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Stronger, with Castolin EutecticStronger, with Castolin Eutectic

Tel:+43 1 869 45 41 www.castolin.com2European Product Catalogue.

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 publi-cation, it is provided for guidance only and Castolin Eutectic will not accept any liability resulting from its use.

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 Eutectic1970’s: Creation of training centers for Maintenance & Repair technologies1978: 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 subsidiaries4 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 deve-lopment 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.

Tel:+43 1 869 45 41 www.castolin.com3European Product Catalogue

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 - 0Fax: +43 - (0)1 - 869 45 41 - 10

email: [email protected]: www.castolin.at


1 LOW HEAT INPUT WELDING ALLOYS 6

11 EUTECTRODE MANUAL ELECTRODES 611.10 Welding Cast Irons 611.20 Welding Steels 711.23 Welding Stainless Steels 811.26 Welding Structural Steels 911.30 Welding Copper Alloys 911.35 Welding Aluminium Alloys 911.40 Gouging, Chamfering, Cutting 911.50 Carbide Alloy Coatings 1011.53 Alloy Steel Coatings 1111.56 Nickel Alloy and Cobalt Alloy Coatings 11

12 CASTOMIG-MAG WELDING WIRES 1212.23 Welding Stainless Steels 1212.26 Welding Structural Steels 1312.30 Welding Copper Alloys 1312.35 Welding Aluminium Alloys 1412.53 Alloy Steel Coatings 1412.56 Nickel Alloy Coatings 14

13 CASTOTIG WELDING RODS 1513.20 Welding Special Steels 1513.23 Welding Stainless Steels 1513.26 Welding Structural Steels 1513.30 Welding Copper Alloys 1613.35 Welding Aluminium Alloys 1613.53 Alloy Steel Coatings 1613.56 Nickel Alloy and Cobalt Alloy Coatings 17

14 ENDOTEC CORED WIRES (GAS SHIELDED) 1814.10 Welding Cast Irons 1814.20 Welding Steels 1814.23 Welding Stainless Steels 1814.50 Carbide Alloy Coatings 1814.53 Alloy Steel Coatings 1914.56 Nickel Alloy and Cobalt Alloy Coatings 20

15 TEROMATEC CORED WIRES (SELF SHIELDED) 2115.50 Carbide Alloy Coatings 2115.53 Alloy Steel Coatings 21

2 LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS 24

21 ECOBRAZ RANGES 2421.10 Capillary Soldering Brazing Alloys 2422.10 Self-Fluxing Brazing Alloys for Copper 2523.10 Gas Welding and Brazing Alloys 2523.20 Wearfacing Alloys 2624.10 Soldering Alloys 2727.10 Fluxes 2828.10 Brazing Light Metal Alloy and Soldering Pastes 31

TABLE OF CONTENTS


3 POWDERS AND WIRES FOR THERMAL SPRAYING 36

31 POWDERS FOR THERMAL SPRAYING 3631.10 RotoTec – Alloy powders for "cold" spray process 3631.20 ProXon – One-step alloy powders for "cold" spray process 3731.30 Eutalloy – Self-fluxing powders for spraying with simultaneous fusion 3831.40 Eutalloy SF – Self-fluxing powders for spraying with simultaneous fusion 3831.50 Eutalloy RW – Self-fluxing powders for spraying with subsequent fusion 3931.60 CastoPlast – Polymer powders for thermal spray process 3931.70 MetaCeram – Ceramic and refractory powders for "cold" thermal spray process 4031.80 EuTroLoy – Alloy powders for PTA (Plasma Transferred Arc) process 40

32 WIRES FOR THERMAL SPRAYING 4132.10 EuTronic Arc spray wires – Alloy wires for arc spraying 41

4 COMPOSITE WEAR FACING MATERIALS 42

41 MECATEC - COLD SURFACING TECHNOLOGY POLYMERS 42

9 CASTODUR DIAMOND PLATES 44

91 WELD CLADDED PLATES 44

92 POWDER COATED PLATES 45

93 CASTOTUBES 45

TABLE OF CONTENTS

1 LOW HEAT INPUT WELDING ALLOYS



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

XHD 2230Ø 2.5 - 3.2 - 4.0

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%

XHD 2480Ø 2.5 - 3.2

Nickel based electrode developed for welding and repair of grey cast iron. Regular deposits. Increased crack resistance.Rm: 320 MPa

2-23Ø 2.5 - 3.2 - 4.0

Nickel iron electrode developed for welding grey cast iron and ductile cast iron. High crack resistance.Rm: 325 MPa Rp0.2: 310 MPa

2-24Ø 2.5 - 3.2 - 4.0

Nickel based electrode developed for welding grey cast iron with soft, machinable deposits. Very easy to use.Rm: 480 MPa Rp0.2: 230 MPa

2240Ø 2.5 - 3.2 - 4.0

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

11 EUTECTRODE MANUAL ELECTRODES

1 LOW HEAT INPUT WELDING ALLOYS1 LOW HEAT INPUT WELDING ALLOYS


1LOW HEAT INPUT WELDING ALLOYS

11.20 WELDING STEELS

640Ø 2.5 - 3.2 - 4.0

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

XHD 646 Ø 2.5 - 3.2Ø 4.0 - 5.0

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

Xuper 680SØ 1.6 - 2.0 - 2.5Ø 3.2 - 4.0

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%

Xuper 690Ø 2.5 - 3.2 - 4.0

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%

Xuper 2222Ø 2.5 - 3.2Ø 4.0 - 5.0

Electrode deposits a high nickel alloy with an austenitic structure for wel-ding all kinds of steel and steel castings in thick sections. Welding nickel alloys and Inconel 600®™. Working temperature: from cryogenic up to 980°C.Rm: 670 MPa Rp0.2: 420 MPa A5: 45%

Designations Properties

690 SFØ 2.5 - 3.2

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%

XHD 2222Ø 2.5 - 3.2 - 4.0

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%

XHD 6868 Ø 2.5 - 3.2 - 4.0

Electrode developed for high speed welding of difficult-to-weld, galva-nised or dissimilar steels. Rebuilding and buttering layers before wear facing. High metal recovery (170%).Rm: 800 MPa Rp0.2: 670 MPa A5: 17.5%




11.23 WELDING STAINLESS STEELS


E 307-17Ø 2.5 - 3.2 - 4.0

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

E 308L-17 Ø 2.5 - 3.2 - 4.0

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

E309MoL-17Ø 3.2 - 4.0

Rutile type electrode depositing low carbon austenitic-ferritic stainless steel. It has increased corrosion resistance, notably to intercrystalline cor-rosion 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

E 310-17Ø 2.5 - 3.2 - 4.0

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

E 316L-17Ø 2.0 - 2.5Ø 3.2 - 4.0

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.

E 318-17Ø 2.5 - 3.2 - 4.0

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

E 385-17Ø 2.5 - 3.2 - 4.0

Electrode developed for homogeneous welding of Z2 NCDU 25-20 (Uranus B6 ®™) 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

33000Ø 2.0 - 2.5 - 3.2

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

33300Ø 2.5 - 3.2

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

33500Ø 2.0 - 2.5 - 3.2

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

Especially for Maintenance Welding of Stainless Steels





11.30 WELDING COPPER ALLOYS

11.26 WELDING STRUCTURAL STEELS



6601Ø 2.5 - 3.2

Rutile electrode for welding usual structural steels in all positions. Rm: 570 MPa Re: 480 MPa A5: 21 % AWS A 5.1: E 6013

6666 Ø 2.5 - 3.2 - 4.0

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

285Ø 3.2 - 4.0

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

XHD 1855Ø 3.2

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

2101SØ 2.5 - 3.2

Electrode developed for the assembly and repair of aluminium alloy castings.Rm: 170 MPa Rp0.2: 95 MPa A5: 5 %

XHD 2100Ø 3.2

Electrode developed for welding wrought aluminium alloys particularly when anodisation is required .


11.40 GOUGING, CHAMFERING, CUTTING


CutTrode 01Ø 3.2 - 4.0 - 5.0

Electrode developed for gas free, high speed cutting and piercing work on all metals in all positions.

ChamferTrode03 / 04Ø 3.2 - 4.0

Electrode developed for fast metal removal and surface preparation by chamfering, grooving and gouging.Elimination of worn and cracked surfaces.

Castinox DØ 2.5 - 3.2

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 %

Especially for Maintenance Welding of Stainless Steels - Continued





11.50 CARBIDE ALLOY COATINGS

N 700Ø 3.2

Electrode depositing chromium carbides for wear protection against abrasion combined with pressure and moderate impact.Hardness: 59-64 HRC.

XHD 6710Ø 3.2 - 4.0

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.

XHD 6715Ø 3.2

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.

5006Ø 2.5 - 3.2Ø 4.0 - 5.0

High metal recovery (170%) electrode developed for anti-wear resurfa-cing of parts subject to combined stresses: abrasion, pressure and mode-rate impact by medium to fine particles.Hardness: 55-60 HRC.

N 6070Ø 4.0

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


XHD 6715

TECHNICAL NOTE

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

5006

N 6070 N 700

6088Ø 5.0

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




11.53 ALLOY STEEL COATINGS

2Ø 2.5 - 3.2

Electrode deposits a chromium, molybdenum, manganese alloy steel develo-ped for anti-wear coating of parts to resist impact, pressure and abrasion.Hardness: 55-60 HRC

6Ø 2.5 - 3.2

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

N 102Ø 3.2 - 4.0

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

EC 3292Ø 2.5 - 3.2

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

XHD 6804Ø 2.5 - 3.2 - 4.0

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


6055Ø 3.2 - 4.0

Electrode deposits a low temperature precipitation hardening marten-sitic 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

35200Ø 3.2 - 4.0

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

11.56 NICKEL ALLOY AND COBALT ALLOY COATINGS


XHD 6865Ø 2.5 - 3.2

High metal recovery (150%) electrode depositing a special nickel alloy, developed for wear protective coatings on hot working tools and diesWorking temperature: up to 950°C.Hardness as welded: 240 HB Work hardened: 360-380 HB.

XHD 6817Ø 3.2

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.




