Global Coating Catalogue 2014 PDF

Castolin Eutectic
Global Coating Technology
Consumables
Equipment
Coating Services
History
Castolin Eutectic milestones in the evolution of coating technology
1906 Foundation of Castolin Eutectic in Lausanne, Switzerland

by Jean-Pierre Wasserman. His stroke of genius : to discover
a way to weld cast iron at a low temperature.
1940 Foundation of Eutectic Welding Alloys Corporation
in New York.
1960 International consolidation under Castolin Eutectic.
1963 Launch of powder spray-fuse Eutalloy® torch for powder
spraying with simultaneous fusion. More than 42,000
units were sold.
1965 Powder production by water atomisation.
1969 Launch of EuTronic Gap® equipment for powder Plasma
Transferred Arc welding.
1971 Launch of RotoTec® I torch for powder cold spraying. More
than 17,000 units were sold.
1976 Powder production by gas atomisation.
1985 Marketed the world’s first amorphous powder for thermal
spraying.
1995 Leading HVOF, Plasma and wire spraying with TAFA acquisition.
2005 Part of the Messer World gas supply company.
2006 World’s first anti-satellite gas atomiser for powder
production in Ireland.
Launch of EAS-4 Arc Wire Spray System.
2007 Launch of Nano-structured wear protection consumables.
2009 Launch of CJK5 HVOF System.
2012 First Laser Cladding facility in Europe.
2013 Monitor Coatings acquired.
2014 Additional Laser Cladding facilities in Korea, Dubai, Austria.
Automated PTA Laser Cladding HVOF

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Table of contents
European Product Catalogue
Introduction
Total Coating Solutions - Technical support, wear labs, production p. 4-5
Coating overview p. 6
Quality Assurance p. 7-8
Powder production p. 9
Spray wire production p. 10
Equipment production p. 11
Our offer p. 12
Powder Spray-Fusing
Eutalloy® Process - One step Spray & Fuse p. 14
Eutalloy® Powders p. 15-16
Eutalloy® Equipment & Accessories p. 17-18
Eutalloy® SF Process - One Step Spray & Fuse for high yield p. 19
Eutalloy® SF Powders p. 20
Eutalloy® SF Equipment & Accessories p. 21-22
Powder Cold or Hot Flame Spraying

RotoTec®, ProXon® & MetaCeram® Processes - Cold Spraying p. 24
RotoTec®, ProXon® & MetaCeram® Powders p. 25-26
Eutalloy® RW Process - Two Step Spray & Fuse p. 27
Eutalloy® RW Powders p. 28
Flame Equipment & Accessories p. 29-30
HVOF Liquid fuel

CastoJet CJK5 p. 32-33
HVOF Applications and Technical p. 34
HVOF Equipment & Accessories p. 35
HVOF Powders p. 36
Laser Technology
Laser Process p. 38
Laser Cladding Advantages p. 39-40
Laser Powders p. 41
Our offer p. 42
PTA Coating
EuTroLoy® Process - Plasma Transferred Arc p. 44
EuTroLoy® - PTA Powders p. 45-46
EuTronic GAP® - PTA Equipment & Accessories p. 47-50
Wire Spraying
EuTronic® Arc Process - Wire Arc Spraying Process p. 52
EuTronic® Arc Spray Wires p. 53
EuTronic® Arc Spray Equipment & Accessories p. 54-56
Services
Integrated Systems - System packages p. 57
Industry partner p. 58
TeroLink® p. 58
CastoLab® Services p. 59
Training p. 59
Information
Technical data & Table p. 60
Periodic Table of the Elements p. 61
Contact p. 62
Index p. 63
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Introduction
Total Coating Solutions
Castolin Eutectic engineers and technicians are all highly qualified to understand industrial application problems in or-
der to recommend optimised tailored solutions. The Research and Development centre is well equipped to resolve most
complex wear phenomena affecting industrial productivity, using appropriate coating technology. Customers can be
be confident that dedicated, in-house development staff will work to fulfill their needs and expectations under a «Total
coating solutions» concept. Using state-of-the-art equipment, every batch of coating alloys produced according to strict
procedures, is rigorously tested by professionals to ensure complete compliance with demanding Castolin Eutectic stan-
dards and exhaustive Quality Assurance criteria.
Overview of the wear phenomena
Abrasion Erosion Impact Friction Heat & Corrosion Cavitation
Classical wear phenomena that occur At Castolin Eutectic, we take the time We have proved for over a century
in industry are : to study industry specific wear phe- that preventive maintenance coating
Abrasion nomena because only when the natu- programs can extend the life of vital
re of the wear is fully understood, machine parts by as much as 500%.
Erosion
can the correct solution be proposed. Only Castolin Eutectic has the «know-
Impact
Damage caused by wear phenomena how» to identify the key critical wear
Friction costs money, especially in lost produc- problems plus the «show-how» to
Heat tion downtime, replacement parts, overcome them, thus greatly increa-
Corrosion repair and ongoing maintenance. sing your plant efficiency and profits.
Cavitation
R&D / Technical Support

