy. Its power as a deoxidising agent makes in-position joining much easier, as well as repairs presenting difficult access. The corrosive flux residue must be removed. Alloys containing not more than 1.5% magnesium.

Other Fluxes

Designations 14 Properties Flux for 14, cast iron filler rod typical of a flake cast iron structure, where deposits require high strength for the repair of cracks, blow-holes, casting defects and building up of worn and missing sections.

Soldering Fluxes

Designations 157 NC AluTin 51 Properties 157 NC is a solder flux in paste form ready for use. Soft solder especially suited for joining aluminium to other metals.

Silver Fluxes

Designations Properties

1020

1802 Atmosin

Flux for Castolin 1020 a CADFREE® quaternary Ag-Cu-Zn-Sn brazing alloy for capillary joining of ferrous metals, plus Cu and Ni alloys. Very high Ag content gives excellent fluidity, low joining temperature and increased mechanical strength in joints. Water/gas-tight sealing of joints. Powder brazing flux for capillary brazing with high silver content alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. This results in an optimal wetting of the filler metal and increase of the capillary effect in the gap between the two surfaces to be joined. The surface active Atmosin helps to obtain an even thickness of the brazing flux, which adheres strongly with the base metal during the heating phase.

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Silver Fluxes ­ CONTINUED

Designations 1802 HF Properties Powder brazing flux for capillary brazing with high silver content alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. This result in an optimal wetting of the filler metal and increase of the capillary effect in the gap between the two surfaces to be joined. The brazing flux 1802 HF is designed for use with induction heating.

1802 PF Atmosin Paste brazing flux for capillary brazing with high silver content alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. The surface active Atmosin helps to obtain an even thickness of the brazing flux, which adheres strongly with the base metal during the heating phase. The brazing operation is easier, this increases the productivity specially for large series of parts. 181 Atmosin Paste with Powder brazing flux for capillary brazing with silver containing alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. The surface active Atmosin helps to obtain an even thickness of the brazing flux, which adheres strongly with the base metal during the heating phase. The brazing operation is easier, this increases the productivity specially for large series of parts. Paste brazing flux for capillary brazing with silver containing alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. The surface active Atmosin helps to obtain an even thickness of the brazing flux, which adheres strongly with the base metal during the heating phase. The brazing operation is easier, this increases the productivity specially for large series of parts. Paste flux for all high-silver content brazing. Silver brazing flux with long continuous activity and high heat resistance. It is recommended for parts in aluminium bronze. Soft solder especially suited for joining aluminium to other metals.

181 PF Atmosin

ActivaTec® 1000 Albro AluTin 51

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28.10 BRAZING LIGHT METAL ALLOY AND SOLDERING PASTES

Brazing-Light Metal Alloy Pastes

Designations 190 AL Properties This alloy in paste form is designed for immediate use without preparation, and provides high-strength assemblies and re-pairs. Combining the filler alloy 190 and 190 NH flux into a ready-to-use paste, this product has been designed for use with automatic metering devices, having a consistency suitable for most such systems.

Brazing-Soldering Alloy Pastes

Designations 157 PA CastoTin® 1 CastoTin® 2 CastoTin® 3 Properties A flux and solder alloy powder combined in paste form, offering non-toxic deposits free from lead, antimony. CastoTin 1 is a tin-lead soldering paste with a corrosive flux. It can be used on stainless, ferrous and copper alloys. CastoTin 2 is a tin soldering paste with a corrosive flux. It can be used on stainless, ferrous, nickel and copper alloys. CastoTin 3 is a tin-lead soldering paste with a non-corrosive flux. It can be used on copper alloys.

Cadfree® Silver Alloy Pastes

Designations 1800 PA Properties Silver-zinc-copper-tin brazing alloy in paste form for capillary joining of stainless steel, ferrous, copper and nickel alloy parts. Very high silver content for improved wetting and very strong joints. This ready-to-use-paste contains a mixture in ideal proportions of atomised filler alloy powder and optimized flux, held together by a special inert organic binding agent.

Silver Alloy Pastes with Cadmium

Designations 1802 PB Properties Silver-zinc-cadmium-copper brazing alloy in paste form, for capillary joining of ferrous-, copper and nickel alloy parts. High silver content for improved wetting and very strong joints. Paste contains a mixture of ideal proportions of atomised filler alloy powder and compatible flux, held together by a special inert organic binding agent in a stable, readyto-use compound. A silver -zinc-cadmium-copper brazing alloy in paste form, water based.

CastoSil

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TECHNICAL NOTE

BRAZING ALLOYS WITH HIGH SILVER CONTENT HAVE MANY ADVANTAGES: · The fluidity of the filler alloy makes brazing easier. · The working temperature of these alloys is below 650°C which requires low thermal energy input. Grain growth during heating cycles reduces the mechanical properties of metal, so it is important to limit heat input. Brazing with high silver alloys therefore only slightly affects the parts in the joint (see picture below, left), and so preserves their properties. · The ductility of the filler alloys provides better performance of the brazed joints in service (resistance to vibrations, clamping, tensile stress, fatigue, etc). · Reducing the time for heating, making the joint and cleaning the residues by using these alloys, significantly reduces the labour and energy costs. · The appearance of the brazed joint ensures a high quality image.

MAGNIFICATION 200 X

MAGNIFICATION 200 X

Capillary silver brazed joint using Xuper 1802 alloy.

Grain growth observed after brazing using a Cu-P-Ag alloy.

TYPES OF COATED RODS F XFC NF ZF MF STANDARD QUALITY COATING XUPER FLEXIBLE COATING THIN COATING ULTRA-THIN COATING MINI-FLUX / PARTIAL COATING

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2 BRAZING & SOLDERING ALLOYS

21 ECOBRAZ RANGES

Composition in % Product 1020 F 1020 XFC® 1666 1666 XFC® 181 181 F 1010 XFC® 1030 XFC® 1802 1802 XFC® 1810 XFC® 38220 B 38220 F 38220 T 38225 B 38225 F 38225 T 38234 B 38234 F 38234 T 38240 B 38240 F 38240 T 38244 B 38244 F 38244 T 38245 B 38245 F 38245 T 38245 XFC® 38249 B 38249 T 38255 B 38255 F 38255 T 38256 B 38256 F 38256 T 38256 XFC® 38330 B 38330 F 38330 T 38330 XFC® 38334 B 38334 F 38334 T 38335 B 38335 F 38335 T 38335 XFC® 38340 B 38340 F 38340 T 38340 XFC® 38345 B 38345 F 38345 T Ag 56,7 56,7 45,1 45,1 19,6 19,6 37,9 35 40 40 29,8 19,4 19,4 19,4 25,9 25,9 25,9 34 34 34 40,7 40,7 40,7 Cu 21,9 21,9 25,3 25,3 46,0 46,0 20,3 25,7 18,3 18,3 27,5 43,8 43,8 43,8 39,7 39,7 39,7 36,6 36,6 36,6 29,3 29,3 29,3 Zn Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. 0.2 0.2 0.2 2.1 2.1 2.1 2.2 2.2 2.2 2 2 2 Sn 5.3 5.3 2 2 Cd Si Ni Other Melting Range in °C Solidus 625 625 660 660 740 740 21.4 19.5 24.1 24.1 23.6 615 625 595 595 604 740 740 740 680 680 680 630 630 630 650 650 650 Product Form Flux Coating Colour Colour Pink Pink Green White White Purple White White

Liquidus Form 665 665 700 700 835 835 670 695 630 630 683 815 815 815 760 760 760 730 730 730 710 710 710 F Coated XFC® Coated Bare Rod XFC® Coated Bare Rod F Coated XFC® Coated XFC® Coated Bare Rod XFC® Coated XFC® Coated Bare Rod F Coated Wire Bare Rod F Coated Wire Bare Rod F Coated Wire Bare Rod F Coated Wire Bare Rod F Coated Wire Bare Rod F Coated Wire XFC® Coated Bare Rod Wire Bare Rod F Coated Wire Bare Rod F Coated Wire XFC® Coated Bare Rod F Coated Wire XFC® Coated Bare Rod F Coated Wire Bare Rod F Coated Wire XFC® Coated Bare Rod F Coated Wire XFC® Coated Bare Rod F Coated Wire

Castolin range - Cadfree® Silver Alloys

Castolin range - Silver Alloys with Cadmium

EcoBraze Cadfree® Silver Alloys

White

White

White

White

White

45 45 45 45 49 49 54,3 54,3 54,3 56,8 56,8 56,8 56,8 30,4 30,4 30,4 30,4 33,9 33,9 33,9 34,7 34,7 34,7 34,7 39,8 39,8 39,8 39,8 44,3 44,3 44,3

26,7 26,7 26,7 26,7 16,3 16,3 21,1 21,1 21,1 22,3 22,3 22,3 22,3 27,2 27,2 27,2 27,2 22,6 22,6 22,6 25,2 25,2 25,2 25,2 19,4 19,4 19,4 19,4 15 15 15

Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal. Bal.