11.56 NICKEL ALLOY AND COBALT ALLOY COATINGS - CONTINUED


N 9025Ø 3.2

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

N 9060Ø 3.2

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

N 9080Ø 3.2 - 4.0

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


12 CASTOMIG-MAG WELDING WIRES


45500 S(ER 316LSi)Ø 0.8 - 1.2 - 1.615 Kg

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

45503 S(ER 308LSi)Ø 0.8 -1.0Ø 1.2 - 1.615 Kg

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

45513 S(ER 310)Ø 1.0 - 1.2 15 Kg

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

45516 S(ER 309LSi) Ø 1.015 Kg

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




45552 S(ER 347) Ø 0.8 - 1.0 - 1.2 15 Kg

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

45554 S (ER 307 Si)Ø 0.8 - 1.0Ø 1.2 - 1.615 Kg

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 %



45250Ø 0.8 - 1.0 - 1.215 Kg

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

45252Ø 0.8 - 1.0 - 1.215 Kg

MAG wire for welding steel resistant to heat and creep up to 570 °C.Rm: >600 MPa Rp0.2: >500 MPa A5: >20%

45257Ø 0.8 - 1.0 - 1.215 Kg

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


12.23 WELDING STAINLESS STEELS - CONTINUED


45703Ø 1.0 - 1.215 Kg

MIG wire for assembly and coating of plain bronze (copper-tin) parts.Rm: 260 MPa A: 20 % DIN 1733 SG-CuSn6

45706Ø 1.0 - 1.215 Kg

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


45751Ø 0.8 - 1.0Ø 1.2 - 1.615 Kg

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




12.35 WELDING ALUMINIUM ALLOYS

45802Ø 0.8 - 1.0 - 1.27.5 Kg

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: AW–AlMg5(A)

45803Ø 1.0 - 1.2 - 1.67.5 Kg

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)

45806Ø 1.0 - 1.27.5 Kg

MIG wire (type AG4MC, 5183) for welding aluminum-magnesium alloys.Rm: >275 MPa Rp0.2: >125 MPa A5: >17 % EN: AW-AlMg5Mn1(A)



45351Ø 0.8 - 1.0Ø 1.2 - 1.615 Kg

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


45365Ø 1.0 - 1.215 Kg

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

45654Ø 1.0 - 1.215 Kg

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





13.20 WELDING SPECIAL STEELS

45507 WS(ER 312)Ø 1.0 - 2.0Ø 2.4 - 3.2

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

45612WØ 1.0 - 1.6Ø 2.0 - 2.4

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 NiCr–3

45654WØ 1.6 - 2.0 - 2.5

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



45500 WS(ER 316L)Ø 1.6 - 2.0 - 2.4

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

45503 WS(ER 308L)Ø 1.0 - 1.6 - 2.0Ø 2.4 - 3.2

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

45513 WS(ER 310)Ø 1.6 - 2.0

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

45552W(ER 347)Ø 1.0 - 2.0Ø 2.4 - 3.2

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 CASTOTIG WELDING RODS


45252WØ 2.0 - 3.0

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

45255WØ 2.0 - 2.4 - 3.0

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





45701WØ 2.0

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

45703WØ 2.0 - 2.5

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

45704WØ 2.0 - 3.0

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

45706WØ 2.0

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


13.35 WELDING ALUMINUM ALLOYS

45801WØ 2.0 - 3.2

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

45802WØ 2.0 - 2.5Ø 3.2 - 4.0

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

45806WØ 2.0

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




45301WØ 1.0 - 1.6Ø 2.0 - 2.4

TIG rod for coating parts subject to heat, thermal shock and plastic deformation.Hardness as welded: 46 HRC

45303WØ 1.0 - 1.6Ø 2.0 - 2.5

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






45406WØ 3.0 - 4.0

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

45412WØ 3.0

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

45421WØ 3.0

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

45612WØ 1.0 - 1.6Ø 2.0 - 2.4

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 A 5.14: ER NiCr–3

45654WØ 1.6 - 2.0 - 2.5

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 A 5.14: ER


45355 WØ 1.0 - 1.6 - 2.0

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

13.53 ALLOY STEEL COATINGS - CONTINUED

45305WØ 1.0 - 1.6

TIG rod for preventive and repair coating of hot working tools.Hardness as welded: 53 HRC

45351 WØ 1.0 - 1.6

TIG rod for coating parts subject to heat, impact, sliding and rolling abrasion.Hardness as welded: 60 HRC






DO*28 SØ 1.215 Kg

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




DO*48Ø 1.615 Kg

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

DO*11Ø 1.615 Kg

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

14.20 WELDING STEELS

DO*02Ø 1.2 - 1.615 Kg

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

DO*22Ø 1.6 15 Kg

Inconel 600®™ 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


DO*266 SØ 1.6 15 Kg

Copper-coated cored wire electrode providing fast solidification, rutile-type slag characteristics.Rm: 510 Mpa A5: 22%

14.10 WELDING CAST IRONS

DO*23Ø 1.0 - 1.215 Kg

Metal cored nickel-iron wire developed for welding cast iron assemblies or rebuilding.Joining cast iron to steel.Hardness: 200 HV30


14 ENDOTEC CORED WIRES (GAS SHIELDED)





DO*04Ø 1.2 - 1.6 15 Kg

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

DO*05Ø 1.615 Kg

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

DO*06Ø 1.615 Kg

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

DO*13 Ø 1.2 - 1.615 Kg

Metal cored wire developed for producing anti-wear coatings, having a high resistance to pressure, impacts and moderate abrasion.Hardness: 58 HRC

DO*15Ø 1.2 - 1.615 Kg

Metal cored wire developed for producing anti-wear coatings on parts subject to impact, abrasion and contact fatigue.Hardness: 58 HRC

DO*16Ø 1.615 Kg

Metal cored wire developed for producing anti-wear coatings having excellent resistance to shocks and to pressures up to 550°C.Hardness: 48 HRC.


14.50 CARBIDE ALLOY COATINGS - CONTINUEDDesignations Properties

DO*395 NØ 1.215 Kg

The slag-free deposit contains a high volume fraction of ultra-hard pha-ses which ensures an excellent performance against abrasion, erosion combined with moderate impact.Hardness (one layer): 69 HRC

DO*33Ø 1.615 Kg

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

DO*30Ø 1.2 - 1.615 Kg

Metal cored wire developed for producing single pass, anti-wear coatings on parts subject to abrasion and erosion by small particles.Hardness: 67 HRC

DO*390 NØ 1.615 Kg

NanoAlloy patended, gas shielded, metal cored alloy wire, ideal for main-tenance and repair applications or batch manufacturing where highest integrity welding, efficiency and productivity are required.Hardness (one layer): 70 HRC

DO*55Ø 1.615 Kg

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




14.53 ALLOY STEEL COATINGS - CONTINUED


DO*60 Ø 1.2 - 1.615 Kg

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

DO*70Ø 1.615 Kg

Metal cored wire depositing a Grade 12 type cobalt base alloy. Excellent resistance to heat, corrosion, abrasion, cavitation and metal-to-metal frictionHardness: 48 HRC

DO*80Ø 1.615 Kg

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


DO*85Ø 1.615 Kg

Metal cored wire depositing a Grade 25 type cobalt base alloy. Excellent resistance to thermal shocks and pressures, as well as abrasion at tempe-ratures up to 950°C and oxidation up to 1200°C.Hardness as welded: 250 HV30 Work hardened: 380 HV30

DO*327Ø 1.615 Kg

Metal cored wire developed for producing multi pass, anti-wear coatings on parts subject to abrasion and erosion by small particles.Hardness: 65 HRC

DO*332Ø 1.615 Kg

Metal cored wire developed for multi pass, anti-wear coatings having excellent resistance to abrasion and moderate impact.Hardness: 60 HRC

CaviTec GMAØ 1.2 - 1.615 Kg

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


DO*322Ø 1.615 Kg

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





3952Ø 1.6 - 2.815 kg

Self shielded cored wire developed for coating parts subject to hot abrasion up to service temperature of 600°C.Hardness: 65 HRC

4601Ø 1.2 - 1.6 - 2.815 Kg

Self shielded cored wire developed for coating parts subject to abrasion without impact.Hardness: 60 HRC

4660Ø 1.2 - 1.6 - 2.815 Kg

Self shielded cored wire developed for coating parts subject to abrasion by medium and large bodiesHardness: 63 HRC


15 TEROMATEC CORED WIRES (SELF SHIELDED)


3205Ø 1.6 - 2.4 - 2.815 Kg

Self shielded cored wire developed for anti-wear coating of low or alloy steel parts with work hardening properties against heavy impact, pres-sure and friction.Hardness as welded: 250 HV30 Work hardened: 390 HV30

4415Ø 1.6 - 2.815 Kg

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

4630Ø 2.815 Kg

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

4923Ø 1.2 - 1.6 - 2.815 Kg

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


4395 NØ 2.815 Kg

Self shielded cored wire developed for coating parts subject to abrasion and erosion combined with moderate impact.Hardness: 69 HRC




TECHNICAL NOTESample 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

TONGS / STEEL INDUSTRY

CROWN GEAR RING – SUGAR REFINERY

MOULD / AUTOMOTIVE

ROTARY CUTTER / CIVIL ENGINEERING

ROTOR DISCS / CEMENT PLANT

HAMMERS / WASTE RECYCLING HYDROPULPER ROTOR / PAPER MILL

2 LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS



21.10 CAPILLARY SILVER BRAZING ALLOYS

Cadfree® Silver Alloys

1020 B - T - XFC 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.


1666 1666 XFC

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.

181 - 181 F Maximum Safety Margin, thanks to its high silver content: either by capillary attraction, in the case of close-fitting components, or by moul-ding in the case of large joint gaps. Joints built up with Castolin 181 are especially resistant to impact and vibrations.

Silver Alloys with Cadmium

1010 XFC 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 flui-dity, lowest joining temperature and high mechanical strength in joints. Water/gas-tight sealing of joints.

1802 - 1802 L 1802 XFC

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.

1810 XFC Versatile and economical, this low temperature brazing alloy is designed for application on copper, brass, bronze and steels. Especially recommen-ded for dissimilar metal combinations such as carbon or alloy steels to copper, brass or bronze.


1030 XFC 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.

21 ECOBRAZ RANGES

2 LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS2 LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS


2BRAZING & SOLDERING ALLOYS

22.10 SELF-FLUXING BRAZING ALLOYS FOR COPPER

Self-Fluxing Copper Alloys

1803D Self-fluxing brazing alloy for copper to copper joining.

1805 Self-fluxing brazing alloy for copper to copper joining.

RB 5246 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 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 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 mechani-cal strength in joints. Water/gas-tight sealing of joints.


RB 5286 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 rodDeposit colour: copper (after cleaning)

23.10 GAS WELDING AND BRAZING ALLOYS

Brazing-Brass/Bronze Alloys

146 MF - 146 XFC 146 is a bronze type alloy for use with cast-iron and carbon steel compo-nents, 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.





18 - 18 MF 18 XFC

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.