Castolin Eutectic employs many en- complex wear problems, as well as rec- you deserve the best analysis, care and
gineers and technicians dedicated to ommending the optimum solutions. service to guarantee the quality and ef-
solving the technical problems of our After all, as a Castolin Eutectic customer, ficiency of your production operations.
customers. The main Castolin Eutectic
Research and Development centre for
welding consumables and powder coat-
ing alloys, is in Dublin. This R&D centre is
one of the most advanced coating tech-
nology laboratories in Europe.
This modern facility is equipped for
in-depth studies of all types of indus-
trial welding and coating applications
geared towards problem-solving solu-
tions. Dublin not only has an automated
Micro Hardness machine, G65, ICP and
XRF units, but also employs a highly-
trained and customer oriented techni-
cal team.
Our team has undertaken more than
3,500 metallurgical study reports over
the last 15 years, to correctly identify
the primary and secondary causes of Testing and development Comparative analysis
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Introduction Introduction
Wear Testing labs

Castolin Eutectic closely co-ope-
rates with world renowned tech-
nical institutes & universities
whose centres of excellence for
modelling wear mechanisms
include fully equipped labora-
tories with scanning electron
microscopes and wear testing
equipment. Such state-of-the-art
Scanning electron microscope
facilities and testing equipment
are essential to accurately moni-
tor progress of wear mechanisms
and to understand the complex
relationship between materials,
microstructures, processes and
applications.
3D surface analysis Wear Pattern analysis
Integrated Production performance

The complete control of coating
powder production within our
own modern manufacturing
plants, ensures highest quality
products to precisely meet user
needs. A proficient research cen-
tre, staffed by skilled engineers
and technicians in daily contact
with OEM producers and indus-
trial users around the world, ena-
bles the powder plants to rapidly
respond to specific customer re-
quirements.
The latest powder production tech-
nologies are perfectly integrated
and managed within the logisti-
cs supply chain to assure the best
service and value to customers.
Powder manufacturing system Powder manufacturing plant
Stringent Quality Controls

Every stage of powder production, from raw material selection to
ingredient preparation and on to the atomisation process and the final
sieving operations, is subject to stringent quality assurance procedures.
CEIL is ISO 9001 : 2000 certified and participates in a centralised Total
Quality Management program with the primary aim of achieving
complete customer satisfaction.
Only under such strict conditions can the finished product consistently
conform to the highest performance demands of OEM producers and
Microscopic analysis industrial users.
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Introduction
Coating overview
There are many different ways to protect against wear and corrosion, each with their respective advantages and
constraints. Your parts can be protected from new or repaired and rebuilt. Below you will find simplified overviews
of the different coating processes, to obtain a quick initial choice for your applications.
Simplified thermal spray
Wire
Heat Source Acceleration Impact