2.7 2.7 2.7 2.7 4.7 4.7 2.2 2.2 2.2 5.3 5.3 5.3 5.3 20.5 20.5 20.5 20.5 19.6 19.6 19.6 18.2 18.2 18.2 18.2 20.5 20.5 20.5 20.5 23.5 23.5 23.5 7.6 7.6

640 640 640 640 680 680 630 630 630 625 625 625 625 610 610 610 610 610 610 610 610 610 610 610 595 595 595 595 605 605 605

680 680 680 680 705 705 660 660 660 665 665 665 665 690 690 690 690 680 680 680 670 670 670 670 630 630 630 630 620 620 620

White White

White

White White

EcoBraze Silver Alloys with Cadmium

White White White

White White White White White

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2 LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS

22.10 SELF-FLUXING BRAZING ALLOYS FOR COPPER

Composition in % Designation Ag Cu Other Castolin range - Self-Fluxing Copper Alloys 1803D 15 Remainder 1805 2 Remainder RB 5246 Remainder RB 5280 2 Remainder RB 5283 15 Remainder RB 5286 5 Remainder P 5 6,2 7 7 5 6 Melting Range °C Solidus Liquidus 645 645 715 650 650 650 800 825 805 820 802 810

23.10 AUTOGENOUS WELDING OF CONSTRUCTION STEEL

Composition in % Product Ag Cu Zn Cd Castolin range - Brazing-Brass/Bronze Alloys 146 MF 60 39 146 XFC® 60 39 16 XFC® 1 48,1 Bal. 18 1 57,8 Bal. 18 MF 1 57,8 Bal. 18 XFC® 1 57,8 Bal. 185 XFC® 47,5 Bal. 80 MF 54,2 Bal. 80 XFC® 54,2 Bal. Castolin range - Fuctional Coatings CastoDrill 8800 1 47,6 42,6 Si Others 1 1 1 ,5 ,5 ,5 ,5 ,3 ,3 Melting Range °C Solidus Liquidus 885 885 885 879 879 879 890 885 885 885 905 905 915 895 895 895 915 910 910 910 Melting Range °C Solidus Liquidus

Composition in % Designation Ni Fe Sn Si C Co Cr W Other WC% Hardness Castolin range - Wear-Facing Alloys CastoDur® 901 1,1 1,1 1,1 2,53 Bal. 32.2 12,21 ,2 55-57 HRC CastoDur® 906 2,56 2,68 1,48 1,26 Bal. 29 4,7 ,2 43,5 HRC TeroCote® 7888 T Bal. 3,1 11 3.2 65% 400-430 Hv Ultimium® 8811 Bal. 2 ,69 12 74% 350-450 Hv Ultimium 8888 Bal. 3,7 9 5 N.A. Ultimium 8888 Cutter Bal. 3,7 9 5 N.A. E 7650 Bal. 30 10 N.A.

1080 1050

1120 1120

24.10 SOLDERING AND LIGHT METAL ALLOYS

Composition in % Product Ag Cu Zn Al Sn Castolin range - Soldering and Light Metal Alloys 1185 MF 90 9 157 3,5 157 T 3,5 1827 1,6 16,3 190 88 1902 8,5 21 F Remainder AluTin 51 31,6 Pb Si Melting Range °C Solidus Liquidus 1020 221 221 270 570 443 570 160 1040 221 221 280 580 599 630 240

12 5,3 Bal.

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2 BRAZING & SOLDERING ALLOYS

27.10 FLUXES

Melting Range °C Product Solidus Liquidus Castolin range - Brass/Bronze Fluxes 16 700 1000 18 700 1000 185 A 700 1000 Castolin range - Light metal fluxes 190 500 700 Castolin range - Other Fluxes 14 700 1000 Castolin range - Silver Alloy Fluxes 1020 450 850 1802 Atmosin 400 780 1802 HF 450 850 1802 PF Atmosin 420 820 181 Atmosin 550 900 181 PF Atmosin 550 900 ActivaTec® 1000 400 800 Albro 400 820 Castolin range - Soft Solder Fluxes 157 NC 150 450 AluTin 51 120 300 Flux Appearance Residue Properties

Dark Grey Paste Yellow Paste Blue Paste White Powder Pink Powder White Powder White Powder White Powder Pink Paste White Powder White Paste White Paste White Paste Yellow Paste Yellow Liquid

Non-Corrosive Non-Corrosive Non-Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive Corrosive

28.10 BRAZING AND SOLDERING PASTES

Composition in % Product Ag Cu Zn Cd Other Al Castolin range - Brazing-Light Metal Alloy Paste 190 AL 88 Castolin range - Brazing-Soft Solder Alloy Pastes 157 PA 3,5 CastoTin® 1 CastoTin® 2 ,2 CastoTin® 3 ,5 Castolin range - Cadfree® Silver Alloy Pastes 1800 PA 56,8 21,9 Bal. Castolin range - Silver Alloy Pastes with Cadmium 1802 PB 40 18,3 Bal. 24,1 CastoSil 40,2 18,7 Bal. 19,9 Si 12 Sn Pb Melting Range °C Solidus Liquidus 570 221 183 232 183 625 595 595 570 221 216 232 238 665 630 630

50 99,8 39,5 5,3

50 60

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3 POWDERS AND WIRES FOR THERMAL SPRAYING

31 POWDERS FOR THERMAL SPRAYING 31.10 ROTOTEC ­ ALLOY POWDERS FOR "COLD" SPRAY PROCESS

Designations Product Type Alloy Ni-Al-Mo Applications Properties

RotoTec 51000

Bond coat for RotoTec 19000 and MetaCeram 28000 powder families, on all metals except Cu and Mg. Pieces operating with metal-to-metal friction such as shafts, bearing surfaces, pistons, etc. Pieces operating with metal-to-metal friction. Wear sleeves for pumps.

~170 HV10 Fusion reaction during spraying creates strong bond with substrate ~250 HV10 Machinable with tools. Good coefficient of friction. Good resistance to corrosion. ~335 HV10 Machinable with tools (very good machinability by turning). Good resistance to frictional wear. ~420 HV10 The best surface finish is obtained by grinding. ~400 HV10 Excellent combination of corrosion, wear resistance and low friction. Machinable with nice surface finish. ~100 HV10 Very good machinability by turning. Excellent coefficient of friction. Low sensitivity to residual stress. ~120 HV10 Very good machinability by turning. Low coefficient of friction.

RotoTec 19300

Alloy Fe-Cr-Ni-Mo

RotoTec 19310

Alloy Fe-Cr-Ni

RotoTec 19400

Alloy Fe-Cr-Ni

Protective couplings for shafts, press pistons, motor casing.

RotoTec 19404

Alloy Fe-Cr-Co-Mo

Pieces operating with metal-to-metal friction and corrosion such as bearing seats, etc. For replacing hard-chrome.

RotoTec 19800

Alloy Cu-Sn-Zn

Guides, slides, journal bearings, bearings.

RotoTec 19850

Alloy Cu-Al

Compressor pistons, trunnions and pulleys.

RotoTec 19868

Alloy Cu-Al-Ni

Interior coatings of chocks, ram slides, ~150 HV10 foundry models. Good machinability by turning. Low coefficient of friction and good pressure resistance. Good corrsion resistance. Bearingseats and wherever a hard and corrosive resistand layer is needed. ~350 HV10 Machinable with tools. Excellent coefficient of friction.

RotoTec 19910

Alloy Ni-Cr-Si-Fe

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31.10 ROTOTEC ­ ALLOY POWDERS FOR "COLD" SPRAY PROCESS - CONTINUED

Designations Product Type Alloy Ni-Cr-Fe-Mo Applications Properties

RotoTec 19940

Wear sleeves for pumps, cylinder rods, ~370 HV10 drying cylinders for papermaking. The best surface finish is obtained by grinding. Good resistance to friction under pressure. Bearing seatings, pistons Used in rebuilding worn parts. ~200 HV10 Very good machinability by turning.

RotoTec 19985 RotoTec 19999

Alloy Ni-Cr-Fe Alloy Ni-Cr-Fe and carbides

Drag roll, wear plates, gripping finger. ~250 HV10 50% carbides High resistance to abrasion. Rough deposit. Sign panels, pylons, gantries, metallic structures, machine casing, port equipment, repair of accidental damage to galvanized structures. Zn >99% Low melting temperature. Sacrificial layers ensuring cathodic protection of ferrous supports against corrosive atmospheric phenomena.

RotoTec LT 29230

Zn base

31.20 PROXON ­ ONE-STEP ALLOY POWDERS FOR "COLD" SPRAY PROCESS

Designations Product Type Alloy Ni-Al-Mo Applications Properties

ProXon 21021

Mechanical seats, feathering sides. Thin and thick anti-wear coatings.

~170 HV10 Used without bonding layer. The best surface condition is obtained by grinding. ~280 HV10 Used without bonding layer. Thick deposit capability (<3mm). ~120 HV10 Used without bonding layer. Good machinability. Low coefficient of friction. Thick deposit capability (<4mm).

ProXon 21031

Alloy Ni-Cr-Al-FeMo Alloy Cu-Al

For components subject to wear and corrosion such as fan blades, shft sleeves and roller bearing seats Compressor pistons, trunnions and pulleys.

ProXon 21071

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31.30 EUTALLOY ­ SELF-FLUXING POWDERS FOR SPRAYING WITH SIMULTANEOUS FUSION

Designations Eutalloy 10009 Product Type Alloy Ni-Cr-B-Si-Fe Applications Resurfacing cams, pushers, stops, guide wheels, filterpress cake stone remover for sugar mill, decanting screw, steam gate components. Coating elements subject to friction. Coating elements of chains, transport screw, wiper segments, brick die frames, claw excavators, rock drill, brush cutter rake, debarking knives 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. Coating of cast iron and steel molds for plastic material and glass. Recoating shafts, eccentrics, bearings Soldering tungsten carbide biscuits on drilling stabilizers, etc. 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. Resurfacing chemical transport screws, fan blades at cement works, augers, and extrusion screws. Blades and segments of mixers, etc. Repair of gears, cast iron valve seats, molds, keyways, bearing seating. Renewing drawing tools Correction of machining errors, etc. Coating of molds for ceramics, rasps. Distributor blades for fertilizer spreaders, cyclone blades, hopper for sand spreading machines, mouths of baggers, etc. Properties ~63 HRc. Low friction coefficient. Good resistance to corrosion, erosion and abrasion under light load. ~65 HRc. 80% tungsten carbides Excellent resistance to abrasion by fine to coarse sized abrasives ~64 HRc. 60% tungsten carbides Excellent resistance to erosion and abrasion by fine to coarse sized abrasives

Eutalloy 10011

Ni-Cr-B-Si-Fe alloy and tungsten carbide Ni-Cr-B-Si-Fe alloy and tungsten carbide

Eutalloy 10112

Eutalloy 10185

Alloy Ni-B-Si

~390 HV30. Well suited for metal-to-metal friction. Excellent corrosion resistance. Machinable with cutting tool. ~260 HV30. Appropriate for new or worn cast iron. Good resistance to corrosion. Machinable with cutting tool.

Eutalloy 10224

Alloy Ni-B-Si

Eutalloy 10611

Co-Ni-Cr-BSi alloy and tungsten carbide Alloy Ni-B-Si

~55 HRc 50% tungsten carbides Excellent resistance to abrasion under pressure and to corrosion. ~240 HV30. Good resistance to shocks and oxidation while hot. Machinable with cutting tool. ~65 HRc. 15% tungsten carbides Excellent resistance to erosion and abrasion by fine abrasives.