185 XFC Cu-Zn-Ni braze welding alloy for repair and rebuilding of metal components.

80 MF 80 XFC

The Castolin alloy 80 is recommended for high strength joints on tubu-lars chassis and bronze bearings and excellent frictional resistance over-lays on shafts etc.

TeroCote® 7888 T with carbides

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 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.

CastoDrill 8800 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 dis-persed through a tough alloy matrix.

23.20 WEARFACING ALLOYS

Wearfacing with Carbides


Brazing-Brass/Bronze Alloys - CONTINUED





Ultimium 8888 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 resis-tance.

Ultimium 8888 Cutter

Castolin 8888 Cutter was specifically designed to be have the «Ultimate Cutting Performance». Only high grade tungsten carbides are used, insuring consistant cutting performance.

E 7650 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.

Wearfacing with Carbides - CONTINUED


CastoDur® N 901 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® N 906 CastoDur 906 is a cobalt base filler metal. This alloy is used in applications where lower hardness with abrasion and corosion resistance are needed.

Wearfacing without Carbides


24.10 SOLDERING ALLOYS

Soft Soldering


157 - 157 T 157 is a solder alloy containing silver but no lead or cadmium, and parti-cularly 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 1827 is a cadmium based soft solder containing silver. It is recommended for joining aluminium to copper.




Light Metal


190 - 190 FBK 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 alumi-nium silicon alloy producing good strength joints and good resistance to corrosion. Not suitable for parts requiring anodised finishes or alumi-nium alloys containing more than 1.5% magnesium.190: Bare rod

1185 MF 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 corro-sion resistance.Castolin 1185 MF is recommended particularly for its excellent resistance to corrosion from sea water and mineral and organic acids, such as sul-phuric, acetic, hydrofluoric and hydrochloric acid diluted to 5%, saline and alkaline solutions.

1902 1902 is a magnesium aluminium alloy. Specially designed for braze wel-ding of magnesium motor-blocks and castings.

21F 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.

AluTin 51 Soft solder especially suited for joining aluminium to other metals.

27.10 FLUXES

16 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.

18 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, elimi-nating zinc oxidation and fuming.

Brass/Bronze Fluxes





185 A 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 conti-nuity. The brazing flux 185 A is designed for use with the following hea-ting methods: oxyacetylene flame and furnace without gas protection.

Brass/Bronze Fluxes - CONTINUED


Light metal fluxes

190 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


14 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.

157 NC 157 NC is a solder flux in paste form ready for use.


Soldering Fluxes


Silver Fluxes


1020 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.

1802 Atmosin 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.




1802 HF 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.

181 PF Atmosin 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.

ActivaTec® 1000 Paste flux for all high-silver content brazing.

Albro Silver brazing flux with long continuous activity and high heat resistance. It is recommended for parts in aluminium bronze.

Silver Fluxes – CONTINUED






190 AL 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.

28.10 BRAZING LIGHT METAL ALLOY AND SOLDERING PASTES

Brazing-Light Metal Alloy Pastes


CastoTin® 1 CastoTin 1 is a tin-lead soldering paste with a corrosive flux. It can be used on stainless, ferrous and copper alloys.

CastoTin® 2 CastoTin 2 is a tin soldering paste with a corrosive flux. It can be used on stainless, ferrous, nickel and copper alloys.

CastoTin® 3 CastoTin 3 is a tin-lead soldering paste with a non-corrosive flux. It can be used on copper alloys.

Brazing-Soldering Alloy Pastes


157 PA A flux and solder alloy powder combined in paste form, offering non-toxic deposits free from lead, antimony.

1800 PA Silver-zinc-copper-tin brazing alloy in paste form for capillary joining of stainless steel, ferrous, copper and nickel alloy parts. Very high silver con-tent 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.

Cadfree® Silver Alloy Pastes


1802 PB 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, ready-to-use compound.

CastoSil A silver -zinc-cadmium-copper brazing alloy in paste form, water based.

Silver Alloy Pastes with Cadmium





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 ener-gy 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.

F STANDARD QUALITY COATING

XFC XUPER FLEXIBLE COATING

NF THIN COATING

ZF ULTRA-THIN COATING

MF MINI-FLUX / PARTIAL COATING

TYPES OF COATED RODS




21 ECOBRAZ RANGES

Melting Product Form Flux Composition in % Range in °C Coating ColourProduct Ag Cu Zn Sn Cd Si Ni Other Solidus Liquidus Form ColourCastolin range - Cadfree® Silver Alloys

1020 F 56,7 21,9 Bal. 5.3 625 665 F Coated Pink1020 XFC® 56,7 21,9 Bal. 5.3 625 665 XFC® Coated Pink1666 45,1 25,3 Bal. 2 660 700 Bare Rod 1666 XFC® 45,1 25,3 Bal. 2 660 700 XFC® Coated Green181 19,6 46,0 Bal. 740 835 Bare Rod 181 F 19,6 46,0 Bal. 740 835 F Coated WhiteCastolin range - Silver Alloys with Cadmium

1010 XFC® 37,9 20,3 Bal. 21.4 615 670 XFC® Coated White1030 XFC® 35 25,7 Bal. 19.5 625 695 XFC® Coated Purple1802 40 18,3 Bal. 24.1 595 630 Bare Rod 1802 XFC® 40 18,3 Bal. 24.1 595 630 XFC® Coated White1810 XFC® 29,8 27,5 Bal. 23.6 604 683 XFC® Coated WhiteEcoBraze Cadfree® Silver Alloys

38220 B 19,4 43,8 Bal. 0.2 740 815 Bare Rod 38220 F 19,4 43,8 Bal. 0.2 740 815 F Coated White38220 T 19,4 43,8 Bal. 0.2 740 815 Wire 38225 B 25,9 39,7 Bal. 2.1 680 760 Bare Rod 38225 F 25,9 39,7 Bal. 2.1 680 760 F Coated White38225 T 25,9 39,7 Bal. 2.1 680 760 Wire 38234 B 34 36,6 Bal. 2.2 630 730 Bare Rod 38234 F 34 36,6 Bal. 2.2 630 730 F Coated White38234 T 34 36,6 Bal. 2.2 630 730 Wire 38240 B 40,7 29,3 Bal. 2 650 710 Bare Rod 38240 F 40,7 29,3 Bal. 2 650 710 F Coated White38240 T 40,7 29,3 Bal. 2 650 710 Wire 38244 B Bare Rod 38244 F F Coated White38244 T Wire 38245 B 45 26,7 Bal. 2.7 640 680 Bare Rod 38245 F 45 26,7 Bal. 2.7 640 680 F Coated White38245 T 45 26,7 Bal. 2.7 640 680 Wire 38245 XFC® 45 26,7 Bal. 2.7 640 680 XFC® Coated White38249 B 49 16,3 Bal. 4.7 7.6 680 705 Bare Rod 38249 T 49 16,3 Bal. 4.7 7.6 680 705 Wire 38255 B 54,3 21,1 Bal. 2.2 630 660 Bare Rod 38255 F 54,3 21,1 Bal. 2.2 630 660 F Coated White38255 T 54,3 21,1 Bal. 2.2 630 660 Wire 38256 B 56,8 22,3 Bal. 5.3 625 665 Bare Rod 38256 F 56,8 22,3 Bal. 5.3 625 665 F Coated White38256 T 56,8 22,3 Bal. 5.3 625 665 Wire 38256 XFC® 56,8 22,3 Bal. 5.3 625 665 XFC® Coated WhiteEcoBraze Silver Alloys with Cadmium

38330 B 30,4 27,2 Bal. 20.5 610 690 Bare Rod 38330 F 30,4 27,2 Bal. 20.5 610 690 F Coated White38330 T 30,4 27,2 Bal. 20.5 610 690 Wire 38330 XFC® 30,4 27,2 Bal. 20.5 610 690 XFC® Coated White38334 B 33,9 22,6 Bal. 19.6 610 680 Bare Rod 38334 F 33,9 22,6 Bal. 19.6 610 680 F Coated White38334 T 33,9 22,6 Bal. 19.6 610 680 Wire 38335 B 34,7 25,2 Bal. 18.2 610 670 Bare Rod 38335 F 34,7 25,2 Bal. 18.2 610 670 F Coated White38335 T 34,7 25,2 Bal. 18.2 610 670 Wire 38335 XFC® 34,7 25,2 Bal. 18.2 610 670 XFC® Coated White38340 B 39,8 19,4 Bal. 20.5 595 630 Bare Rod 38340 F 39,8 19,4 Bal. 20.5 595 630 F Coated White38340 T 39,8 19,4 Bal. 20.5 595 630 Wire 38340 XFC® 39,8 19,4 Bal. 20.5 595 630 XFC® Coated White38345 B 44,3 15 Bal. 23.5 605 620 Bare Rod 38345 F 44,3 15 Bal. 23.5 605 620 F Coated White38345 T 44,3 15 Bal. 23.5 605 620 Wire




22.10 SELF-FLUXING BRAZING ALLOYS FOR COPPER

Composition in % Melting Range °CDesignation Ag Cu Other P Solidus LiquidusCastolin range - Self-Fluxing Copper Alloys1803D 15 Remainder 5 645 8001805 2 Remainder 6,2 645 825RB 5246 Remainder 7 715 805RB 5280 2 Remainder 7 650 820RB 5283 15 Remainder 5 650 802RB 5286 5 Remainder 6 650 810

23.10 AUTOGENOUS WELDING OF CONSTRUCTION STEEL

Composition in % Melting Range °CProduct Ag Cu Zn Cd Si Others Solidus LiquidusCastolin range - Brazing-Brass/Bronze Alloys146 MF 60 39 1 885 905146 XFC® 60 39 1 885 90516 XFC® 1 48,1 Bal. 1 885 91518 1 57,8 Bal. ,5 879 89518 MF 1 57,8 Bal. ,5 879 89518 XFC® 1 57,8 Bal. ,5 879 895185 XFC® 47,5 Bal. ,5 890 91580 MF 54,2 Bal. ,3 885 91080 XFC® 54,2 Bal. ,3 885 910Castolin range - Fuctional CoatingsCastoDrill 8800 1 47,6 42,6 885 910

24.10 SOLDERING AND LIGHT METAL ALLOYS

Composition in % Melting Range °CDesignation Ni Fe Sn Si C Co Cr W Other WC% Hardness Solidus LiquidusCastolin range - Wear-Facing AlloysCastoDur® 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 1080 1120Ultimium® 8811 Bal. 2 ,69 12 74% 350-450 Hv 1050 1120Ultimium 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.