Powder of particles
Coating
Max
Heating Coating Coating
Coating Coating Base mate- coating Coating Deposition Deposition Operating Equipment
of work- surface micro- Bonding
families material rial thickness structure rate yield costs investment
piece size porosity
mm
Powder Excellent Liquid fuel,
HVOF - Metals All Low 0.5 Small to Lamelar > 1% mechanical Medium Low combustion Medium to
Tungsten metals Large gases High
Carbide bond
Powder
Laser MetalsTungsten All Low 5 (15) Small to Homoge 0% Excellent High Medium Electricity High
Cladding Carbides
metals Very Large -neous Fusion
Powder. Good.
RotoTec Metals & All Low 3 Medium Lamelar 5 to 15% Mechanical Medium to Medium to Combustion Low
polymer metals to large & micro- high high gases
diffusion
Good.
ProXon Powder. All Low 2 (5)* Medium Lamelar 5 to 15% Mechanical Medium Medium to Combustion Low
Metals metals to large & micro- high gases
diffusion
Good.
Meta- Powder. All Low 0,4 (1)* Medium Lamelar 5 to 15% Mechanical Low Medium Combustion Low
Ceram Ceramic metals & micro- gases
diffusion
Powder. Steels,
Eutalloy Self-fluxing cast iron, Medium 2 (6)* Small & Homoge- Negligible Very good. Medium Medium Combustion Low
alloys (aluminium to high precise neous Diffusion gases
bronze) *
Eutalloy Powder.
SF Self-fluxing Steels & cast
iron High 2 (6)* Medium
to large
Homoge-
neous Negligible Very good.
Diffusion High High Combustion
gases Low
alloys
Eutalloy Powder.
RW Self-fluxing Steels & cast
iron High 2 (6)* Medium Homoge-
neous Negligible Very good. Medium to Medium to
Diffusion high high
Combustion
gases Low
alloys
Powder or Steels,
EuTroLoy wire. cast iron, Medium 2 (10)* Large Homoge- Negligible Excellent. Medium to High Electricity & Medium
Metals (aluminium to high neous Fusion high shielding gas
bronze) *
Good. Electricity &
EuTronic Wire. All Low 1 to 2 Very large Lamelar 1 to 10% Mechanical High Medium compressed Medium
Arc Metals metals & micro- air
diffusion
(...)* request special precaution or coating material Best Second choice
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Quality Assurance
Over the last few years, the need for quality assured, thermally sprayed coatings has steadily grown. A Total Quality
Management system in a general spraying workshop, education, detailed procedures and quality control testing
are the key elements for success.
Education They must confirm every complet- bond strength measurement and
The first step for a new operator ed step with a signature and the lead to incorrect values.
is to complete a general training sprayed coating has also to be ap- Hardness
course in thermal spraying and proved by the foreman before the
The coating hardness can be meas-
then to gain practical experience part can be delivered.
ured either on a ground area of
over a period of at least 3 months. If The spray shop should store this the surface or in the cross section
a company is prepared to introduce document in a form suitable to be of the coating thickness. However
a complete QA-system, the ETS (Eu- delivered together with the sprayed ,due to the laminar nature of some
ropean Thermal Sprayer) course is part to the customer. coating structures, hardness values
the next step.
Quality control may vary depending on where the
measurement is taken. A special
The quality control of sprayed parts

can be carried out in many different
Detailed procedures ways. The most important coating
properties to control are : Vickers hardness testing machine
The best way to produce consistent,
allows the thin cross-section of the
repeatable, high quality coatings bond strength
coating to be accurately measured
is to follow a specific documented hardness in HV (Hardness Vickers number).
working procedure which guides
porosity Different loading levels can be pre-
the operator through all the neces-
microstructure selected depending on the coating
sary steps before, during and after
A typical spray shop can achieve hardness – the smaller the applied
spraying. The operator must detail
a good understanding of the final load, the higher the surface finish
every important step such as; work-
coating integrity by spraying five requirements.
piece data, surface cleaning meth-
od, preheating temperature, choice test coupons. Four test coupons are Alternative macro hardness test-
of spraying material, maximum then used for bond strength meas- ing machines such as Brinell (HB)
temperature during spraying, final urements and the last coupon can or Rockwell (HRC) use spherical and
coating thickness and whether test be used for hardness, porosity and conical indenters respectively.
pieces were sprayed. microstructure verification purposes. Porosity
Bond strength The coating porosity can be meas-
The coating bond strength is nor- ured indirectly using the water im-
mally measured according to the pregnation method. This involves
EN 582 standard, which describes the diffusion of water to saturate the
the complete procedure. It is es- coating under vacuum conditions. By
sential to use adhesives with low weighing the coating before and af-
penetration properties otherwise ter water impregnation, the weight
there is a risk that the glue will flow increase is mathematically recalcu-
through the coating down to the lated into volume terms, which indi-
substrate. This will influence the cates the coating porosity degree.
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Introduction
Quality Assurance
Microstructure of different materials by measur- The CIAT equipment consists of a
The coating microstructure can be ing the degree of wear caused by drum with two internal impellers
readily examined using an optical hard quartz sand particles forced to both rotating in the same direc-
microscope. The operator can view move against and across the speci- tion but with different speeds. The
directly the coating microstructure, men surface. test specimens are mounted on the
thickness, degree of bonding, de- CIAT - Continuous Impact and Abrasion faster impeller. As the drum rotates
lamination effects, micro or macro Test at a maximum 60 rpm, whilst the
cracks, approximate porosity and The CIAT is a wear test to measure impeller with the mounted speci-
oxide content. resistance to abrasion combined mens spins at 650 rpm, the rotating
with impact using an impeller tum- drum throws the loaded abrasive
bler machine. particles to hit the impeller thus
provoking rapid combined wear to
the mounted specimens.
Wear test methods