Eutalloy 10680

Eutalloy 15999

Ni-Cr-B-Si-Fe alloy and tungsten carbide

31.40 EUTALLOY SF ­ SELF-FLUXING POWDERS FOR SPRAYING WITH SIMULTANEOUS FUSION

Designations Eutalloy SF 15211 Product Type Ni-Cr-B-Si-Fe alloy and tungsten carbide Applications All round powder for anti-abrasion. Properties ~60 HRc 60% tungsten carbides Excellent resistance to erosion and abrasion by fine to coarse sized abrasives.

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3 POWDERS FOR THERMAL SPRAYING

31.50 EUTALLOY RW ­ SELF-FLUXING POWDERS FOR SPRAYING WITH SUBSEQUENT FUSION

Designations Eutalloy RW 12112 Product Type Ni-Cr-B-Si-Fe alloy and tungsten carbide Applications Recoating wear pieces of agricultural machines, mixer blades, ceramic press feeder plungers. Resurfacing pump wear sleeves, steel industry transport rollers. Coating incineration boiler tubes. Machine elements in food and chemistry industry. Properties ~710 HV30. 35% tungsten carbides Excellent resistance to erosion and abrasion.

Eutalloy RW 12494

Alloy Ni-Cr-B-Si-Fe

~310 HV30 Very good resistance to corrosion. Suitable for friction under light loads. Machinable with cutting tool. ~390 HV30. Suited for impact and friction Machinable with cutting tool. ~680 HV30. Very low coefficient of friction and good abrasion resistance. Excellent resistance to corrosion and especially to seawater. ~740 HV30 Excellent frictional and corrosion resistance. Excellent corrosion resistance. ~760 HV30. 40% tungsten carbides Excellent resistance to abrasion. ~600 HV30 Excellent wear and corrosion resistance to both reducing and oxidizing environments ~40 HRC Good resistance against friction and impact. Excellent corrosion resistance.

Eutalloy RW 12495 Eutalloy RW 12496

Alloy Ni-Cr-B-Si-Fe Alloy Ni-Cr-B-Si-Fe

Coating of wear sleeves for pumps, glassworks feed plunger, valve parts: seats, flaps, etc. Coating cylinder rods, wear sleeves, pump pistons and faucet parts. Resurfacing coal dust separators. etc.

Eutalloy RW 12497

Alloy Ni-Cr-B-Si-FeMo-Cu Ni-Cr-B-Si-Fe alloy and tungsten carbide Alloy Ni-Cr-Mo-SiB-Cu Alloy Ni-Cr-Si-Fe-B

Coating protective couplings, cylinder rods, wear and seal sleeves, Pelton turbine injection needle valves, etc. Coating stainless steel pieces. Coating fan blades, mixer, transport screw, tensioning pulleys, guides. Wear parts for agricultural equipment, etc Boiler tubes, shaft and sleeves in waste incineration, chemical, pulp and paper industries Plungers and other rotating parts.

Eutalloy RW 12999

Eutalloy RW 53606

Eutalloy RW PE 8040.02

31.60 CASTOPLAST ­ POLYMER POWDERS FOR THERMAL SPRAY PROCESS

Designations Product Type Polyamide Applications Properties CastoPlast 103 Thermoplastic coatings. Protection of parts that need to resist urban, rural, marine and chemical corrosion. Good resistance to UV. Good electrical insulation. Well suited for mechanical rebuilding even in thick layers. Stands up well to friction and abrasion ~75 ShD Breakdown voltage ~30 kV/mm Max. service temperature 100°C. Max. peak temperature 140°C Melting temperature 185°C. Good resistance to alkaline or saline solutions and to hydrocarbons and solvents.

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3 POWDERS AND WIRES FOR THERMAL SPRAYING

31.70 METACERAM ­ CERAMIC AND REFRACTORY POWDERS FOR "COLD" THERMAL SPRAY PROCESS

Designations MetaCeram 28010 Product Type Cr2O3 Applications On RotoTec 51000 bonding layer. Cable gland seatings, shaft protector sleeves, seam ring joint seatings Plungers, pump shafts, feed chutes. Properties Microhardness of the particles ~2400 HV10g Max. service temperature 500 °C. Product density 5.2 kg/dm High hardness, excellent resistance to corro3 sion, low coefficient of friction. Microhardness of the particles ~1950 HV10g Max. service temperature 1000 °C. Product density 4.0 kg/dm . 3 High hardness, excellent resistance to corrosion. Good electrical insulation (dependent on deposit thickness). Microhardness of the particles ~1600 HV10g Max. service temperature 1000 °C. Product density 4.0 kg/dm. Good resistance to corrosion and good friction properties.

3

MetaCeram 28020

Al2O3 TiO2(2.2%)

On RotoTec 51000 bonding layer. seam ring joint seatings, cable gland seatings, shaft protector sleeves, electrical isolation of machine parts, press rings for making radial tyres, sifting plate

MetaCeram 28030

Al2O3 TiO2(13%)

On RotoTec 51000 bonding layer. Printer cylinders, paper transport rollers, thread guide, wear and sliding plates, induction oven parts. On RotoTec 51000 bonding layer. Combustion chamber thermal insulation parts, crucibles, foundry machine parts, ladle for steel and iron works, guide wheels for wire zinc baths, pyrometer tubes.

MetaCeram 28085

ZrO2 CaO (30%)

Microhardness of the particles ~700 HV10g Max. service temperature 1200 °C. Product density 5.4 kg/dm3. Excellent thermal insulation and stands up to thermal shocks. 3 Non wetting for liquid metals.

31.80 EUTROLOY ­ ALLOY POWDERS FOR PTA (PLASMA TRANSFERRED ARC) PROCESS

Designations EuTroLoy 16006.04 Product Type Applications Properties ~40 HRC High 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. ~28 HRC Excellent resistance to high-temperature oxidisation and reducing atmospheres and to corrosion by organic and mineral acids. For operating temperatures up to 1100 °C. Alloy Valve seats, protective shaft sleeves, Co-Cr-W-Ni-Fe shaft seal surfaces, tools in the wood (Gr. 6 Type) and plastic processing industry, stirrer components, valve parts, extruder screws, etc.

EuTroLoy 16008.04

Alloy Co-Cr-Mo-Ni

Hot-working tools, forming dies, cutting blades, pump and turbine components, components for large steam valves, etc.

EuTroLoy 16012.04

Alloy Co-Cr-W-Ni-Fe Slide valve seats, extruder screws (Gr. 12 Type) 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

~46 HRC High 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.

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3 POWDERS FOR THERMAL SPRAYING

32 WIRES FOR THERMAL SPRAYING 32.10 EUTRONIC ARC ­ ALLOY WIRES FOR ARC SPRAYING

Designations EuTronic Arc 502 Product Type Applications Properties Hardness ~860 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat erosion, thermal shock up to 650°C Hardness ~260 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat corrosion, erosion up to 900°C and oxidation Hardness ~640 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat metal-to-metal friction, corrosion and oxidation Hardness ~230 HV0.3 Self bonding alloy for thick or thin coatings with good corrosion resistance. Easy machinabillity, like machining solid mild steel Alloy Cement cooler plates, boiler water Fe-Cr-Ti-Si-Mn wall protection, pulp production digesters, steam turbine casings, cracking installations, high temperature cyclone, fume extractors etc. Alloy Fe-Cr-Al-Mo Corrosion and erosion resistant protective coatings in boiler equipment up to 900°C

EuTronic Arc 509

EuTronic Arc 532

Alloy Fe-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

EuTronic Arc 579

Alloy Worn general engineering compoFe-Ni-Cr-Si-Mn 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 exchangers, process piping, etc. Alloy Fe-Cr-B-Si-Mn Abrasion, erosion and adhesion resistant protective coatings in pumps, boiler tubes, water walls and fans.

EuTronic Arc 595

Hardness ~1200 HV0.3 Self bonding alloy for thick or thin coatings with good corrosion resistance.

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4 COMPOSITE WEAR FACING MATERIALS

41 MECATEC ­ COLD SURFACING TECHNOLOGY POLYMERS

Designations Applications Properties

MeCaTeC Express 100

Cold, ultra-rapid setting paste. Emergency rebuilding, protecting and repairing 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. Cold, rapid setting fluid for general repairs. Protecting and repairing damaged machine parts such as keyways, machine beds, bearing housings, engine, gearbox casings, cast iron machine housings, pump and valve parts, etc. Cold, rapid setting paste for general repairs. rebuilding, protecting and repairing damaged machine parts such as: keyways, machine beds, bearing houings, engine, gearbox casings, cast iron machine housings, pump and valve parts, etc. Cold, rapid setting paste for anti-corrosion and anti-abrasion coatings. Rebuilding, protecting and repairing damaged or new machine parts such as butterfly valve, gate valves, pump housings, propellors, hydraulic rams, diaphragms, etc. Cold, rapid setting fluid for anti-abrasion coatings. Protecting and repairing damaged or new machine parts such as mixer blades, hoppers, vessels, chutes, pump impellors, fan blades, elbows and conduits. Cold, rapid setting paste for food and beverage industry. Rebuilding, protecting and repairing damaged stainless steel parts used in the food industry such as shafts, chutes, trays, water vessels, piping, valve parts, pump parts, etc. Cold, rapid setting paste for anti-erosion coatings. All applications needing thick coatings to resist wear by abrasion and erosion. Rebuilding, protecting and repairing damaged machine parts such as sand pumping equipment, slurry pumps, screw conveyors, pipe elbows, chutes for clinker, cement and ash handling pipes, 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 Repairs of deep cracks or to fill narrow cavities in steel, cast iron, aluminium, bronze and concrete. Can also be easily machined, drilled or tapped. Service temperature up to 120 °C All-positional patch repairs of cracks or fissures in steel, cast iron, aluminium, bronze and concrete. Easy to fit machine, drill, tap or sand. Service temperature up to 120 °C All-positional protection against wear by a variety of corrosive liquids, abrasive media, slurry erosion and cavitation effects. Can be precision machined, drilled or tapped whilst exhibiting exceptional resistance to pressure and deformation. Service temperature up to 175 °C Brushable in thin layers over large areas or complex forms. Protection against wear by low pressure abrasion and erosion. Smooth surface finish and high electrical insulating properties. Machinable by grinding. Service temperature up to 175 °C For use in potable water systems. All-positional, rust free, safe repairs of cracks, fissures or dents in stainless steel. Can also be easily machined, drilled or tapped. Service temperature up to 120 °C Protection against wear in severe erosion and abrasion. The tough, composite matrix is reinforced with ultra resilient Kevlar fibres and a dense dispersion of hard, wear resistant ceramic phases. Service temperature up to 120 °C

MeCaTeC 101F

MeCaTeC 101P

MeCaTeC 102P

MeCaTeC 103F

MeCaTeC 104P

MeCaTeC A5

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4 COMPOSITE WEAR FACING MATERIALS

Designations

Applications

Properties

MeCaTeC A5HT

Same applications as MeCaTeC A5 but for increased 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. 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) All-positional repairs. 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 Bond M is a primer compound used for optimising the adhesive bonding properties of MeCaTeC 110F or 110P to Metallic substrates. MeCaTeC Bond R is a primer compound used for optimising the adhesive bonding properties of MeCaTeC 110F or 110P to Rubber substrates. MECATEC Bond R is additionally used for bonding to other non-metallic substrates such as already cured MeCaTeC 110F or 110P coatings, fibreglass materials, concrete surfaces, wooden parts.