Composition in % Melting Range °CProduct Ag Cu Zn Al Sn Pb Si Solidus LiquidusCastolin range - Soldering and Light Metal Alloys1185 MF 90 9 1020 1040157 3,5 221 221157 T 3,5 221 2211827 1,6 16,3 270 280190 88 12 570 5801902 8,5 443 59921 F Remainder 5,3 570 630AluTin 51 31,6 Bal. 160 240




27.10 FLUXES

Melting Range °C Flux Appearance Residue PropertiesProduct Solidus LiquidusCastolin range - Brass/Bronze Fluxes16 700 1000 Dark Grey Paste Non-Corrosive18 700 1000 Yellow Paste Non-Corrosive185 A 700 1000 Blue Paste Non-CorrosiveCastolin range - Light metal fluxes190 500 700 White Powder CorrosiveCastolin range - Other Fluxes14 700 1000 Pink Powder CorrosiveCastolin range - Silver Alloy Fluxes1020 450 850 White Powder Corrosive1802 Atmosin 400 780 White Powder Corrosive1802 HF 450 850 White Powder Corrosive1802 PF Atmosin 420 820 Pink Paste Corrosive181 Atmosin 550 900 White Powder Corrosive181 PF Atmosin 550 900 White Paste CorrosiveActivaTec® 1000 400 800 White Paste CorrosiveAlbro 400 820 White Paste CorrosiveCastolin range - Soft Solder Fluxes157 NC 150 450 Yellow Paste CorrosiveAluTin 51 120 300 Yellow Liquid Corrosive

28.10 BRAZING AND SOLDERING PASTES

Composition in % Melting Range °CProduct Ag Cu Zn Cd Other Al Si Sn Pb Solidus LiquidusCastolin range - Brazing-Light Metal Alloy Paste190 AL 88 12 570 570Castolin range - Brazing-Soft Solder Alloy Pastes157 PA 3,5 221 221CastoTin® 1 50 50 183 216CastoTin® 2 ,2 99,8 232 232CastoTin® 3 ,5 39,5 60 183 238Castolin range - Cadfree® Silver Alloy Pastes1800 PA 56,8 21,9 Bal. 5,3 625 665Castolin range - Silver Alloy Pastes with Cadmium1802 PB 40 18,3 Bal. 24,1 595 630CastoSil 40,2 18,7 Bal. 19,9 595 630

3 POWDERS AND WIRES FOR THERMAL SPRAYING



31.10 ROTOTEC – ALLOY POWDERS FOR "COLD" SPRAY PROCESS

Designations Product Applications Properties Type

RotoTec51000

AlloyNi-Al-Mo

Bond coat for RotoTec 19000 and MetaCeram 28000 powder families, on all metals except Cu and Mg.

~170 HV10Fusion reaction during spraying creates strong bond with substrate

RotoTec19300

AlloyFe-Cr-Ni-Mo

Pieces operating with metal-to-metal friction such as shafts, bearing surfa-ces, pistons, etc.

~250 HV10Machinable with tools. Good coefficient of friction. Good resistance to corrosion.

RotoTec19310

AlloyFe-Cr-Ni

Pieces operating with metal-to-metal friction. Wear sleeves for pumps.

~335 HV10 Machinable with tools (very good machinability by turning).Good resistance to frictional wear.

RotoTec19400

AlloyFe-Cr-Ni

Protective couplings for shafts, press pistons, motor casing.

~420 HV10The best surface finish is obtained by grinding.

RotoTec19404

AlloyFe-Cr-Co-Mo

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

~400 HV10Excellent combination of corrosion, wear resistance and low friction. Machinable with nice surface finish.

RotoTec19800

AlloyCu-Sn-Zn

Guides, slides, journal bearings, bearings.

~100 HV10 Very good machinability by turning. Excellent coefficient of friction. Low sensitivity to residual stress.

RotoTec19850

AlloyCu-Al

Compressor pistons, trunnions and pulleys.

~120 HV10 Very good machinability by turning.Low coefficient of friction.

RotoTec19868

AlloyCu-Al-Ni

Interior coatings of chocks, ram slides, foundry models.

~150 HV10 Good machinability by turning.Low coefficient of friction and good pres-sure resistance. Good corrsion resistance.

31 POWDERS FOR THERMAL SPRAYING

RotoTec19910

AlloyNi-Cr-Si-Fe

Bearingseats and wherever a hard and corrosive resistand layer isneeded.

~350 HV10 Machinable with tools. Excellent coefficient of friction.

3 POWDERS AND WIRES FOR THERMAL SPRAYING3 POWDERS AND WIRES FOR THERMAL SPRAYING


3POWDERS FOR THERMAL SPRAYING

RotoTec19999

AlloyNi-Cr-Fe and carbides

Drag roll, wear plates, gripping finger. ~250 HV10 50% carbidesHigh resistance to abrasion.Rough deposit.

RotoTec LT29230

Zn base 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 protec-tion of ferrous supports against corrosive atmospheric phenomena.

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


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

ProXon21021

AlloyNi-Al-Mo

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

~170 HV10Used without bonding layer.The best surface condition is obtained by grinding.

ProXon21031

AlloyNi-Cr-Al-Fe-Mo

For components subject to wear and corrosion such as fan blades, shft sleeves and roller bearing seats

~280 HV10Used without bonding layer. Thick deposit capability (<3mm).

ProXon21071

AlloyCu-Al

Compressor pistons, trunnions and pulleys.

~120 HV10 Used without bonding layer. Good machinability. Low coefficient of friction. Thick deposit capability (<4mm).


RotoTec19985

AlloyNi-Cr-Fe

Bearing seatings, pistonsUsed in rebuilding worn parts.

~200 HV10Very good machinability by turning.

RotoTec19940

AlloyNi-Cr-Fe-Mo

Wear sleeves for pumps, cylinder rods, drying cylinders for papermaking.

~370 HV10The best surface finish is obtained by grinding. Good resistance to friction under pressure.




31.30 EUTALLOY – SELF-FLUXING POWDERS FOR SPRAYING WITH SIMULTANEOUS FUSION

Eutalloy10009

AlloyNi-Cr-B-Si-Fe

Resurfacing cams, pushers, stops, guide wheels, filterpress cake stone remover for sugar mill, decanting screw, steam gate components. Coating elements subject to friction.

~63 HRc.Low friction coefficient. Good resistance to corrosion, erosion and abrasion under light load.

Eutalloy10011

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

Coating elements of chains, transport screw, wiper segments, brick die fra-mes, claw excavators, rock drill, brush cutter rake, debarking knives

~65 HRc.80% tungsten carbidesExcellent resistance to abrasion by fine to coarse sized abrasives

Eutalloy 10112


Coating of machine parts used in the transport, handling and proces-sing of minerals: transport screws, clay mixers, dies, segments, wipers, turbine impeller, fan impeller, pump screw, etc.

~64 HRc.60% tungsten carbidesExcellent resistance to erosion and abrasion by fine to coarse sized abrasives

Eutalloy10185

AlloyNi-B-Si

Coating of cast iron and steel molds for plastic material and glass.Recoating shafts, eccentrics, bearingsSoldering tungsten carbide biscuits on drilling stabilizers, etc.

~390 HV30.Well suited for metal-to-metal friction.Excellent corrosion resistance.Machinable with cutting tool.

Eutalloy10224

AlloyNi-B-Si

Repairing glass mold edges, gear teeth, exhaust manifolds, pump bodies, brakes on drawing tools.Bonding layer before welding with electrode on cast iron that is difficult to weld, etc.

~260 HV30.Appropriate for new or worn cast iron.Good resistance to corrosion.Machinable with cutting tool.

Eutalloy10611

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

Resurfacing chemical transport screws, fan blades at cement works, augers, and extrusion screws. Blades and segments of mixers, etc.

~55 HRc50% tungsten carbidesExcellent resistance to abrasion under pressure and to corrosion.

Eutalloy10680

AlloyNi-B-Si

Repair of gears, cast iron valve seats, molds, keyways, bearing seating. Renewing drawing tools Correction of machining errors, etc.

~240 HV30.Good resistance to shocks and oxidation while hot.Machinable with cutting tool.

Eutalloy15999


Coating of molds for ceramics, rasps. Distributor blades for fertilizer sprea-ders, cyclone blades, hopper for sand spreading machines, mouths of bag-gers, etc.

~65 HRc.15% tungsten carbides Excellent resistance to erosion and abrasion by fine abrasives.


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

Eutalloy SF15211


All round powder for anti-abrasion. ~60 HRc60% tungsten carbidesExcellent resistance to erosion and abrasion by fine to coarse sized abrasives.





Eutalloy RW12112


Recoating wear pieces of agricultural machines, mixer blades, ceramic press feeder plungers.Resurfacing pump wear sleeves, steel industry transport rollers.

~710 HV30.35% tungsten carbidesExcellent resistance to erosion and abrasion.

Eutalloy RW12494

AlloyNi-Cr-B-Si-Fe

Coating incineration boiler tubes.Machine elements in food and chemistry industry.

~310 HV30Very good resistance to corrosion.Suitable for friction under light loads.Machinable with cutting tool.

Eutalloy RW12495

AlloyNi-Cr-B-Si-Fe

Coating of wear sleeves for pumps, glassworks feed plunger, valve parts: seats, flaps, etc.

~390 HV30.Suited for impact and frictionMachinable with cutting tool.

Eutalloy RW12496

AlloyNi-Cr-B-Si-Fe

Coating cylinder rods, wear sleeves, pump pistons and faucet parts.Resurfacing coal dust separators. etc.

~680 HV30.Very low coefficient of friction and good abrasion resistance.Excellent resistance to corrosion and especially to seawater.

Eutalloy RW12497

AlloyNi-Cr-B-Si-Fe-Mo-Cu

Coating protective couplings, cylinder rods, wear and seal sleeves, Pelton turbine injection needle valves, etc.Coating stainless steel pieces.

~740 HV30Excellent frictional and corrosion resistance.Excellent corrosion resistance.

Eutalloy RW12999


Coating fan blades, mixer, transport screw, tensioning pulleys, guides.Wear parts for agricultural equipment, etc

~760 HV30.40% tungsten carbidesExcellent resistance to abrasion.

Eutalloy RW53606

AlloyNi-Cr-Mo-Si-B-Cu

Boiler tubes, shaft and sleeves in waste incineration, chemical, pulp and paper industries

~600 HV30Excellent wear and corrosion resistance to both reducing and oxidizing environ-ments

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


31.60 CASTOPLAST – POLYMER POWDERS FOR THERMAL SPRAY PROCESS

CastoPlast103

Polyamide 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 ShDBreakdown voltage ~30 kV/mmMax. service temperature 100°C.Max. peak temperature 140°CMelting temperature 185°C.Good resistance to alkaline or saline solutions and to hydrocarbons and solvents.