ASTM G65 abrasion test
The ASTM G65 procedure simulates
a three body wear system designed
to generate reproducible test data Environmental awareness & Quality standards
in order to rank materials by their Reduce, re-use, recycle:
resistance to low stress abrasion. The Castolin Eutectic philosophy to conserve the earth's precious resources
The testing equipment uses a rotat- and give added value to old and worn parts is acknowledged worldwide. In
ing rubber wheel and dry sand to our production facilities we have programs to reduce our environmental
establish the abrasion resistance impact and all our production is ISO 9001:2000 certified.
Abrasive sand
Force
Test specimen
Rotating wheel
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Powder production
Overview of the Powder production processes
Castolin Eutectic has made a major investment at its Dublin (Ireland) consumables plant. In a bid to increase both
efficiency and productivity, the new powder plant incorporates a substantial advance in atomisation technology.
This improvement optimizes powder quality for Castolin Eutectic customers.
Historical Development of Thermal sation. Only with cobalt and other formed in the atomising vessel. The
Spray Powder Atomisation non self-fluxing alloys did dry, inert hot plume of just-atomised drop-
During the first half of the 20th gas atomisation become the indus- lets then passes through this cloud,
century, the earliest thermal spray try standard. However, while this causing the droplets to collide with
powders used to be limited to self- avoided the risk of any oxidation smaller, colder particles of the cloud.
by the water quench, it was found Castolin Eutectic, with over 40 years
fluxing, nickel-based alloys. These
that the particle shape was some-
earlier powders were very resistant of experience in water atomisation
times inferior to water-quenched
to oxidation and were therefore at- and over 15 years in gas atomisation,
powder. Small «satellites» were of-
omised with steam, water or air and is concentrating its know-how at the
ten found welded to the surface of
reached reasonable properties. In- world’s most advanced powder plant
the particles. This seemed to occur
ert gas atomisation in earlier atom- more frequently when finer pow- in Dublin. Leading-edge, powder
isers was carried out using nitrogen, ders were atomised. This feature production specialists were enrolled
and then quenching the particles reduced packing density, flowability as partners to create a state-of-the-
into water. This process produced and could disturb the thermal spray art and unique «anti-satellite» sys-
powders with less oxidation than by satellites being detached. tem. This system was designed us-
air, steam or water atomisation, ing exhaustive Computational Fluid
and also with excellent particle Cause of Satellite Formation
Dynamic (CFD) modelling to ensure
shape. This was because freezing of During dry gas atomisation, sat- that the intended suppression of the
the spray took place within an inert ellite formation is caused mostly dust cloud is indeed achieved. The
gas, allowing for better spherodi- when a dense dust-particle-cloud is
number of particles with satellites
is therefore significantly reduced. As
material proof of this technology’s
success, the appearance of the pow-
gas gas ders under the microscope was vis-
ibly improved.
Melted Metal
Yesterday’s Technology,
Tomorrow’s Technology - today
Another advantage is the increase
in the flow rate through spraying
system passages, with fewer distur-
bances due to satellites.
The new gas atomisation allows
for the production of highly alloyed
powders containing reactive ele-
ments. This would be impossible
with water atomisation. Such pow-
ders can be formulated to produce
unique combinations of wear and
corrosion resistant coatings.
By developing and producing in-
house, every step of the production
is controlled. Only high quality raw
materials are used and every batch
is strictly controlled and tested. Ad-
ditionally products can be adapted
Yesterday’s Technology Technology, Tomorrow’s Technology - today to customers needs.
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Introduction
Spray wire production
Overview of the
spray wire production
processes
Today the vast majority of wires
used for arc wire spraying are solid,
extruded wires of standard com-
positions of zinc and aluminium.
By shifting to the more advanced
«cored wire», innovation in sur-
face protection is easier to achieve.
Cored wires consist of hollow metal
wires filled with different powders
(metal and mineral). The flexibility
in choice of metal and powder com-
positions, have enabled us to pro-
duce wire compositions with new
high-tech production equipment
that are impossible to produce as
solid wires. Such wires have been
tuned for arc wire spraying and to
produce unique combinations of
wear and corrosion properties for
applications in boiler protection, for
example. Thermal spraying with wires
Unique wire production unit
Quality wire awaiting baking Unique wire characteristics