MeCaTeC 110F

Cold, rapid setting fluid for anti-impact coatings. 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. Cold, rapid setting paste for anti-impact coatings. Rebuilding, protecting and repairing damaged or new machine parts such as conveyor belts, hydraulic installations, fluid transport systems, anti-slip surfaces, fan blades, pump parts, vibration dampers, rubber components, etc Primer fluid for optimum substrate bonding to metal. Same applications as MeCaTeC 110F and 110P. Primer fluid for optimum substrate bonding to rubber. Same applications as MeCaTeC 110F and 110P.

MeCaTeC 110P

MeCaTeC Bond M MeCaTeC Bond R

Express 100

Abrasion Cavitation Corrosion Erosion Friction Impact Electric Insulation Emergencies General repair Machining Food and drink Max. temperature °C 90

101F/P

102P

103F

104P

A5/A5HT

110F/P

120

175

175

120

120/250*

50/80**

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9 CASTODUR DIAMOND PLATES

91 WELD CLADDED PLATES

Designations Thicknesses Properties (The thicknesses are shown as follows - thickness of metal base + thickness of protective layer) CDP 4624 5+3 6+4 8+5 10 + 5 15 + 5 Weld cladded wear plate for abrasion and erosion resistance. This is a chromium carbide alloy wearplate, ideal for applications, where the right balance between price and service life is required. Hardness: 57 - 60 HRC Carbide content: > 30% Standard plate dimensions: 1500 x 3000mm Surface coating: 1220 x 2740mm (3.34m²). Weld cladded wear plate for extreme abrasion and erosion resistance. This is the real high load resistant wearplate with a unique overlay and a complex carbide structure with high density of hard particles. Hardness: 62 - 65 HRC Carbide content: > 50% Standard plate dimensions: 1500 x 3000mm Surface coating: 1220 x 2740mm (3.34m²). 30% increased wear resistance with XuperWave geometry. XuperWave bed and crack morphology provide nonparallel geometry to wear flow direction. Weld cladded wear plate for extreme abrasion and erosion resistance. Hardness: 62 - 65 HRC Carbide content: > 50% Standard plate dimensions: 1500 x 3000mm Surface coating: 1220 x 2740mm (3.34m²).

CDP 4666

5+3 6+4 8+5 10 + 5 15 + 5

CDP 4666 XuperWave

5+3 6+4 8+5 10 + 5 15 + 5

On request

Designations Thicknesses Properties (The thicknesses are shown as follows - thickness of metal base + thickness of protective layer) CDP 3952 6+4 8+5 10 + 5 Weld cladded wear plate for hot abrasion and erosion. Especially designed for extra fine erosive / abrasive medias and critical applications, where every additional day in service is critical. Maximum service temperature is 700°C. Hardness: 63 - 65 HRC Carbide content: > 50% Standard plate dimensions: 1500 x 3000mm Surface coating: 1220 x 2740mm (3.34m²). Weld cladded wear plate especially for the combined wear of abrasion and impact. Hardness: 53 - 55 HRC Carbide content: > 50% Standard plate dimensions: 1500 x 3000mm Surface coating: 1220 x 2740mm (3.34m²).

CDP 4623i

8+5 10 + 5 15 + 5

Standard support plates in unalloyed S235 type steel. Standard cutting techniques - e.g. plasma arc, water jets or laser - may be applied. Castolin offers a comprehensive range of solutions for virtually all wear-intensive fields of heavy industry in the form of CDP plates and CastoTubes. On request there are also different types of support plates and special thicknesses of metal base and protective layer.

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9 CASTODUR DIAMOND PLATES

92 POWDER COATED PLATES

Designations Thicknesses Properties (The thicknesses are shown as follows - thickness of metal base + thickness of protective layer) CDP 496 4+2 Powder coated wear plate to combat erosion. The Ni Cr B Si alloy deposit offers excellent resistance to wear by metal-to-metal friction, erosion and a wide range of corrosive conditions. Hardness: 55 HRC Standard plate dimensions: 850 x 1250mm Surface coating: 800 x 1200mm (0.96m²). Powder coated wear plate for extreme abrasion and erosion resistance. The deposit consists of a wear resistant Ni Cr B Si matrix and additions of fine dispersed tungsten carbides. Matrix hardness: 55 HRC Carbide hardness: > 1.700 HV0.03 Carbid content: 35% Standard plate dimensions: 850 x 1250mm Surface coating: 800 x 1200mm (0.96m²).

CDP 112

2+1 4+2

93 CASTOTUBES

Designations CastoTubes Properties Applied internal coating thicknesses are typically 3.0 - 4.5mm. The TeroMatec 4666 wearfacing alloy contains multiple hard phases which resist abrasion and erosion up to 500°C. Tubes with inner diameter from 82 up to 277mm, a maximum length of 3m and different wall thicknesses are available. CastoTubes are available with slip-on or integral flanges in accordance with DIN standards. Hardness: 62 - 65 HRC Carbide content: > 50%

TECHNICAL NOTE

Applications

All activities where wear by abrasion is a major problem and the operation costs and work stoppages caused by this type of wear must be reduced.

Engineering

Castolin Eutectic manufactures complete finished solutions ready for immediate installation in accordance with your engineering specifications and to suit your individual requirements. Even sophisticated designs can be realised with CDP and CastoTubes

Installation

By welding the metal base side which has good weldability with EutecTrode 6666 or 640, EnDOtec DO*02, CastoMag 45250 or 45554 S.

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9 CASTODUR DIAMOND PLATES

CERTIFICATION: THE ASSURANCE OF WELDING QUALITY

THESE DAYS INDUSTRY MANAGERS ATTRIBUTE MORE AND MORE IMPORTANCE TO THE QUALITY OF WELDED JOINTS AND RESPECTING PROCEDURES. BUSINESSES THEREFORE NEED TO PROVIDE PROOF THAT THE PRESCRIBED WELDING PARAMETERS HAVE BEEN FOLLOWED AND CERTIFICATION IS ONE OF THE SIMPLE WAYS TO DO THIS.

WHO NEEDS CERTIFICATION?

Everyone who: · Works with Q.A. (ISO 9000) · Must follow procedures for welding · Has to apply the European standard EN 729-2 (Welding Quality Requirements/Level 2: Total Quality) · Wants to confirm the good condition and accuracy of the measurement and display devices integrated in their welding equipment. · Needs a certificate to attest that their welding equipment is perfectly operational.

THE STRONG POINTS OF THE CASTOLIN SOLUTION

· Castolin uses a mobile load bench to make the measurements, which ensures much more precise values than by using manual welders. · Castolin, with its knowledge of welding and technology developments in this domain, avoids risk causing errors when handling the machines and interpreting the results. · Castolin services include verification and not just certification. We in fact certify the units to be good or bad, compared with the established or required standards, so that the client knows exactly where they stand. · The Castolin services include, if the measurement devices are not within the tolerances, and if it is possible, the adjustment of the devices to restablish the prescribed tolerances. · The Castolin services can also be extended to include, during the same visit, preventive maintenance of the equipment. This way the client can have a machine that is fully checked and maintained. · With the readings, Castolin provides a graphic representation of the deviances making it possible to see accurately and quickly whether the verified instruments are within the margins. · The contract that Castolin offers, for a modest fee, liberates clients from the administrative constraints and follow-up of maintenance programs.

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9 VARIOUS WELDING ACCESSORIES

TECHNICAL DATA REFERENCES

Stronger, with

Castolin Eutectic

WEAR & FUSION TECHNOLOGY

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EUROPEAN STANDARDS FOR STEEL

EXAMPLES OF DESIGNATIONS

SYMBOLIC

DESIGNATION

NUMERIC

DESIGNATION

NF A 35-501

SYMBOLIC

DESIGNATION

NUMERIC

DESIGNATION

NF A 35-501

GENERAL PURPOSE CONSTRUCTION STEEL PER EN 10027 S 185 S 235 JRG1 S 235 JRG2 S 235 JO S 235 J2G3 S 275 JR S 275 JO 1.0035 1.0036 1.0038 1.0114 1.0116 1.0044 1.0143 A33 E24-2 E24-2 NE E24-3 E24-4 E28-2 E28-3 S 275 J2G3 S 355 JO S 355 K2G3 E 295 E 355 E 360 1.0144 1.0553 1.0595 1.0050 1.0060 1.0070 E28-4 E36-3 E36-4 A50-2 A60-2 A70-2

UNALLOYED STEEL FOR QUENCHING AND TEMPERING PER EN 10083-1 C22E C25E C30E C35E C40E 1.1151 1.1153 1.1178 1.1181 1.1186 XC 16 XC 25 XC 32 XC 38 XC 42 C45E C50E C55E C60E 1.1191 1.1206 1.1203 1.1221 XC 48 XC 50 XC 55 XC 60

FINE-GRAINED WELDABLE CONSTRUCTION STEEL PER EN 10113-3 S355M S355ML S420ML 1.8823 1.8834 1.8834 E355R E355FP E420R S420ML S460M S460ML 1.8836 1.8827 1.8838 E420FP E460R E460FP

FINE-GRAINED STEEL FOR PRESSURE VESSELS PER EN 10028-3 P355N P355NH P355NL1 1.0562 1.0565 1.0566 A510AP A510AP A510FP1 P460N P460NH P460NL1 1.8905 1.8935 1.8915 A555AP A550AP A550FP1