Eutalloy RWPE 8040.02

AlloyNi-Cr-Si-Fe-B

Plungers and other rotating parts. ~40 HRCGood resistance against friction and impact. Excellent corrosion resistance.




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

MetaCeram28010

Cr2O3 On RotoTec 51000 bonding layer.Cable gland seatings, shaft protector sleeves, seam ring joint seatingsPlungers, pump shafts, feed chutes.

Microhardness of the particles ~2400 HV10gMax. service temperature 500 °C.Product density 5.2 kg/dm High hardness, excellent resistance to corro-sion, low coefficient of friction.

MetaCeram28020

Al2O3TiO2(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

Microhardness of the particles ~1950 HV10gMax. service temperature 1000 °C.Product density 4.0 kg/dm .High hardness, excellent resistance to corrosion.Good electrical insulation (dependent on deposit thickness).

MetaCeram28030

Al2O3TiO2(13%)

On RotoTec 51000 bonding layer.Printer cylinders, paper transport rollers, thread guide, wear and sliding plates, induction oven parts.

Microhardness of the particles ~1600 HV10gMax. service temperature 1000 °C.Product density 4.0 kg/dm. Good resistance to corrosion and good fric-tion properties.

MetaCeram28085

ZrO2 CaO (30%)

On RotoTec 51000 bonding layer.Combustion chamber thermal insula-tion parts, crucibles, foundry machine parts, ladle for steel and iron works, guide wheels for wire zinc baths, pyrometer tubes.

Microhardness of the particles ~700 HV10gMax. service temperature 1200 °C.Product density 5.4 kg/dm .Excellent thermal insulation and stands up to thermal shocks.Non wetting for liquid metals.


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

EuTroLoy16006.04

AlloyCo-Cr-W-Ni-Fe(Gr. 6 Type)

Valve seats, protective shaft sleeves, shaft seal surfaces, tools in the wood and plastic processing industry, stirrer components, valve parts, extruder screws, etc.

~40 HRCHigh abrasion resistance under pressure and impact stress (cavitation). Heat and corrosion resistant. Low coefficient of sliding metal friction, insensitive to adhesive wear. For operating temperatures up to 750 °C.

EuTroLoy16012.04

AlloyCo-Cr-W-Ni-Fe(Gr. 12 Type)

Slide valve seats, extruder screws for plastic masses, feed screws for sawdust and hydropulpers in the paper industry, tools in the timber industry, segments of nose rings and clinker cooling plates, tools for the paper, plastics and timber processing

~46 HRCHigh abrasion resistance under pressure and impact stress (cavitation). Heat and corrosion-resistant. Low coefficient of sliding metal friction, insensitive to adhesive wear. For operating temperatures up to 750 °C.


EuTroLoy16008.04

AlloyCo-Cr-Mo-Ni

Hot-working tools, forming dies, cut-ting blades, pump and turbine com-ponents, components for large steam valves, etc.

~28 HRCExcellent resistance to high-temperature oxidisation and reducing atmospheres and to corrosion by organic and mineral acids.For operating temperatures up to 1100 °C.




32.10 EUTRONIC ARC – ALLOY WIRES FOR ARC SPRAYING

EuTronicArc 502

Alloy Fe-Cr-Ti-Si-Mn

Cement cooler plates, boiler water wall protection, pulp production digesters, steam turbine casings, cracking installations, high tempera-ture cyclone, fume extractors etc.

Hardness ~860 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat erosion, thermal shock up to 650°C

EuTronicArc 509

Alloy Fe-Cr-Al-Mo

Corrosion and erosion resistant pro-tective coatings in boiler equipment up to 900°C

Hardness ~260 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat cor-rosion, erosion up to 900°C and oxidation

EuTronicArc 532

Alloy Fe-Cr-Mn-C

Alternative to 13%Cr-steel. Hard chrome replacement on hydraulic pistons. Wear resistant layers for rol-lers in paper machines, bearing- and sealing seats

Hardness ~640 HV0.3 Self bonding alloy with enhanced surface wear resistance properties to combat metal-to-metal friction, corrosion and oxidation

EuTronicArc 579

Alloy Fe-Ni-Cr-Si-Mn

Worn general engineering compo-nents, undersize external or internal diameters, bearing seats and faces, housings, shrink or force fit areas, flat surfaces etc. Hot gas corrosion pro-tective coatings in heat exchangers, process piping, etc.

Hardness ~230 HV0.3 Self bonding alloy for thick or thin coatings with good corrosion resistance. Easy machinabillity, like machining solid mild steel


32 WIRES FOR THERMAL SPRAYING

EuTronicArc 595

Alloy Fe-Cr-B-Si-Mn

Abrasion, erosion and adhesion resis-tant protective coatings in pumps, boiler tubes, water walls and fans.

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

4 COMPOSITE WEAR FACING MATERIALS


4 COMPOSITE WEAR FACING MATERIALS

41 MECATEC – COLD SURFACING TECHNOLOGY POLYMERS

MeCaTeCExpress 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, contai-ners, engine, gear box casings, worn pump hou-sings, etc.

Formulated for applications needing a fast reac-tion with an application or handling time of 5 minutes. Curing will even occur at temperatu-res down to +5°C. Can also be easily machined, drilled or tapped.Service temperature up to 90 °C

MeCaTeC101F

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.

Repairs of deep cracks or to fill narrow cavities in steel, cast iron, aluminium, bronze and con-crete. Can also be easily machined, drilled or tapped.Service temperature up to 120 °C

MeCaTeC101P

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.

All-positional patch repairs of cracks or fissures in steel, cast iron, aluminium, bronze and con-crete. Easy to fit machine, drill, tap or sand.Service temperature up to 120 °C

MeCaTeC102P

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, hydrau-lic rams, diaphragms, etc.

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

MeCaTeC103F

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.

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

Designations Applications Properties

MeCaTeC104P

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.

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

MeCaTeCA5

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.

Protection against wear in severe erosion and abrasion. The tough, composite matrix is rein-forced with ultra resilient Kevlar fibres and a dense dispersion of hard, wear resistant cera-mic phases.Service temperature up to 120 °C

4 COMPOSITE WEAR FACING MATERIALS4 COMPOSITE WEAR FACING MATERIALS

4COMPOSITE WEAR FACING MATERIALS


MeCaTeCA5HT

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.

MeCaTeC110F

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 ins-tallations, etc.

Pourable, durable elastomer resistant to tearing. Useful for damping machine vibrations, reducing sound waves and harmful noise levels. Good electrical insulating properties. To be used with primer compounds MECATEC Bond M or Bond R.Service temperature up to 80 °C (dry)

MeCaTeC110P

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, vibra-tion dampers, rubber components, etc

All-positional repairs. Elastomer resistant to tea-ring. 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)

MeCaTeCBond M

Primer fluid for optimum substrate bonding to metal.Same applications as MeCaTeC 110F and 110P.

MeCaTeC Bond M is a primer compound used for optimising the adhesive bonding properties of MeCaTeC 110F or 110P to Metallic substrates.

MeCaTeCBond R

Primer fluid for optimum substrate bonding to rubber.Same applications as MeCaTeC 110F and 110P.

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.

Designations Applications Properties

Express 100 101F/P 102P 103F 104P A5/A5HT 110F/P

Abrasion

Cavitation

Corrosion

Erosion

Friction

Impact

Electric Insulation

Emergencies

General repair

Machining

Food and drink

Max. temperature °C 90 120 175 175 120 120/250* 50/80**

9 CASTODUR DIAMOND PLATES


91 WELD CLADDED PLATES

CDP 4624 5 + 36 + 48 + 510 + 515 + 5

Weld cladded wear plate for abrasion and erosion resistance. This is a chromium car-bide alloy wearplate, ideal for applications, where the right balance between price and service life is required.Hardness: 57 - 60 HRCCarbide content: > 30%Standard plate dimensions: 1500 x 3000mmSurface coating: 1220 x 2740mm (3.34m²).

CDP 4666 5 + 36 + 48 + 510 + 515 + 5

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 HRCCarbide content: > 50%Standard plate dimensions: 1500 x 3000mmSurface coating: 1220 x 2740mm (3.34m²).

CDP 4666XuperWave

5 + 36 + 48 + 510 + 515 + 5

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 HRCCarbide content: > 50%Standard plate dimensions: 1500 x 3000mmSurface coating: 1220 x 2740mm (3.34m²).

CDP 3952 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 HRCCarbide content: > 50%Standard plate dimensions: 1500 x 3000mmSurface coating: 1220 x 2740mm (3.34m²).

CDP 4623i Weld cladded wear plate especially for the combined wear of abrasion and impact.Hardness: 53 - 55 HRCCarbide content: > 50%Standard plate dimensions: 1500 x 3000mmSurface coating: 1220 x 2740mm (3.34m²).

6 + 48 + 510 + 5

8 + 510 + 515 + 5

Designations Thicknesses Properties (The thicknesses are shown as follows - thickness of metal base + thickness of protective layer)

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.

On request



9CASTODUR DIAMONDPLATES

92 POWDER COATED PLATES

93 CASTOTUBES

CDP 496 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 HRCStandard plate dimensions: 850 x 1250mmSurface coating: 800 x 1200mm (0.96m²).

4 + 2

CDP 112 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 tungs-ten carbides. Matrix hardness: 55 HRCCarbide hardness: > 1.700 HV0.03Carbid content: 35%Standard plate dimensions: 850 x 1250mmSurface coating: 800 x 1200mm (0.96m²).

2 + 14 + 2

CastoTubes 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 HRCCarbide 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 rea-lised 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.



CERTIFICATION: THE ASSURANCE OF WELDING QUALITYTHESE 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 integra-

ted 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.