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Equipment production
Our equipment DNA is
ease-of-use, quality, sim-
plicity, reliability
In the history of Castolin Eutectic,
thermal spray coating equipment
has been developed, designed and
manufactured in-house since 1963.
Since the launch of the first Eutral-
loy torches in 1993, Castolin Eutec-
tic have sold more than 80,000 ther-
mal spray units around the world
encompassing also PTA, arc wire
spray and HVOF in addition to the
early oxyacetylene devices.
In keeping with the Swiss tradition

of highest quality and precision,
these thermal spray torches carry
our DNA of ease of use, reliability,
robustness and simplicity and are
designed to bring out the best from Assembly of a PTA assembly
our powders. Today, many of the key,
high precision components are still
manufactured in Switzerland to
maintain these high standards and
reproducibility.
Testing of each torch Assembly
Accessories, kits and spare parts Modelling

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Introduction
Our offer
The complete spectrum to all three variables are controlled Many of our customers prefer that
ensure the right Solution and optimised can the coating per- we apply this know-how directly on
form to its full capacity, as illustra- their parts without getting involved
In the fight against wear and corro- ted below. in the details of thermal spray coa-
sion using thermal spray technolo- Painstaking optimisation work with ting powders, equipment and opti-
gies, utlimately the only thing that powder or wire specifications, torch mised parameters. For these custo-
counts is the end-product; the coa- design and then spray parameter mers we have the CastoLab Services
ting. optimisation must be gone through workshops.
Failure or success of the coating will with subsequent microstructural For the customer who wants a com-
be determined by its properties and analysis, wear testing and mechani- plete turn-key solution in order to
its suitability to protect in the given cal testing of the coating to be able guarantee Castolin Eutectic Quality
harsh environment. Basically, the to give the utlimate coating. Coatings in their own workshop or
key properties of coatings are:
This is easier if you control the OEM production facility, we also of-
Chemistry manufacture of the powders/wires fer a fully Integrated Thermal Spray
Microstructure and the design/manufacture of the System, based on our various tech-
Mechanical properties that keep torch and delivery system. Things nologies.
the integrity of the coating get easier if you understand wear Castolin Eutectic is unique in offe-
and corrosion and know which mi- ring such a broad range of options
The above parameters need to be crostructure, chemistry and mecha- for obtaining quality coatings for
optimised by perfecting the quality nical properties are needed to suc- our customers. This is our unique
of the powder, the quality of the de- ceed. This is the unique strength of offer.
position equipment and the quality Castolin Eutectic after 100 years of
of the spray parameters. Only when solving wear problems.
Integrated Laser system Castolab Services