STEEL FOR BOILERS PER EN 10028-2 P235GH P265GH P295GH P355GH 1.0345 1.0425 1.0481 1.0473 A37CP A42CP A48CP A52CP 16MO3 13CRMO4-5 10CRMO9-10 1.5415 1.7335 1.7380 15D3 15CD4-05 10CD9-10

HIGH YIELD STRENGTH STEEL FOR COLD FORMING PER EN 10149-2 S315MC S355MC S420MC 1.0972 1.0976 1.0980 E315D E355D E420D S500MC S550MC S700MC 1.0984 1.0986 1.8974 E490D E560D E690D

STEEL RESISTANT TO ATMOSPHERIC CORROSION PER EN 10155 S235JOW S235J2W S355JOWP 1.8958 1.8961 1.8945 E24W3 E24W4 E36WA3 S355J2WP S355JOW S355K2G1W 1.8946 1.8959 1.8966 E36WA4 E36WB3 E36WB4

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10 TECHNICAL DATA REFERENCES

EXAMPLES OF DESIGNATIONS

EN 10027-1 EN 10027-2 NF A AISI

STAINLESS STEELS PER EN 10027-1 AND EN 10027-2 X12CRMNNIN 17.7.5 X12CRMNNIN 18.9.5 X9CRNI 18.8 X9CRNI 18.9 X4CRNI 18.12 X3CRNICU 18.9.4 X4CRNI 18.10 X2CRNI 18.9 X2CRNI 19.11 X2CRNIN 18.10 X10CRNI 25.21 X1CRNISI 18.15.4 X4CRNIMO 17.12.2 X4CRNIMO 17.13.3 X2CRNIMO 17.12.2 X2CRNIMO 17.12.3 X2CRNIMON 17.11.2 X2CRNIMON 17.13.3 X6CRNIMOTI 17.12.2 X6CRNIMONB 17.12.2 X2CRNIMO 18.15.04 X6CRNITI 18.10 X6CRNINB 18.10 X2CRNIMON 17.13.5 X2CRNIMON 17.12.3 X1CRNIMON 25.22.2 1.4372 1.4310 1.4305 1.4303 1.4567 1.4301 1.4307 1.4306 1.4311 1.4335 1.4381 1.4401 1.4438 1.4404 1.4432 1.4429 1.4571 1.4580 1.4438 1.4541 1.4550 1.4439 1.4434 1.4468 1.4539 1.4537 Z 12 CMN 17.07 AZ Z 11 CN 18.8 Z 8 CNF 18.09 Z 5 CN 18.11 FF Z 3 CNU 18.10 Z 7 CN 18.09 Z 3 CN 19.11 Z 3 CN 18.10 Z 3 CN 18.10 AZ Z 8 CN 25.20 Z 1 CNS 17.15 Z 7 CND 17.11.02 Z 7 CND 17.12.02 Z 3 CND 17.12.02 Z 3 CND 17.13.03 Z 3 CND 17.11 AZ Z 6 CNDT 17.12 Z 6 CNDNB 17.12 Z 3 CND 19.15.04 Z 6 CNT 18.10 Z 6 CNNB 18.10 Z 3 CND 18.14.05 AZ Z 3 CND 19.14 AZ Z 2 CND 25.22 AZ Z 2 NCDU 25.20 Z 2 NCDU 25.25.05 AZ 201 301 303 305 XM 5/18.9 LW 304 304 L 304 L 304 LN 310 S 18.15 316 316 316 L 316 L 316 LN 316 TI 316 CB 317 L 321 347 317 L4 317 LN 310 MOLN 904 L URSB8

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PRINCIPAL GRADES OF ALUMINUM

EXAMPLES OF DESIGNATIONS

ALUMINIUM AND ALLOYS SERIES NFA 02.104 NFA 02.004

ALUMINIUM ALLOYS PER NFA 02.104 AND NFA 02.004 ALUMINUM, PURITY > 99,00% 1000

1050 A 1070 A 1080 1100 1199 1200 2011 2014 2017A 2024 2030 2117 2618A 3002 3003 3004 3005 3105 4145 4006 4145 4043 4047 5005 5052 5056A 5083 5086 5150 5251 5454 5754 6005A 6060 6061 6081 6082 6106 7010 7020 7049A 7050 7075

A5 A7 A8 A45 A9 A4 A-U5 PB BI A-U4SG A-U4G A-U4G1 A-U4PB A-U2 G A-U2GN A-M1 A-M1G A-MG 0,5 AS1 AS1FE AS4 AS5 AS12 A-G 0,6 A-G5M A-G4MC A85-GT A-G2M A-G3M A-GS A-SGM 0,3 A-SGM 0,7 A-Z5G A-Z8GU A-Z5GU

ALUMINUM COPPER ALLOYS

2000

ALUMINUM MANGANESE ALLOYS

3000

ALUMINUM SILICON ALLOYS

4000

ALLOYS

ALUMINUM-MAGNESIUM-SILICON

5000

ALLOYS ALUMINUM-ZINC-MAGNESIUM

6000

ALLIAGES ALUMINIUM-ZINC-MAGNÉSIUM

7000

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MECHANICAL TESTING

THESE SYMBOLS ARE USED:

IMPACT STRENGTH K TENSILE STRENGTH RM YIELD STRENGTH AT ELONGATION A5 HARDNESS H

10 TECHNICAL DATA REFERENCES

0.2% Rp0.2

THE IMPACT STRENGTH AND ELONGATION INDICATE THE DUCTILITY. THESE VALUES ALWAYS CHANGE IN THE SAME SENSE. (IF K DECREASES, A5 ALSO DECREASES).

THE TENSILE STRENGTH , THE YIELD STRENGTH AND THE HARDNESS INDICATE THE TOUGHNESS. THESE VALUES ALWAYS CHANGE IN THE SAME SENSE. (IF RM INCREASES, RP AND H ALSO INCREASE.)

K

RM

Rp02

A

H

IMPACT TESTING (K)

DEFINITION : The impact strength of a material is measured using an impact testing machine (Charpy or Izod) allowing an assessment of the property of brittleness. Unified French bar (KCU) Standardized test specimen whose notch is U shaped. Bar using the Charpy test (KCV). Standardized test specimen whose notch is V shaped.

UF RESILIENCE: V RESILIENCE:

Measure Property

Former Units

New Units

Conversion

KCU KCV

Kgf/cm2 Kgf/cm2

J/cm2 J/cm2

1J/cm2= 0,0102 Kgf/cm2 1J/cm2= 0,0102 Kgf/cm2

TENSILE TESTING

Test method The test involves subjecting a test specimen to a tensile force until it breaks in order to determine the metal's mechanical properties. Subject to an increasing tensile force, the test specimen stretches uniformly up to a certain characteristic value. This value where the applied load remains stationary is the elastic limit or yield point for steels . If the load is removed, the test specimen returns approximately to its original length. If the load continues to increase, the stretching increases and becomes permanent, followed by breakage ­ this is the Ulimate Tensile Strength.

With this test, it is possible to define three mechanical properties: · Tensile strength (Rm) · Yield strength (Rp) The property indicates a material's resistance to breaking. This property indicates a material's capacity to stretch or deform elastically.

Rm(Mpa)= Rpo,2 (Mpa)=

F(N) S(mm2) F'(N) S(mm2)

· Elongation A5

This property indicates a material's capacity to stretch or deform plastically. It is the value of the elongation in percent, measured after the rupture of a tensile test specimen.

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MECHANICAL TESTING

Hardness testing (H)

The hardness of a material is assessed by the resistance that it offers to the penetration of a hard body. Hardness can be related to the material's tensile strength (Rm). Brinell test (HB): Indenter is a hard steel ball. Rockwell test (HR): Indenter is a hard ball (HRB) or diamond cone (HRC) Vickers hardness test (HV): Indenter is a diamond pyramid with a conical base Shore hardness test (SK): Indenter is a steel point.

In the following comparison table, the hardness values are only approximate averages. No mathematical data can make an absolute conversion possible. Therefore be careful to avoid erroneous conversions between these different hardness testing methods. KG/MM2 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 65 67 69 71 74 76,5 79 82 84,5 87 88 89,5 90 92 94,5 97 99 100 102 103 104 105 107 108 110 111 HB 84,6 90,3 95,5 101 107 113 118 124 129 135 141 146 152 158 163 169 174 183 188 194 199 208 215 223 231 237 245 248 252 253 259 267 274 278 282 287 290 293 295 300 304 309 313 HV HRB HRC SHORE KG/MM2 113 114 116 117 119 120 123 126 129 130 132 134 136 139 141 143 145 148 150 152 154 156 158 161 164 168 171 173 176 178 180 183 185 187 189 191 193 195 197 200 206 211 222 HB 319 321 327 329 335 339 345 354 363 385 390 398 401 409 415 420 426 432 438 444 448 454 457 464 470 481 488 492 499 503 507 514 518 522 526 530 534 538 543 547 560 569 587 HV 318 320 325 327 333 337 343 352 361 404 410 418 424 431 437 443 450 457 463 470 474 482 486 494 502 515 524 529 538 543 548 558 564 570 575 581 587 593 599 606 626 640 671 HRB 110 35 110,5 36 111 111,6 112 114,4 37 38 38,5 41 42 43 115 44 45 46 62 63 60 51 52 53 54 57 58 50 HRC 34 SHORE 49

173 178 187 192 197 203 210 218 225 233 239 247 249 253 254 260 267 274 279 282 287 290 293 295 300 303 309 312

53 58 63 66 69 71,5 73,5 75,5 77,5 79,5 81 83 84,5 86 87,5 89,5 91 92 93,5 95,5 96,5 98 99,5 100,5 102

15,5 17,5 19 21

30 31 32 33 34 35 36 37 38 39 40

47 48 49

65 66 68 69 70 71 72 73 74

24 103 104 104,8 105,8 25 26 27 28 29 30 45 31 108 32 108,9 33 109,5 48 47 46

50 51 52

41 42 43 44

107,3 107,5

53 75 54 55 57 76 78 79 81,5

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PREHEATING STEELS

PREHEATING IS A FUNCTION OF THE STEEL'S CARBON CONTENT AND THE SECTION THICKNESS. WE RECOMMEND FOR A CARBON EQUIVALENT: · UP TO 0.25%: PREHEATING IS UNNECESSARY. · BETWEEN 0.25 AND 0.40%: PREHEAT TO 100 ­ 200°C. · BETWEEN 0.45 AND 0.80%: PREHEAT TO 200 ­ 350°C.