9VARIOUS WELDING ACCESSORIES

TECHNICAL DATA REFERENCES

WEAR & FUSION TECHNOLOGY

Stronger, with Castolin EutecticStronger, with Castolin Eutectic



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 1.4372 Z 12 CMN 17.07 AZ 201

X12CRMNNIN 18.9.5 1.4310 Z 11 CN 18.8 301

X9CRNI 18.8 1.4305 Z 8 CNF 18.09 303

X9CRNI 18.9 1.4303 Z 5 CN 18.11 FF 305

X4CRNI 18.12 1.4567 Z 3 CNU 18.10 XM 5/18.9 LW

X3CRNICU 18.9.4 1.4301 Z 7 CN 18.09 304

X4CRNI 18.10 1.4307 Z 3 CN 19.11 304 L

X2CRNI 18.9 1.4306 Z 3 CN 18.10 304 L

X2CRNI 19.11 1.4311 Z 3 CN 18.10 AZ 304 LN

X2CRNIN 18.10 1.4335 Z 8 CN 25.20 310 S

X10CRNI 25.21 1.4381 Z 1 CNS 17.15 18.15

X1CRNISI 18.15.4 1.4401 Z 7 CND 17.11.02 316

X4CRNIMO 17.12.2 1.4438 Z 7 CND 17.12.02 316

X4CRNIMO 17.13.3 1.4404 Z 3 CND 17.12.02 316 L

X2CRNIMO 17.12.2 1.4432 Z 3 CND 17.13.03 316 L

X2CRNIMO 17.12.3 1.4429 Z 3 CND 17.11 AZ 316 LN

X2CRNIMON 17.11.2 1.4571 Z 6 CNDT 17.12 316 TI

X2CRNIMON 17.13.3 1.4580 Z 6 CNDNB 17.12 316 CB

X6CRNIMOTI 17.12.2 1.4438 Z 3 CND 19.15.04 317 L

X6CRNIMONB 17.12.2 1.4541 Z 6 CNT 18.10 321

X2CRNIMO 18.15.04 1.4550 Z 6 CNNB 18.10 347

X6CRNITI 18.10 1.4439 Z 3 CND 18.14.05 AZ 317 L4

X6CRNINB 18.10 1.4434 Z 3 CND 19.14 AZ 317 LN

X2CRNIMON 17.13.5 1.4468 Z 2 CND 25.22 AZ 310 MOLN

X2CRNIMON 17.12.3 1.4539 Z 2 NCDU 25.20 904 L

X1CRNIMON 25.22.2 1.4537 Z 2 NCDU 25.25.05 AZ URSB8


SYMBOLIC NUMERIC NF A 35-501 SYMBOLIC NUMERIC NF A 35-501 DESIGNATION DESIGNATION DESIGNATION DESIGNATION GENERAL PURPOSE CONSTRUCTION STEEL PER EN 10027 S 185 1.0035 A33 S 275 J2G3 1.0144 E28-4S 235 JRG1 1.0036 E24-2 S 355 JO 1.0553 E36-3S 235 JRG2 1.0038 E24-2 NE S 355 K2G3 1.0595 E36-4S 235 JO 1.0114 E24-3 E 295 1.0050 A50-2S 235 J2G3 1.0116 E24-4 E 355 1.0060 A60-2S 275 JR 1.0044 E28-2 E 360 1.0070 A70-2S 275 JO 1.0143 E28-3

UNALLOYED STEEL FOR QUENCHING AND TEMPERING PER EN 10083-1

C22E 1.1151 XC 16 C45E 1.1191 XC 48C25E 1.1153 XC 25 C50E 1.1206 XC 50C30E 1.1178 XC 32 C55E 1.1203 XC 55C35E 1.1181 XC 38 C60E 1.1221 XC 60C40E 1.1186 XC 42

FINE-GRAINED WELDABLE CONSTRUCTION STEEL PER EN 10113-3

S355M 1.8823 E355R S420ML 1.8836 E420FPS355ML 1.8834 E355FP S460M 1.8827 E460RS420ML 1.8834 E420R S460ML 1.8838 E460FP

FINE-GRAINED STEEL FOR PRESSURE VESSELS PER EN 10028-3

P355N 1.0562 A510AP P460N 1.8905 A555APP355NH 1.0565 A510AP P460NH 1.8935 A550APP355NL1 1.0566 A510FP1 P460NL1 1.8915 A550FP1

STEEL FOR BOILERS PER EN 10028-2

P235GH 1.0345 A37CP 16MO3 1.5415 15D3P265GH 1.0425 A42CP 13CRMO4-5 1.7335 15CD4-05P295GH 1.0481 A48CP 10CRMO9-10 1.7380 10CD9-10P355GH 1.0473 A52CP HIGH YIELD STRENGTH STEEL FOR COLD FORMING PER EN 10149-2

S315MC 1.0972 E315D S500MC 1.0984 E490DS355MC 1.0976 E355D S550MC 1.0986 E560DS420MC 1.0980 E420D S700MC 1.8974 E690D STEEL RESISTANT TO ATMOSPHERIC CORROSION PER EN 10155

S235JOW 1.8958 E24W3 S355J2WP 1.8946 E36WA4S235J2W 1.8961 E24W4 S355JOW 1.8959 E36WB3S355JOWP 1.8945 E36WA3 S355K2G1W 1.8966 E36WB4

EUROPEAN STANDARDS FOR STEEL


10TECHNICAL DATAREFERENCES


EN 10027-1 EN 10027-2 NF A AISI

STAINLESS STEELS PER EN 10027-1 AND EN 10027-2

X12CRMNNIN 17.7.5 1.4372 Z 12 CMN 17.07 AZ 201

X12CRMNNIN 18.9.5 1.4310 Z 11 CN 18.8 301

X9CRNI 18.8 1.4305 Z 8 CNF 18.09 303

X9CRNI 18.9 1.4303 Z 5 CN 18.11 FF 305

X4CRNI 18.12 1.4567 Z 3 CNU 18.10 XM 5/18.9 LW

X3CRNICU 18.9.4 1.4301 Z 7 CN 18.09 304

X4CRNI 18.10 1.4307 Z 3 CN 19.11 304 L

X2CRNI 18.9 1.4306 Z 3 CN 18.10 304 L

X2CRNI 19.11 1.4311 Z 3 CN 18.10 AZ 304 LN

X2CRNIN 18.10 1.4335 Z 8 CN 25.20 310 S

X10CRNI 25.21 1.4381 Z 1 CNS 17.15 18.15

X1CRNISI 18.15.4 1.4401 Z 7 CND 17.11.02 316

X4CRNIMO 17.12.2 1.4438 Z 7 CND 17.12.02 316

X4CRNIMO 17.13.3 1.4404 Z 3 CND 17.12.02 316 L

X2CRNIMO 17.12.2 1.4432 Z 3 CND 17.13.03 316 L

X2CRNIMO 17.12.3 1.4429 Z 3 CND 17.11 AZ 316 LN

X2CRNIMON 17.11.2 1.4571 Z 6 CNDT 17.12 316 TI

X2CRNIMON 17.13.3 1.4580 Z 6 CNDNB 17.12 316 CB

X6CRNIMOTI 17.12.2 1.4438 Z 3 CND 19.15.04 317 L

X6CRNIMONB 17.12.2 1.4541 Z 6 CNT 18.10 321

X2CRNIMO 18.15.04 1.4550 Z 6 CNNB 18.10 347

X6CRNITI 18.10 1.4439 Z 3 CND 18.14.05 AZ 317 L4

X6CRNINB 18.10 1.4434 Z 3 CND 19.14 AZ 317 LN

X2CRNIMON 17.13.5 1.4468 Z 2 CND 25.22 AZ 310 MOLN

X2CRNIMON 17.12.3 1.4539 Z 2 NCDU 25.20 904 L

X1CRNIMON 25.22.2 1.4537 Z 2 NCDU 25.25.05 AZ URSB8


SYMBOLIC NUMERIC NF A 35-501 SYMBOLIC NUMERIC NF A 35-501 DESIGNATION DESIGNATION DESIGNATION DESIGNATION GENERAL PURPOSE CONSTRUCTION STEEL PER EN 10027 S 185 1.0035 A33 S 275 J2G3 1.0144 E28-4S 235 JRG1 1.0036 E24-2 S 355 JO 1.0553 E36-3S 235 JRG2 1.0038 E24-2 NE S 355 K2G3 1.0595 E36-4S 235 JO 1.0114 E24-3 E 295 1.0050 A50-2S 235 J2G3 1.0116 E24-4 E 355 1.0060 A60-2S 275 JR 1.0044 E28-2 E 360 1.0070 A70-2S 275 JO 1.0143 E28-3

UNALLOYED STEEL FOR QUENCHING AND TEMPERING PER EN 10083-1

C22E 1.1151 XC 16 C45E 1.1191 XC 48C25E 1.1153 XC 25 C50E 1.1206 XC 50C30E 1.1178 XC 32 C55E 1.1203 XC 55C35E 1.1181 XC 38 C60E 1.1221 XC 60C40E 1.1186 XC 42

FINE-GRAINED WELDABLE CONSTRUCTION STEEL PER EN 10113-3

S355M 1.8823 E355R S420ML 1.8836 E420FPS355ML 1.8834 E355FP S460M 1.8827 E460RS420ML 1.8834 E420R S460ML 1.8838 E460FP

FINE-GRAINED STEEL FOR PRESSURE VESSELS PER EN 10028-3

P355N 1.0562 A510AP P460N 1.8905 A555APP355NH 1.0565 A510AP P460NH 1.8935 A550APP355NL1 1.0566 A510FP1 P460NL1 1.8915 A550FP1

STEEL FOR BOILERS PER EN 10028-2

P235GH 1.0345 A37CP 16MO3 1.5415 15D3P265GH 1.0425 A42CP 13CRMO4-5 1.7335 15CD4-05P295GH 1.0481 A48CP 10CRMO9-10 1.7380 10CD9-10P355GH 1.0473 A52CP HIGH YIELD STRENGTH STEEL FOR COLD FORMING PER EN 10149-2

S315MC 1.0972 E315D S500MC 1.0984 E490DS355MC 1.0976 E355D S550MC 1.0986 E560DS420MC 1.0980 E420D S700MC 1.8974 E690D STEEL RESISTANT TO ATMOSPHERIC CORROSION PER EN 10155

S235JOW 1.8958 E24W3 S355J2WP 1.8946 E36WA4S235J2W 1.8961 E24W4 S355JOW 1.8959 E36WB3S355JOWP 1.8945 E36WA3 S355K2G1W 1.8966 E36WB4

EUROPEAN STANDARDS FOR STEEL


PRINCIPAL GRADES OF ALUMINUM


ALUMINIUM SERIES NFA 02.104 NFA 02.004

AND ALLOYS ALUMINIUM ALLOYS PER NFA 02.104 AND NFA 02.004

ALUMINUM, PURITY > 99,00% 1000 1050 A A5

1070 A A7

1080 A8

1100 A45

1199 A9

1200 A4

ALUMINUM COPPER ALLOYS 2000 2011 A-U5 PB BI

2014 A-U4SG

2017A A-U4G

2024 A-U4G1

2030 A-U4PB

2117 A-U2 G

2618A A-U2GN

ALUMINUM MANGANESE ALLOYS 3000 3002 -

3003 A-M1

3004 A-M1G

3005 A-MG 0,5

3105 -

ALUMINUM SILICON ALLOYS 4000 4145 AS1

4006 AS1FE

4145 AS4

4043 AS5

4047 AS12

ALLOYS 5000 5005 A-G 0,6

ALUMINUM-MAGNESIUM-SILICON 5052 -

5056A A-G5M

5083 -

5086 A-G4MC

5150 A85-GT

5251 A-G2M

5454 -

5754 A-G3M

ALLOYS 6000 6005A -

ALUMINUM-ZINC-MAGNESIUM 6060 A-GS

6061 -

6081 A-SGM 0,3

6082 A-SGM 0,7

6106 -

ALLIAGES 7000 7010 -

ALUMINIUM-ZINC-MAGNÉSIUM 7020 A-Z5G

7049A A-Z8GU

7050 -

7075 A-Z5GU


10TECHNICAL DATAREFERENCESPRINCIPAL GRADES OF ALUMINUM

Rpo,2 (Mpa)=F’(N)

S(mm2)

THESE SYMBOLS ARE USED: IMPACT STRENGTH K

TENSILE STRENGTH RM

YIELD STRENGTH AT 0.2% Rp0.2

ELONGATION A5

HARDNESS H

TENSILE TESTING

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.)