Parameters
Consumables
Equipment
Equipment Powders System integration CastoLab Services
Optimised coating
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Eutalloy® - Eutalloy® SF
Powder
Spray Fusing
Simplified overview
Max
Coating Coating Base mate- coating Coating Deposition Deposition Operating Equipment
of work- surface micro- Bonding rate yield investment
families material rial thickness structure costs
piece size porosity
mm
Powder. Steels,
Eutalloy Self-fluxing cast iron, Medium 2 (6)* Small & Homoge- Negligible Very good. Medium Medium Combustion Low
alloys (aluminium to high precise neous Diffusion gases
bronze) *
Eutalloy Powder.
SF Self-fluxing Steels & cast
iron High 2 (6)* Medium
to large
Homoge- Negligible Very good.
neous Diffusion High High Combustion
gases Low
alloys
Best Second choice
(...)* request special precaution or coating powder
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Powder Spray-Fusing
Eutalloy® Process - One step Spray & Fuse
Basic Principles
of Eutalloy® process
Function
The powder is introduced into the
torch flame and sprayed in a semi-
molten state onto the preheated
part, for fusion. Bonding is achie-
ved by diffusion of the alloys into
the base metal.
Advantages Applications
Eutalloy® provides a wide range of The Eutalloy® process is designed
benefits compared with conven- for protective coating of machine
tional arc welding process and PTA parts and tools subject to a variety
processes: of wear phenomena. Eutalloy®-
No dilution of the base material type oxy acetylene torches are ca-
Metallurgical bonding with no pable of delivering a wide range
Best purity and performance
dilution of Eutalloy® alloy, on of alloys in powder form. The Eu-
of the coating alloy
stainless steel (enlarged x 500). talloy® system has a coating di-
Homogeneous and pore free
A) Deposit mension range from 0.10 mm to
coatings
thicknesses of several millimetres.
B) Diffusion zone Smooth surface for low post The spraying followed by fusion
C) Base metal welding machining and also method can fine-coat to 0.05 mm.
when compared with cold The hardness of a deposit can vary
Bonding of the coating alloy and thermal spraying from 15 to 65 HRC, depending on
base metal is similar to that ob- Higher bond strength the alloy composition. Such depo-
tained in brazing: a liquid phase Better shock resistance sits are perfectly homogeneous
is linked with a solid phase, by and dense.
Thicker coatings capabilities
diffusion. The wetting qualities
of alloys are due to the synergis- Technical data
tic nature of certain constituents. Flame temperature: 3200 °C
These resist oxide formation on Particle velocity: not relevant
the substrate surface during
Deposition rate: 2 to 6 kg/h
spraying, and promote bonding
with the base metal. An oxide- Coating material: Self-fluxing
free surface is essential. Melting Ni, Co or Fe base in powder form
ranges, depending on the type Coating thickness: 0.05 to 10 mm
of alloy, vary between 850°C and Coating density: 100%
1100°C. Spraying distances vary Noise level: 70 - 80 dB(A)
between 6 and 20 mm.
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Powder Spray-Fusing Powder
Spray-Fusing
Eutalloy® Powders
Designations Product Applications Properties