10 TECHNICAL DATA REFERENCES

Never preheat steel with 12 ­ 14% manganese During welding make sure that the part's temperature does not exceed 250°C. For tempered steel, follow the supplier's recommendations for the preheating temperature which could be between 200 and 500°C.

TYPE OF STEEL CURRENT DESIGNATION CARBON CONTENT RECOMMENDED PREHEAT TEMPERATURE

UNALLOYED STEEL

XC 18 XC 25 XC 32 XC 38 XC 42 XC 48 XC 80 15 D 3 20 D 5 - M 30 M 7 40 M 7 45 M 7 Z 120 M 12 100 C 6 Z 12 C 13 Z 8 C 17 (AISI 430) Z 10 C 24 (AISI 446) 25 CD 4 42 CD 4 30 CD 12 10 CN 6 20 NC 6 35 NC 6 30 NC 11 20 NC D 2 40 NC D 3 35 NC D 16 Z 6 CN 18 ­ 10 Z 6 CND 18- 12 Z 6 CN 25 -20

0,15 ­ 0,20 0,20 ­ 0,30 0,30 ­ 0,35 0,35 ­ 0,40 0,40 ­ 0,45 0,45 ­ 0,50 0,75 ­ 0,85 0,10 ­ 0,20 0,20 ­ 0,30 0,30 ­ 0,35 < 0,30 < 0,44 < 0,50 1,5 0,95 ­ 1,10 < 0,10 < 0,10 < 0,10 0,20 ­ 0,30 0,30 ­ 0,45 0,28 ­ 0,35 < 0,12 < 0,20 < 0,40 < 0,35 0,17 ­ 0,23 0,36 ­ 0,43 0,30 ­ 0,37 GENERALLY

THE CARBON CONTENT VARIES FROM 0.03 TO

< 100°C 100 ­ 150°C 150 ­ 250°C 150 ­ 300°C 150 ­ 350°C 200 ­ 400°C 300 ­ 400°C 150 ­ 250°C 200 ­ 320°C 250 ­ 450°C 210 ­ 320°C 260 ­ 430°C 320 ­ 480°C

NOT RECOMMENDED

STEELS ALLOYED WITH MOLYBDENUM

STEEL WITH MANGANESE

STEEL WITH CHROMIUM

200 ­ 800°C 200 ­ 400°C 200 ­ 400°C 200 ­ 400°C 200 ­ 300°C 250 ­ 350°C 300 ­ 400°C 200 ­ 300°C 250 ­ 350 °C 300 ­ 400°C 400 ­ 500°C 200 ­ 300°C 350 ­ 400°C 400 ­ 600°C GENERALLY

PREHEATING IS NOT NECESSARY

STEEL WITH CHROMIUM, MOLYBDENUM

STEEL WITH NICKEL, CHROME

STEEL WITH NICKEL, CHROMIUM, MOLYBDENUM

STAINLESS STEEL

0.08

NOTE : The preheating temperatures shown in this table have been defined as a function of the carbon content. It should be emphasized that the preheating temperatures do not take into account additional elements, the section thickness, or the location of the weld. The use of highly alloyed CASTOLIN welding products with superior mechanical properties makes it possible to safely lower these preheating temperatures, even eliminating them in certain situations. For example, for a 35NCD15 steel, welding with a conventional electrode requires preheating to 400 - 600°C, whereas using the 2222 electrode allows preheating to only 250 - 300°C.

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THEORETICAL VOLUME AND WEIGHT OF METAL

(to fill a one-meter chamfer in flat position)

V Joints

60°

Interior Angle

Exterior Angle

90°

90° a

S

e

s a mm 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 9 10 11 12 13 14 15 cm3/m 6 8,5 12,5 16 21 26 31,5 37 42 49,5 57 65 73,5 94 114 138 163 190 224 248 Kg/m 0,05 0,07 0,10 0,13 0,16 0,20 0,25 0,29 0,33 0,39 0,45 0,51 0,58 0,67 0,89 1,08 1,28 1,49 1,76 1,95 s mm 2 3 4 5 6 7 8 9 10 11 12 15 18 20 22 25 cm3/m 3 7 9 13,5 19,5 26,5 34,5 43 53,5 67 79 123 174 206 225 331 Kg/m 0,02 0,05 0,07 0,11 0,15 0,21 0,27 0,34 0,42 0,53 0,62 0,97 1,37 1,62 2,00 2,60

s mm 4 5 6 7 8 9 10 11 12 14 15 16 18 20 25

e mm 1 1 1

BASIS OF CALCULATION: volume to be deposited times density. average density used for the preceding data: 8kg/dm3. the values are only approximate; the exact quantities depend on several factors (shape of the bead, gap between the plates, metal recovery, etc.). FOR ALUMINUM AND ALUMINUM ALLOYS: FOR MAGNESIUM AND MAGNESIUM ALLOYS: FOR ELECTRODES: Divide the resulting values by 3. Divide the resulting values by 4.5. Multiply the resulting values by 1.2.

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PRINCIPAL METALS

METAL

IRON COPPER ALUMINUM MAGNESIUM LEAD ZINC TIN CADMIUM NICKEL CHROMIUM TUNGSTEN VANADIUM MOLYBDENUM MANGANESE COBALT TITANIUM SILVER STEEL TYPE 304 L STAINLESS STEEL TYPE 316 STAINLESS STEEL TYPE 310 STAINLESS STEEL CAST IRON BRASS BRONZE MONEL NICKEL SILVER

10 TECHNICAL DATA REFERENCES

CHEMICAL SYMBOL

Fe CU AL Mg Pb Zn Sn Cd Ni Cr W V Mo Mn Co Ti Ag Fe + C Fe+C+Cr+Ni Fe+C+Cr+Ni+Mo Fe+C+Cr+NI Fe+C CU+ZN CU+SN NI+CU CU+ZN+NI

MELTING POINT (°C)

1535 1083 658 650 327 420 232 321 1452 1800 3400 1720 2622 1242 1495 1800 961 1400-1500 1450 env. 1420 env. 1450 env. 1130-1400 900 env. 900 env. 1300-1350 900-1100

DENSITY (KG/DM3)

7,8 8,5 ­ 8,9 2,7 1,85 11,4 8,9 7,3 8,6 8,9 7,1 19,1 6,0 10,2 7,3 8,9 4,5 10,5 7,8 8,03 7,92 8,03 7,2 ­ 7,8 8,5 8,5 ­ 8,9 8,5 ­ 9,0 8,5 ­ 9,0

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ASSEMBLY AND REPAIR OF THE PRINCIPAL METALS

NOTE :

THE FOLLOWING TABLES ONLY SHOW SOME POSSIBILITIES AND THE PRODUCTS / PROCESS ARE NOT ARRANGED IN ORDER OF PREFERENCE. (THE FINAL CHOICE OF THE PROCESS OPTIONS AND ALLOY IN FACT DEPENDS ON FACTORS LIKE STRESS ON THE PARTS, DIMENSIONS, AVAILABLE FACILITIES, ETC.) THEIR CHOICE DOES NOT PRECLUDE TAKING INTO CONSIDERATION APPLICATION TECHNIQUES AND PROCEDURES TO BE FOLLOWED. IN SOME CASES, CONTACT WITH CASTOLIN TECHNICAL SERVICES WILL BE NECESSARY.

ASSEMBLY AND REPAIR OF CAST IRON

Grades and Standards Process options Most Commonly Used Alloys CASTOLIN 14 F CASTOLIN 157 CASTOLIN 197 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN 1030 XFC CASTOLIN 16 XFC CASTOLIN 18 XFC EUTALLOY 10224 EUTECTRODE 223 EUTECTRODE 224 EUTECTRODE 2.44 NC EUTECTRODE XHD 2230 EUTECTRODE 2240 EUTECTRODE XHD 2480 CASTOLIN 16 XFC EUTECTRODE 223 EUTECTRODE XHD 2230 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN 1030 XFC CASTOLIN 1702 CASTOLIN 16 XFC CASTOLIN 18 XFC EUTECTRODE 223 EUTECTRODE 224 EUTECTRODE XHD 2230 EUTECTRODE 2240 EUTECTRODE XHD 2480 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN1030 XFC CASTOLIN 1702 CASTOLIN 16 XFC EUTECTRODE 223 EUTECTRODE 224 CEUTECTRODE XHD 2230 EUTECTRODE 2240 EUTECTRODE XHD 2480 EUTECTRODE XHD 2230 EUTECTRODE 2240 EUTECTRODE XHD 2480 Clutch forks, Manipulator fingers, Levers Uses and Types of Parts

GREY CAST IRON NFA 32101 NFA 32102 Ft 10 Ft 15 Ft 20 Ft 25 Ft 30 Ft 35 Ft 40

Homogeneous welding Soldering Silver brazing

Thin or heavy castings Current cast iron applications. Machine casing, frames, Engine blocks, Faucets, valves, Pressing dies

Brazing

EUTALLOY process Manual arc process

PEARLITIC MALLEABLE IRON A 32703 MP 50.5 ­ MP 60.3 MP 70.2 FERRITIC MALLEABLE CAST IRON

WITH WHITE CORE

Brazing Manual arc process

NF 32701 MB 40.10 MB 35.7

Silver Brazing

Joints, Branches, Hubs

Brazing

Manual arc process

FERRITIC MALLEABLE CAST IRON

WITH BLACK CORE

Parts of all complex shapes, difficult to forge.

NF 32702 NN 35.10 NN 32.8 NN38.18

Silver Brazing Brazing Manual arc process

UNALLOYED IRON

WITH SPHEROIDAL GRAPHITE

Manual arc process

NFA 32201 FGS 800.2 FGS 700.2 FGS 600.3 FGS 500.7 FGS 400.12 FGS 370.17

Cam shafts, Crankshafts, Disk brakes, Cylinders, Jaws, pump body, Pinions, Gears.

Alloy cast iron alloys are not list in these tables. Nickel, chromium, molybdenum, and silicon sometimes present in these types of cast iron give them specific mechanical properties and structures. They are used in the domains of wear by abrasion, corrosion and heat.