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) The property indicates a material’s resistance to breaking.

• Yield strength (Rp) This property indicates a material’s capacity to stretch or

deform elastically.

• 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.

Measure Former New Conversion

Property Units Units

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

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

HARp02RMK

Rm(Mpa)=F(N)

S(mm2)

MECHANICAL TESTING

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.

UF RESILIENCE: Unified French bar (KCU) Standardized test specimen whose notch is U shaped.

V RESILIENCE: Bar using the Charpy test (KCV). Standardized test specimen whose notch is V shaped.


KG/MM23032343638404244464850525456586062656769717476,5798284,5878889,5909294,59799100102103104105107108110111

HB84,690,395,5101107113118124129135141146152158163169174183188194199208215223231237245248252253259267274278282287290293295300304309313

HV

173178187192197203210218225233239247249253254260267274279282287290293295300303309312

HRB

535863666971,573,575,577,579,5818384,58687,589,5919293,595,596,59899,5100,5102

103104104,8105,8

107,3107,5

108

108,9

109,5

HRC

15,517,51921

24

2526272829

30

31

32

33

SHORE

30313233343536373839

40

414243

44

45

46

47

48

KG/MM2113114116117119120123126129130132134136139141143145148150152154156158161164168171173176178180183185187189191193195197200206211222

HB319321327329335339345354363385390398401409415420426432438444448454457464470481488492499503507514518522526530534538543547560569587

HV318320325327333337343352361404410418424431437443450457463470474482486494502515524529538543548558564570575581587593599606626640671

HRB

110

110,5

111111,6112114,4

115

HRC34

35

36

373838,541

42

43

44

45

46

4748

49

50

51

52

53

5455

57

SHORE

49

50

5152535457

58

60

62

63

6566

68

6970

7172

73

74

75

76787981,5

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 baseShore 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 diffe-rent hardness testing methods.

MECHANICAL TESTING


10TECHNICAL DATAREFERENCESMECHANICAL TESTING

TYPE OF STEEL

UNALLOYED STEEL

STEELS ALLOYED WITH MOLYBDENUM

STEEL WITH MANGANESE

STEEL WITH CHROMIUM

STEEL WITH CHROMIUM, MOLYBDENUM

STEEL WITH NICKEL, CHROME

STEEL WITH NICKEL, CHROMIUM, MOLYBDENUM

STAINLESS STEEL

RECOMMENDED PREHEAT

TEMPERATURE

< 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

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

CARBON CONTENT

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

0.08

CURRENT DESIGNATION

XC 18XC 25XC 32XC 38XC 42XC 48XC 80

15 D 320 D 5 - M

30 M 740 M 745 M 7

Z 120 M 12

100 C 6Z 12 C 13

Z 8 C 17(AISI 430)Z 10 C 24(AISI 446)

25 CD 442 CD 4

30 CD 12

10 CN 620 NC 635 NC 6

30 NC 11

20 NC D 240 NC D 3

35 NC D 16

Z 6 CN 18 – 10

Z 6 CND 18- 12

Z 6 CN 25 -20

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.

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.

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.


smm

4

5

6

7

8

9

10

11

12

14

15

16

18

20

25

emm

1

1

1

amm

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

smm

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

V Joints

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

Interior Angle Exterior Angle

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: Divide the resulting values by 3.FOR MAGNESIUM AND MAGNESIUM ALLOYS: Divide the resulting values by 4.5.FOR ELECTRODES: Multiply the resulting values by 1.2.

60°

S

e

90°

a

s

90°

THEORETICAL VOLUME AND WEIGHT OF METAL


10TECHNICAL DATAREFERENCESTHEORETICAL VOLUME AND WEIGHT OF METAL

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

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

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)

PRINCIPAL METALS


Uses and Types of Parts

Thin or heavy castingsCurrent cast iron applications.

Machine casing, frames,Engine blocks,Faucets, valves,Pressing dies

Clutch forks,Manipulator fingers,Levers

Joints,Branches,Hubs

Parts of all complex shapes, difficult to forge.

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

ASSEMBLY AND REPAIR OF CAST IRON

Grades and Standards

GREY CAST IRON

NFA 32101NFA 32102Ft 10Ft 15 Ft 20Ft 25Ft 30Ft 35Ft 40

PEARLITIC MALLEABLE IRON

A 32703MP 50.5 – MP 60.3MP 70.2FERRITIC MALLEABLE CAST IRON WITH WHITE CORE

NF 32701MB 40.10MB 35.7

FERRITIC MALLEABLE CAST IRON WITH BLACK CORE

NF 32702NN 35.10NN 32.8NN38.18

UNALLOYED IRON WITH SPHEROIDAL GRAPHITE

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

Process options

Homogeneous welding

Soldering

Silver brazing

Brazing

EUTALLOY process

Manual arc process

Brazing

Manual arc process

Silver Brazing

Brazing

Manual arc process

Silver Brazing

BrazingManual arc process

Manual arc process

Most Commonly Used Alloys

CASTOLIN 14 F

CASTOLIN 157CASTOLIN 197CASTOLIN 181CASTOLIN 1030 FCASTOLIN 1030 XFCCASTOLIN 16 XFCCASTOLIN 18 XFC

EUTALLOY 10224

EUTECTRODE 223EUTECTRODE 224EUTECTRODE 2.44 NC EUTECTRODE XHD 2230EUTECTRODE 2240EUTECTRODE XHD 2480

CASTOLIN 16 XFC

EUTECTRODE 223EUTECTRODE XHD 2230CASTOLIN 181CASTOLIN 1030 FCASTOLIN 1030 XFCCASTOLIN 1702CASTOLIN 16 XFCCASTOLIN 18 XFCEUTECTRODE 223EUTECTRODE 224EUTECTRODE XHD 2230EUTECTRODE 2240EUTECTRODE XHD 2480CASTOLIN 181CASTOLIN 1030 FCASTOLIN1030 XFCCASTOLIN 1702CASTOLIN 16 XFCEUTECTRODE 223EUTECTRODE 224CEUTECTRODE XHD 2230EUTECTRODE 2240EUTECTRODE XHD 2480EUTECTRODE XHD 2230EUTECTRODE 2240EUTECTRODE XHD 2480

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.

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 THE PRINCIPAL METALS



ASSEMBLY AND REPAIR OF STEEL


E 24 (A 37)E 26 (A 42)

E 30 (A 47)E 36 (A 52)

A 50A 60A 70E 355E 375E 420E 460

XC 25XC 38XC 42XC48XC 42 TS

38 CD 4 - 18 CD 425 CD 4 - 35 CD 442 CD 4 - 30 DC 1250 CV 4 - 20 NC 630 NC 1118 NCD 619 NCD 32Z 120 M 1216 NC D 13

20 NCD 250 CV 440 NCD 3 – 35 CD 442 CD 4 – 55 S 745 SCD 6

100 C 6Z 200 C 12Z 160 CDV 5Z 100 CDV 545 CDV 6 – 40 NCD 1635 NCD 16 – Z 35 CDV 555 NCDV 7

Process options

Silver Brazing

Brazing

Manual arc process

MAG processMIG process

Open arc processSilver Brazing


Manual arc process

Open arc processMAG processMIG process


Manual arc process

TIG process


CASTOLIN 1030 FCASTOLIN XUPER 1802CASTOLIN 16 XFCCASTOLIN 18 XFCEUTECTRODE 640 EUTECTRODE XHD 646EUTECTRODE Xuper 680 SEUTECTRODE 690EUTECTRODE 3218EUTECTRODE 4257EUTECTRODE 6464EUTECTRODE 66*66 NEUTECTRODE XHD 6868CASTOMIG 45250CASTOMIG 45251CASTOMIG 45554CASTOMIG 45513ENDOTEC DO*02TeroMatec 3302CASTOLIN 1030 FCASTOLIN1030 XFCCASTOLIN 1702

CASTOLIN 16 XFCEUTECTRODE XHD 646EUTECTRODE Xuper 680 SEUTECTRODE 690EUTECTRODE 66*66 NEUTECTRODE XHD 6865EUTECTRODE 2222EUTECTRODE XHD 646EUTECTRODE Xuper 680 SEUTECTRODE 690EUTECTRODE XHD 6865EUTECTRODE 2222TeroMatec 3302CASTOMIG 45250CASTOMIG 45251CASTOMIG 45554CASTOMIG 45513CASTOLIN 16 XFCEUTECTRODE Xuper 680 SEUTECTRODE 690EUTECTRODE XHD 6865EUTECTRODE 2222 EUTECTRODE XHD 6868EUTECTRODE Xuper 680 SEUTECTRODE 690EUTECTRODE XHD 6865EUTECTRODE 2222 EUTECTRODE XHD 6868CASTOTiG 45507 WCASTOTiG 45612 W


Construction métallique

Traveling craneStorage tanks,Sheet metal works,Piping,Exchangers,Coolers, silos,Platforms, mobile structures for railway material.

Machine framesMechanically welded

General mechanics,Connecting rods, shafts, spindles Racks, piston rodsClutch forks,Coupling jaws,Lifting shafts,Coupling hooks,Crankshafts,Differential cases,Drive train components

Public works,Mines,Cement works,Wearing plates,Quarry materialsPublic works machinery,Oven hoop,Crusher.