Type
Eutalloy® 10009 Alloy Resurfacing cams, pushers, stops, guide ~63 HRC
Product N° Ni-Cr-B-Si-Fe wheels, filterpress cake stone remover for Low friction coefficient. Good resis-
100603 0.7 kg sugar mill, decanting screw, steam gate tance to corrosion, erosion and abra-
100604 3.5 kg components. Coating elements subject sion under light load.
to friction.
Eutalloy® 10011 Ni-Cr-B-Si- Coating elements of chains, transport ~65 HRC
100605 0.7kg Fe alloy and screw, wiper segments, brick die frames, 80% tungsten carbides.
tungsten claw excavators, rock drill, brush cutter Excellent resistance to abrasion by
carbide rake, debarking knives fine to coarse sized abrasives.
Eutalloy® 10112 Ni-Cr-B-Si- Coating of machine parts used in the ~64 HRC
100608 0.7kg Fe alloy and transport, handling and processing of 60% tungsten carbides.
tungsten minerals: transport screws, clay mixers, Excellent resistance to erosion and
100609 3.5kg
carbide dies, segments, wipers, turbine impeller, abrasion by fine to coarse sized abra-
103508 12.5kg fan impeller, pump screw, etc. sives.
Eutalloy® 10185 Alloy Coating of cast iron and steel molds for ~390 HV30
100610 0.7kg Ni-B-Si plastic material and glass. Well suited for metal-to-metal fric-
Recoating shafts, eccentrics, bearings tion.
100611 3.5kg
Soldering tungsten carbide biscuits on Excellent corrosion resistance.
drilling stabilizers, etc. Machinable with cutting tool.
Eutalloy® 10224 Alloy Repairing glass mold edges, gear teeth, ~250 HV30
100613 0.7kg Ni-B-Si exhaust manifolds, pump bodies, brakes Appropriate for new or worn cast
on drawing tools. iron.
100614 3.5kg
Bonding layer before welding with Good resistance to corrosion.
103509 12.5kg electrode on cast iron that is difficult to Machinable with cutting tool.
weld, etc.
Eutalloy® 10611 Co-Ni-Cr-B- Resurfacing chemical transport screws, ~55 HRC
100617 0.7kg Si alloy and fan blades at cement works, augers, and 50% tungsten carbides.
tungsten extrusion screws. Blades and segments Excellent resistance to abrasion
100618 12.5kg
carbide of mixers, etc. under pressure and to corrosion.
Eutalloy® 10680 Alloy Repair of gears, cast iron valve seats, ~240 HV30
100621 0.7kg Ni-B-Si molds, keyways, bearing seating. Good resistance to shocks and oxida-
Renewing drawing tools. Correction of tion while hot.
100622 3.5kg
machining errors, etc. Machinable with cutting tool.
Eutalloy® 15999 Ni-Cr-B-Si- Coating of molds for ceramics, rasps. ~65 HRC
202799 0.7kg Fe alloy and Distributor blades for fertilizer spreaders, 15% tungsten carbides.
tungsten cyclone blades, hopper for sand sprea- Excellent resistance to erosion and
carbide ding machines, mouths of baggers, etc. abrasion by fine abrasives.
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Powder Spray-Fusing
Eutalloy® Powders

Type
Eutalloy® LT PE 8418 Self-fluxing, Repair of mould damage on the seams or ~ 240 HV30 (~18 HRC)
103398 4.5kg nickel base edges. Easy to machine or file. Grain size -106 µm.
alloy Low energy input for the fusion.
103404 12.5kg
Spot repairs.
Eutalloy® LT PE 8422 Self-fluxing, Repair or protection of mould compo- ~ 270 HV30 (~22 HRC)
103399 4.5kg nickel base nents: seams, blow heads, guide rings. Grain size -106 µm.
alloy Low energy input for the fusion.
103405 12.5kg
Small to medium repairs.
Eutalloy® LT PE 8426 Self-fluxing, Brazing of tungsten carbides on stabiliz- ~26 HRC (~300 HV30)
103400 4.5kg nickel base ers.Extensive repairs and preventive coat- Grain size -106 µm.
alloy ings on seams, edges and guides. Low energy input for the fusion.
103406 12.5kg
Fast deposition.
Eutalloy® LT PE 8431 Self-fluxing, Fast repairs and extensive preventive ~31 HRC
103401 4.5kg nickel base coatings on mould edges and guides. Grain size -106 µm.
alloy with Low energy input for the fusion.
103407 12.5kg
addition of Cr Good wetting properties and fast.
and Mo
Eutalloy® LT PE 8435 Self-fluxing, Extensive repairs and preventive coatings ~35 HRC
103402 4.5kg nickel base on neck rings or blow head. Grain size -106 µm.
alloy with Low energy input for the fusion.
103408 12.5kg
addition of Cr Enhanced fluidity and fast.
and Mo
Eutalloy® LT PE 8440 Self-fluxing, Enhanced weldability at high hardness ~40 HRC
103403 4.5kg nickel base level on bottom plates, baffles and guide Grain size -106 µm.
alloy with plates. Low energy input for the fusion.
103409 12.5kg
addition of Cr Fast deposition with enhanced fluidity.
and Mo
1014
www.castolin.com
Spray-Fusing
Eutalloy® Equipment
SuperJet-S-Eutalloy®
SuperJet-S- Eutalloy® is an oxy-acety- Advantages
lene thermal spray torch, which deli- Flexible, multi purpose and fast
vers very precise anti-wear protec-
tive coatings, thanks to its sensitive Rapid shut-off of acetylene and
controls. Alloy powders are sprayed oxygen while maintaining setting
onto the part to be coated and are Reliable and precise coatings
fused simultaneously. Diffusion bon- Usable in all positions on a wide
ding with the base metal ensures range of base metals, including
that it does not reach its melting steels, alloy steels, stainless steels
point. The dense coating is not af- and cast-iron
fected by dilution and retains all its
designed properties.
SuperJet-S- Eutalloy® Kit