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10 TECHNICAL DATA REFERENCES

ASSEMBLY AND REPAIR OF STEEL

Grades and Standards Process options Most Commonly Used Alloys CASTOLIN 1030 F CASTOLIN XUPER 1802 CASTOLIN 16 XFC CASTOLIN 18 XFC EUTECTRODE 640 EUTECTRODE XHD 646 EUTECTRODE Xuper 680 S EUTECTRODE 690 EUTECTRODE 3218 EUTECTRODE 4257 EUTECTRODE 6464 EUTECTRODE 66*66 N EUTECTRODE XHD 6868 CASTOMIG 45250 CASTOMIG 45251 CASTOMIG 45554 CASTOMIG 45513 ENDOTEC DO*02 TeroMatec 3302 CASTOLIN 1030 F CASTOLIN1030 XFC CASTOLIN 1702 CASTOLIN 16 XFC EUTECTRODE XHD 646 EUTECTRODE Xuper 680 S EUTECTRODE 690 EUTECTRODE 66*66 N EUTECTRODE XHD 6865 EUTECTRODE 2222 EUTECTRODE XHD 646 EUTECTRODE Xuper 680 S EUTECTRODE 690 EUTECTRODE XHD 6865 EUTECTRODE 2222 TeroMatec 3302 CASTOMIG 45250 CASTOMIG 45251 CASTOMIG 45554 CASTOMIG 45513 CASTOLIN 16 XFC EUTECTRODE Xuper 680 S EUTECTRODE 690 EUTECTRODE XHD 6865 EUTECTRODE 2222 EUTECTRODE XHD 6868 EUTECTRODE Xuper 680 S EUTECTRODE 690 EUTECTRODE XHD 6865 EUTECTRODE 2222 EUTECTRODE XHD 6868 CASTOTiG 45507 W CASTOTiG 45612 W Uses and Types of Parts Construction métallique

E 24 (A 37) E 26 (A 42) E 30 (A 47) E 36 (A 52) A 50 A 60 A 70 E 355 E 375 E 420 E 460

Silver Brazing Brazing Manual arc process

Traveling crane Storage tanks, Sheet metal works, Piping, Exchangers, Coolers, silos, Platforms, mobile structures for railway material. Machine frames Mechanically welded

MAG process MIG process

XC 25 XC 38 XC 42 XC48 XC 42 TS 38 CD 4 - 18 CD 4 25 CD 4 - 35 CD 4 42 CD 4 - 30 DC 12 50 CV 4 - 20 NC 6 30 NC 11 18 NCD 6 19 NCD 32 Z 120 M 12 16 NC D 13

Open arc process Silver Brazing

Brazing Manual arc process

General mechanics, Connecting rods, shafts, spindles Racks, piston rods Clutch forks, Coupling jaws, Lifting shafts, Coupling hooks, Crankshafts, Differential cases, Drive train components Public works, Mines, Cement works, Wearing plates, Quarry materials Public works machinery, Oven hoop, Crusher.

Manual arc process

Open arc process MAG process MIG process

20 NCD 2 50 CV 4 40 NCD 3 ­ 35 CD 4 42 CD 4 ­ 55 S 7 45 SCD 6 100 C 6 Z 200 C 12 Z 160 CDV 5 Z 100 CDV 5 45 CDV 6 ­ 40 NCD 16 35 NCD 16 ­ Z 35 CDV 5 55 NCDV 7

Brazing Manual arc process

Agricultural machine parts, Torque shafts, Gear boxes, Coupling hooks.

Manual arc process

Cold cutting, forging, stamping tools, Tools for casting aluminum and copper alloys under pressure.

TIG process

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ASSEMBLY AND REPAIR OF THE PRINCIPAL METALS

ASSEMBLY AND REPAIR OF STEEL

Grades and Standards Process options Most Commonly Used Alloys CASTOLIN 1702 CASTOLIN RB 3217 EUTECTRODE Xuper 680 S EUTECTRODE 2222 EUTECTRODE XHD 6865 CASTOMIG 45002 CASTOMIG 45554 CASTOMIG 45513 ENDOTEC DO*02 CASTOTiG 45507 W CASTOTiG 45612 W CASTOTiG 45513 W CASTOLIN 157 CASTOLIN 1702 CASTINOX 1610 S EUTECTRODE 33500 CASTOTiG 45500 W CASTOTiG 45513 W CASTOTiG 45612 W CASTOLIN 157 CASTOLIN 1030 F CASTOLIN1030 XFC CASTOLIN 1702 CASTOLIN 1020 F CASTOLIN 1020 XFC CASTOLIN 1702 EUTECTRODE Xuper 680 S EUTECTRODE 690 CASTOTiG 45507 W CASTOTiG 45513 W EUTECTRODE 33300 EUTECTRODE 33226 EUTECTRODE 33273 EUTECTRODE E 310- 17 EUTECTRODE 2222 CASTOMIG 45513 CASTOMIG 45612 CASTOTiG 45513 W CASTOTiG 45612 W CASTOLIN 157 CASTOLIN 1020 F CASTOLIN 1020 XFC CASTOLIN 1702 CASTINOX 1610 S EUTECTRODE Xuper 1616 EUTECTRODE 33500 CASTOMIG 45500 CASTOMIG 45612 CASTOTiG 45500 W CASTOTiG 45612 W EUTECTRODE 33300 EUTECTRODE 33273 EUTECTRODE 6825 CASTOMIG 45513 CASTOMIG 45612 CASTOMIG 45654 CASTOTiG 45513 W Uses and Types of Parts Pump parts, Surgical instruments Hydraulic turbines, Gates, Rotors, Molds for plastics.

Z 12 C 13 Z 30 C 13 Z 12 C 13 M Z 12 CN 13 02 M Z 6 CN 17 04 M

Silver Brazing Manual arc process

MIG process

TIG process

Z 8 C 15 Z 10 C 17

Soldering Silver Brazing Manual arc process TIG process

Metallic constructions, Decorative tubes, Furniture, flatware, hub caps

Z 2 CN 18.10 Z 6 CN 18.09

Soldering Silver Brazing

Boilermaking, Valves and fittings Heat exchanger, Pressure equipment, Pipe works, storage containers. Mechanical parts, Fan blades Fins, pumps, turbines.

Z 8 CN 20.11 Z 15 CN 24.13

Silver Brazing Manual arc process TIG process

Z 12 CN 25.20 Z 12 CNS 25.20 Z 8 CN 25.20 M

Manual arc process

Covering oven tunnels, Thermal treatment baskets and grills, Molded parts.

MIG process TIG process Z 2 CND 17.13 Z 6 CND 17.12 Z2 CND 19.15 Z 6 CNT 18.10 Z 6 CNNb 18.10 Soldering Silver Brazing

Manual arc process

Boilermaking, Heat exchanger, Storage tanks, Pipe works, Pressure equipment.

MIG process TIG process Z 2 CNNb 25.20 Z 5 CNDU 21.08 Manual arc process

MIG process

Same usage as the steel CN 25.20. Improved resistance to corrosion in acid environments with strongly reducing or oxidizing properties.

TIG process

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ASSEMBLY AND REPAIR OF PRINCIPAL COPPER ALLOYS

ASSEMBLY AND REPAIR OF COPPER AND BRONZES

Grades and Standards Process options Most Commonly Used Alloys CASTOLIN 157 CASTOLIN 181 CASTOLIN 800 CASTOLIN 1030 F CASTOLIN1666 XFC CASTOLIN 1702 CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN 1810 F CASTOLIN XUPER 1802 CASTOLIN 1806 CASTOLIN 18 XFC CASTOLIN 157 CASTOLIN 181 CASTOLIN 800 CASTOLIN 1030 F CASTOLIN 1666 XFC CASTOLIN 1702 CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN 1810 F CASTOLIN XUPER 1802 CASTOLIN 1806 CASTOLIN 18 XFC CASTOTiG 45706 W CASTOLIN 157 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN 1666 XFC CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN 1810 F CASTOLIN XUPER 1802 CASTOTiG 45703 W CASTOTiG 45706 W EUTECTRODE 285 CASTOLIN 18 XFC CASTOLIN 157 CASTOLIN 1030 F CASTOLIN 1666 XFC CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN 1810 F CASTOLIN XUPER 1802 CASTOLIN 157 CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN 1030 F CASTOLIN 1666 XFC Uses and Types of Parts

10 TECHNICAL DATA REFERENCES

COPPER Cu/A1 Cu/A2 (oxygen Cu/A3 present)

Soldering Silver Brazing

Electrical and mechanical uses, Arms of spot welders, Jewelry making, Kitchen utensils

Cu/b (deoxidized Cu/c1 without Cu/c2 oxygen)

Brazing Soldering Silver Brazing

BRONZES (Cu+Sn) UE 9 P UE 12 P

Brazing TIG process Soldering Silver Brazing

General uses, Rubbing parts,. Valves and fittings, Bearing bushings, Mechanical construction, Low-cut parts Segments.

TIG process Manual arc process Brazing (potentially) Soldering Silver brazing

UE 16 UE 18

Gears, Segments.

*UE 4 Pb *UE 7 Z Pb 5

Soldering Silver Brazing

Easy to use, Parts subject to rubbing.

*NB: fragile with arc process

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ASSEMBLY AND REPAIR OF PRINCIPAL COPPER ALLOYS

Grades and Standards Process options Most Commonly Used Alloys CASTOLIN 157 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN1666 XFC CASTOLIN 1810 F CASTOLIN XUPER 1802 CASTOLIN 18 XFC CASTOLIN 45706 W CASTOLIN 157 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN1666 XFC CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN XUPER 1802 CASTOLIN 18 XFC CASTOLIN 157 CASTOLIN 1030 F CASTOLIN 1666 XFC CASTOLIN 1810 F CASTOLIN XUPER 1802 CASTOLIN 157 CASTOLIN 1030 F CASTOLIN 1666 XFC CASTOLIN 1020 F CASTOLIN XUPER 1802 CASTOLIN 157 CASTOLIN 157 CASTOLIN 181 CASTOLIN 1030 F CASTOLIN1666 XFC CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN XUPER 1802 CASTOLIN 1810 F CASTOLIN 157 CASTOLIN 1030 F CASTOLIN1666 XFC CASTOLIN XUPER 1802 CASTOLIN 1810 F CASTOMIG 45751 CASTOMIG 45750 CASTOTiG 45706 W CASTOTiG RB 5248 CASTOLIN 157 CASTOLIN 181 CASTOLIN 1020 F CASTOLIN 1800 CASTOLIN 1702 CASTOLIN XUPER 1802 CASTOLIN 45751 W CASTOLIN RB 3229 CASTOMIG 45612 CASTOMIG 45751 EUTECTRODE 2222 Uses and Types of Parts Sheet metal, sections Condenser tubes, Locksmithing, Decoration, lighting, Musical instruments.