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

Cold cutting,forging, stamping tools,

Tools for casting aluminum and copper alloys under pressure.



Pump parts,Surgical instrumentsHydraulic turbines,Gates,Rotors,Molds for plastics.

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

Boilermaking,Valves and fittingsHeat exchanger,Pressure equipment, Pipe works, storage containers.

Mechanical parts,Fan bladesFins, pumps, turbines.

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

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

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

ASSEMBLY AND REPAIR OF STEEL


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

Z 8 C 15Z 10 C 17

Z 2 CN 18.10Z 6 CN 18.09

Z 8 CN 20.11Z 15 CN 24.13

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

Z 2 CND 17.13Z 6 CND 17.12Z2 CND 19.15Z 6 CNT 18.10Z 6 CNNb 18.10

Z 2 CNNb 25.20Z 5 CNDU 21.08

Process options

Silver Brazing

Manual arc process

MIG process

TIG process

SolderingSilver BrazingManual arc process

TIG process

SolderingSilver Brazing

Silver BrazingManual arc process

TIG process

Manual arc process

MIG process

TIG process


Manual arc process

MIG process

TIG process

Manual arc process

MIG process

TIG process


CASTOLIN 1702CASTOLIN RB 3217EUTECTRODE Xuper 680 SEUTECTRODE 2222EUTECTRODE XHD 6865CASTOMIG 45002CASTOMIG 45554CASTOMIG 45513ENDOTEC DO*02CASTOTiG 45507 WCASTOTiG 45612 WCASTOTiG 45513 WCASTOLIN 157CASTOLIN 1702CASTINOX 1610 SEUTECTRODE 33500CASTOTiG 45500 WCASTOTiG 45513 WCASTOTiG 45612 WCASTOLIN 157CASTOLIN 1030 FCASTOLIN1030 XFCCASTOLIN 1702CASTOLIN 1020 FCASTOLIN 1020 XFCCASTOLIN 1702EUTECTRODE Xuper 680 SEUTECTRODE 690CASTOTiG 45507 WCASTOTiG 45513 WEUTECTRODE 33300EUTECTRODE 33226EUTECTRODE 33273EUTECTRODE E 310- 17EUTECTRODE 2222CASTOMIG 45513CASTOMIG 45612CASTOTiG 45513 WCASTOTiG 45612 WCASTOLIN 157CASTOLIN 1020 FCASTOLIN 1020 XFCCASTOLIN 1702CASTINOX 1610 SEUTECTRODE Xuper 1616EUTECTRODE 33500CASTOMIG 45500CASTOMIG 45612CASTOTiG 45500 WCASTOTiG 45612 WEUTECTRODE 33300EUTECTRODE 33273EUTECTRODE 6825CASTOMIG 45513CASTOMIG 45612CASTOMIG 45654CASTOTiG 45513 W

ASSEMBLY AND REPAIR OF THE PRINCIPAL METALS



ASSEMBLY AND REPAIR OF COPPER AND BRONZES


COPPER

Cu/A1Cu/A2 (oxygenCu/A3 present)

Cu/b (deoxidizedCu/c1 withoutCu/c2 oxygen)

BRONZES (Cu+Sn)UE 9 PUE 12 P

UE 16UE 18

*UE 4 Pb*UE 7 Z Pb 5

Process options


BrazingSolderingSilver Brazing

BrazingTIG processSolderingSilver Brazing

TIG process

Manual arc processBrazing (potentially)SolderingSilver brazing



CASTOLIN 157CASTOLIN 181CASTOLIN 800CASTOLIN 1030 FCASTOLIN1666 XFCCASTOLIN 1702CASTOLIN 1020 FCASTOLIN 1800 CASTOLIN 1810 FCASTOLIN XUPER 1802CASTOLIN 1806CASTOLIN 18 XFCCASTOLIN 157CASTOLIN 181CASTOLIN 800CASTOLIN 1030 FCASTOLIN 1666 XFCCASTOLIN 1702CASTOLIN 1020 FCASTOLIN 1800 CASTOLIN 1810 FCASTOLIN XUPER 1802CASTOLIN 1806CASTOLIN 18 XFCCASTOTiG 45706 WCASTOLIN 157CASTOLIN 181CASTOLIN 1030 FCASTOLIN 1666 XFCCASTOLIN 1020 FCASTOLIN 1800 CASTOLIN 1810 FCASTOLIN XUPER 1802CASTOTiG 45703 WCASTOTiG 45706 WEUTECTRODE 285CASTOLIN 18 XFC

CASTOLIN 157CASTOLIN 1030 FCASTOLIN 1666 XFCCASTOLIN 1020 FCASTOLIN 1800 CASTOLIN 1810 FCASTOLIN XUPER 1802CASTOLIN 157CASTOLIN 1020 FCASTOLIN 1800CASTOLIN 1030 FCASTOLIN 1666 XFC


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

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

Gears,Segments.

Easy to use,Parts subject to rubbing.

ASSEMBLY AND REPAIR OF PRINCIPAL COPPER ALLOYS

*NB: fragile with arc process



Sheet metal, sectionsCondenser tubes,Locksmithing,Decoration, lighting,Musical instruments.

Mechanical parts,Parts cut low at high speed.

Joints.

High resistance brass,Marine tubes and parts.

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

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


BRASS(ZINC IS THE MAIN ADDITIONAL ELEMENT.)

ordinary brass,(UZ 5 à UZ 15).

UZ 20 à UZ 30

UZ 37 à UZ 40

*UZ 38 Pb 1E

*UZ 38 Pb 2

UZ 15 à 3 NS

ALUMINUM BRONZE (CU + SN)

UA 9UA 9MUA 10 N FeUA 10 Fe4UA 10 NUA 14 Fe

CUPRONICKELAND NICKEL-SILVER

Process options

Soft SolderingSilver brazing

BrazingTIG process (potentially)SolderingSilver Brazing

BrazingSolderingSilver Brazing


Soldering (brazing difficult,

because of lead exudation)

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

Soldering (Alutin 51 flux)

Silver Brazing (Albro flux)

MIG process

TIG process

SolderingSilver brazing

TIG process

MIG process

Manual arc process


CASTOLIN 157CASTOLIN 181CASTOLIN 1030 FCASTOLIN1666 XFCCASTOLIN 1810 FCASTOLIN XUPER 1802CASTOLIN 18 XFCCASTOLIN 45706 W

CASTOLIN 157CASTOLIN 181CASTOLIN 1030 FCASTOLIN1666 XFCCASTOLIN 1020 FCASTOLIN 1800 CASTOLIN XUPER 1802CASTOLIN 18 XFCCASTOLIN 157CASTOLIN 1030 FCASTOLIN 1666 XFCCASTOLIN 1810 FCASTOLIN XUPER 1802CASTOLIN 157CASTOLIN 1030 FCASTOLIN 1666 XFCCASTOLIN 1020 FCASTOLIN XUPER 1802CASTOLIN 157

CASTOLIN 157

CASTOLIN 181CASTOLIN 1030 FCASTOLIN1666 XFCCASTOLIN 1020 FCASTOLIN 1800 CASTOLIN XUPER 1802CASTOLIN 1810 FCASTOLIN 157

CASTOLIN 1030 FCASTOLIN1666 XFCCASTOLIN XUPER 1802CASTOLIN 1810 FCASTOMIG 45751CASTOMIG 45750CASTOTiG 45706 WCASTOTiG RB 5248CASTOLIN 157CASTOLIN 181CASTOLIN 1020 FCASTOLIN 1800CASTOLIN 1702CASTOLIN XUPER 1802CASTOLIN 45751 WCASTOLIN RB 3229CASTOMIG 45612CASTOMIG 45751EUTECTRODE 2222

ASSEMBLY AND REPAIR OF PRINCIPAL COPPER ALLOYS

*NB: Braze welding difficult and fragile on interior angle


10TECHNICAL DATAREFERENCESASSEMBLY AND REPAIR OF LIGHT ALLOYS


ALUMINIUM A 5(1050)

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

AS 7B AS 7 B3AS 10B AS 12


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

Buildings, façade panels and coverings.Boiler making, automobile, railway, transport tankers, household appliance material.

Casing, Mechanical parts,Valves and fittings.

Process options

Soldering

Manual arc processMIG processSoldering

BrazngManual arc processBrazingManual arc processMIG process

TIG process



CASTOLIN 1827(décapant Alutin 51)CASTOLIN 190CASTOILIN 21 FEUTECTRODE XHD 2100CASTOMIG 45803CASTOLIN 1827(décapant Alutin 51)CASTOLIN 190CASTOLIN 21 FEUTECTRODE XHD 2100CASTOLIN 21 FEUTECTRODE XHD 2100CASTOMIG 45802CASTOMIG 45805CASTOTiG 45802 WCASTOTiG 45805 WCASTOLIN 210EUTECTRODE 2101 S


n Products

n Industry

n Services

n TeroLink

n News

n Events

n Downloads

Catalogues

Literature

Wall charts

TeroLink AAP’s

n New products

n News letter

CASTOLIN ONLINE.

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

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.

n Over 6,000 successful applications

n Technical data

n Method statements

n Cost saving and performance enhancing sheets

www.castolin.comwww.castolin.com



PERIODIC TABLE OF ELEMENTS.


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.

NEW Waste & RecyclingA 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.

CemTecA 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.



PRODUCT LITERATURE

INDUSTRY PROGRAMMES

Pulp & PaperPulp 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.

This is a selection of our wide range of product marketing literature

More available on request.

Other Industry Programmes are available on request.


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.

ConsultancyAdopting a “Consultancy” approach, we have experience of providing bes-poke 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’.

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

n Take a look at your wear issues

n Review your requirements

n Provide turnkey solutions to resolve your problems.

PROJECT MANAGEMENT



Creative solutions through Specialist Workshops

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.

n Service equipment

n Installation and repair of equipment

n Offer validation & calibration of equipment

n Dedicated service manager

n 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.

CastoLab is the sub-contract engineering Wear & Fusion and service division of Castolin Eutectic, offe-

ring 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

service is available.

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:

n TIG

n MMA & MIG/MAG

n THERMAL SPRAYING

n ARC SPRAY

n PTA

n BRAZING

n POLYMERIC COATING

n FUSE COATING

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

CastoLab

Service

SERVICE


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 world-leading reputation as the first to market in product development.Where we lead, others follow.

Where we lead,others follow



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 ad-

vanced 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

POLYMERIC COATING

FUSE COATING

Training

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

Contact us to book your training course now

Castolin GmbHAustrian 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