BRASS (ZINC IS THE MAIN

ADDITIONAL ELEMENT.)

Soft Soldering Silver brazing

ordinary brass, (UZ 5 à UZ 15). Brazing TIG process (potentially) Soldering Silver Brazing

UZ 20 à UZ 30

UZ 37 à UZ 40

Brazing Soldering Silver Brazing

*UZ 38 Pb 1E

Soldering Silver Brazing

Mechanical parts, Parts cut low at high speed.

Joints.

*UZ 38 Pb 2 UZ 15 à 3 NS

Soldering (brazing difficult,

because of lead exudation)

Soldering (Alutin 51 flux) Silver Brazing (Albro flux)

High resistance brass, Marine tubes and parts.

ALUMINUM BRONZE (CU + SN) UA 9 UA 9M UA 10 N Fe UA 10 Fe4 UA 10 N UA 14 Fe

Soldering (Alutin 51 flux) Silver Brazing (Albro flux)

MIG process TIG process Soldering Silver brazing

Chemical industry, Refrigerant tubes, Steam faucets, Gears, propellers, propeller shafts, Sea water pumps Drawing dies, Cylinder pistons

CUPRONICKEL AND NICKEL-SILVER

TIG process MIG process Manual arc process

Good resistance to corrosion, Hydraulic material parts, Condenser tubes, Pump bodies, Silversmithing, Food industry. Breweries, Glassmaking molds.

*NB: Braze welding difficult and fragile on interior angle

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ASSEMBLY AND REPAIR OF LIGHT ALLOYS

Grades and Standards Process options Most Commonly Used Alloys CASTOLIN 1827 (décapant Alutin 51) CASTOLIN 190 CASTOILIN 21 F EUTECTRODE XHD 2100 CASTOMIG 45803 CASTOLIN 1827 (décapant Alutin 51) CASTOLIN 190 CASTOLIN 21 F EUTECTRODE XHD 2100 CASTOLIN 21 F EUTECTRODE XHD 2100 CASTOMIG 45802 CASTOMIG 45805 CASTOTiG 45802 W CASTOTiG 45805 W CASTOLIN 210 EUTECTRODE 2101 S Uses and Types of Parts

10 TECHNICAL DATA REFERENCES

ALUMINIUM A 5 (1050)

Soldering

Aluminum alloys Manganese AM 1 (3003) AM 1G (3004) AM G 05 (3005) Aluminum alloys Magnesium AG 0,6 (5005) AG 3 M 5 (5754 X)

Manual arc process MIG process Soldering

Materials for chemical and food industry, Building coverings, Household appliances, Boiler making, decorative pieces, reflectors Boiler making, pressed parts, materials for food and household appliance industries.

Brazng Manual arc process Brazing Manual arc process MIG process TIG process

Buildings, façade panels and coverings. Boiler making, automobile, railway, transport tankers, household appliance material. Casing, Mechanical parts, Valves and fittings.

AS 7B AS 10B

AS 7 B3 AS 12

Brazing Manual arc process

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CASTOLIN ONLINE.

www.castolin.com

Visit the Castolin website for the very latest news and information from the market leaders in wear protection and fusion technology.

n n n n n n n

Products Industry Services TeroLink News Events Downloads Catalogues Literature Wall charts TeroLink AAP's New products News letter

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TEROLINK - THE APPLICATION DATABANK.

With our extensive experience and a network of world wide customers, we have developed a market leading database ­ TeroLink ­ with the very latest development in applications solutions. We also provide training as well as promoting potential cost savings in the cement industry.

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Over 6,000 successful applications Technical data Method statements Cost saving and performance enhancing sheets

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10 TECHNICAL DATA REFERENCES

PERIODIC TABLE OF ELEMENTS.

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INDUSTRY PROGRAMMES

INDUSTRY PROGRAMMES FROM CASTOLIN EUTECTIC

Castolin Eutectic - with their wealth of experience in wear protection ­ have developed a series of "Industry Programmes" that look at specific applications of wear throughout major world wides industries that encounter significant High Load, High Wear issues.

High Load, High Wear

A guide to the various types of wear and their causes in high load environments, industries that have high wear issues as well as example applications with problem, solution and cost savings to customer.

CemTec

A tour of the various plant equipment and processes specific to the Cement industry, common wear problems encountered in these environments and applications with their solutions, cost savings and life enhancing data. Castolin Eutectic is part of a dedicated global CemTec team focused on providing solutions to wear protection in the cement industry.

NEW Waste & Recycling

A guide to the different types of recycling sectors, from Waste to Glass and Tyres to Sewage, Castolin Eutectic have a programme of proven wear protection solutions designed to enhance product life and reduce costs.

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10 TECHNICAL DATA REFERENCES

INDUSTRY PROGRAMMES

Pulp & Paper

Pulp and paper mills have a unique range of wear and corrosion problems. For example severe abrasion is found in the wood yard at the debarking stage while abrasion and/ or erosion occurs in the production of chips and their transport to the digesters.

Tool & Die

Castolin Eutectic works together with Tool & Die manufacturers and also their major users (such as automotive companies and component producers shaping steel, aluminium, glass, etc.) The tool and die steels used have to withstand severe impact and wear during service, whilst maintaining their exact dimensional tolerances for many thousands of parts. Consequently, the steels are usually complex in their manufacturing and very sensitive. The ability to repair cracked sections, renovate worn areas or make slight geometry modifications by welding, can lead to large cost savings and flexibility gains.

Other Industry Programmes are available on request.

PRODUCT LITERATURE

This is a selection of our wide range of product marketing literature More available on request.

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DEVELOPMENT AND PROJECT MANAGEMENT

Choosing Castolin Eutectic as your industrial partner brings clear benefits - higher quality manufactured products, enhanced durability, increased productivity and significantly improved profits.

PROJECT MANAGEMENT

Castolin Eutectic's world-wide experience enables us to:

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Take a look at your wear issues Review your requirements Provide turnkey solutions to resolve your problems.

Consultancy

Adopting a "Consultancy" approach, we have experience of providing bespoke solutions to meet your every need, whether it is joining solutions or enhanced wear protection from site surveys through to the development of products specific to your requirements.

Plant Survey

We offer an in-depth plant survey where appropriate to identify the best solution to specific problems. This thorough on-site study is conducted in partnership with plant engineers to analyse all aspects of the situation and develop a problem-solving strategy.

Documentation covering the application areas is produced, leading to a method statement describing step-by-step the procedure for repairs and wear prevention and an estimate of potential cost savings. This ensures quality control and reproducibility of the process, thereby detailing `best practice'.

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10 TECHNICAL DATA REFERENCES

SERVICE

CastoLab

service is available.

Creative solutions through Specialist Workshops

CastoLab is the sub-contract engineering Wear & Fusion and service division of Castolin Eutectic, offering a complete and comprehensive service for the maintenance and repair of machine parts and major components subject. Work can either be undertaken in the workshop facility or alternatively, an on-site

CastoLab utilises the latest Wear and Fusion technologies and materials and is fully equipped with the most advanced processes for repair maintenance. Highly experienced engineers will undertake a complete study of your manufacturing equipment from diagnosis of the problem, preparation and reclamation treatment of the component, final machining, a detailed inspection and test of all treated parts to make them ready for use. CastoLab has the facility to offer:

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TIG MMA & MIG/MAG THERMAL SPRAYING ARC SPRAY PTA BRAZING POLYMERIC COATING FUSE COATING

We also offer small and medium batch production runs of semi finished products in the above processes

Service

Clear benefits from service excellence

Choosing Castolin Eutectic as your industrial partner brings clear benefits - higher quality manufactured products, enhanced durability, increased productivity and significantly improved profits.

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Service equipment Installation and repair of equipment Offer validation & calibration of equipment Dedicated service manager Industrial gas equipment inspection by trained personel

These benefits are delivered across a huge range of industries and are supported by top-quality customer service and fast response.

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PRODUCTION

Reliability Performance Value for Money

Reliability. Performance. Value for Money

These are important values for customers of Castolin Eutectic who demand the best ­ and we strive to offer the best; first time ­ every time.

At our manufacturing facilities around the world we continue to produce the highest quality products to suit requirements of customers and their demanding applications. This is reflected by the number and variety of products available as well as the quality which is in evidence when using our products. Included in this catalogue are a number of products which we have been selling for years; in some cases over 20 or 30 years old ­ for example 1020 XFC, 680S, 244 and Eutalloy 10675. They are quite simply so good at their application that they are unsurpassed, even to this day.

RESEARCH & DEVELOPMENT

Our vast accumulated research and development data enable us to create state-of-the-art solutions through our qualified technical support engineers in different countries around the world. With Castolin Eutectic, you are tapping into a wealth of information shared between hundreds of experts over the five main continents. This means that we are continually on the cutting edge of new products, with a worldleading reputation as the first to market in product development. Where we lead, others follow.

Where we lead, others follow

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10 TECHNICAL DATA REFERENCES

Training

Knowledge Transfer by Training

Castolin Eutectic offers industry a range of specialised training courses, which covers all aspects of the welding processes, e.g. MMA, Mig, Tig. Brazing, Soldering and Thermal Spray Coatings. These courses can be tailor-made to suit your company requirements and conducted to all levels of operators, from basic skills to advanced levels. Depending on your requirements for your operators courses can comprise 100% practical or theoretical, or a mixture of both, and are aimed at both manual staff and skilled engineers. Training courses offered by Castolin Eutectic TIG MMA & MIG/MAG THERMAL SPRAYING ARC SPRAY PTA BRAZING

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TIG MMA & MIG/MAG THERMAL SPRAYING ARC SPRAY PTA BRAZING POLYMERIC COATING FUSE COATING

POLYMERIC COATING FUSE COATING

Contact us to book your training course now

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Castolin GmbH Austrian Market Center, Brunner Strasse 69, A-1235 Vienna Tel: +43 1 869 45 41 - 0 Fax: +43 1 869 45 41 - 10 Email: [email protected] Web: www.castolin.com

06/2008

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