Contents of the equipment case:
1 torch with heat shield Accessories such as:
6 tip assemblies for different flame adjustable spanner
sizes to be used according to spark lighter
the size of the part or type of welding goggles
coating required
hose couplings
set of nozzle cleaners *
Also included are Eutalloy® powders set of injector cleaners
for a wide range of applications. special screwdriver *
Alloy types: 10680 – 10009 – 10185 cleaning rad *
– 10112 set of Teflon washers *
Product N° Solution R 103 to protect the adjacent
750731 SuperJet-S- complete kit areas from undesirable overspray.
Product N°
290102 SuperJet-S- kit with A1S, B3S and C5S
Other kits with different content are available
on request. Please ask your local Castolin
Eutectic company
* packed in a plastic box.
KoolTip
Special water cooled tip assemblies called KoolTip® kits are recommended
whenever the SuperJet-S-torch is subject to high duty cycle usage or pro-
longed thermal reflections.
C6 water-cooled tip assembly kit contents:

assembly with cooling device Accessories such as:
set of connecting water hoses spark lighter
special heat shield welding goggles
nozzle cleaner *
injector cleaner *
set of Teflon washers *
Product N°
203867 KoolTip C6S kit * packed in a plastic box.
1014
www.eutectic.com
Powder Spray-Fusing
Eutalloy® Accessories
Accessories for SuperJet-S- Eutalloy®
C6 Air cooled Tip

The C6 Air cooled tip is for use when water cooling is not possible. The air
cooled version has been specifically designed for this torch. C6 tips have
become a standard feature in industry.
Product N°
205073 C6 Air Cooled Tip
Nozzles
Product N° This nozzle is made out of highly alloyed Cu with structural hardening, a
290129 A0S special wear resistant copper alloy which improves service life. It can be
290130 A1S screwed on & off easily. Every standard kit is delivered with this nozzle
290131 A2S
290132 B3S
type.
290133 B4S
290134 C5S
Heavy duty Nozzles

Product N°
205117 A2S WC
Reinforced with Tungsten–Carbide
205104 B3S WC
This nozzle can be supplied as an option. Each type can be screwed easily
205116 B4S WC
205105 C5S WC
onto the corresponding standard tips. It is recommended when using pow-
290138 C6S-3 WC ders containing abrasive hard particles such as tungsten-carbides.
This wear-resistant spray nozzle will help you in terms of longer service life
or consistent quality coating.
C6-3 is special nozzle with 3 holes for the powder outlet to coat large sur-
faces.
Compact heavy duty tip

Product N° Tungsten–Carbide brazed on the tube
290078 A0S WC/HT
290079 A1S WC/HT This is the solution for all applications where access is a problem and
290080 A2S WC/HT visibility of the fusion bath is a must. It is recommended for Glass Works
290081 B3S WC/HT
290082 B4S WC/HT
and all big users of powders containing hard particles. It is available as an
290083 C5S WC/HT option.
Compact heavy duty tube

Product N° Tungsten–Carbide brazed on the tube
290084 A0S WC/HT
290085 A1S WC/HT Same as the compact heavy duty tip, however without the gas mixer. It is
290086 A2S WC/HT
available as an option.
290087 B3S WC/HT
290088 B4S WC/HT
290089 C5S WC/HT
1014
www.castolin.com
Spray-Fusing
Eutalloy® SF Process - One Step Spray & Fuse for high yield
Function
The Eutalloy® SF flame spraying
process is designed to deposit a
range of wear resistant powder
coatings with high deposit effi-
ciency. It uses the CastoDyn DS
8000 oxy-acetylene powder spray
system equipped with an SF Lance
to coat onto slowly moving or sta-
tionary even surfaces of massive
steel parts in a one-step Spray &
Fuse operation. CastoDyn DS 8000® Powder Spray with SF Lance
The water cooled SF Lance robust
design has been engineered to Applications Technical data
perform higher powder deposi- A range of self fluxing Eutalloy® SF Flame temperature: 3200 °C
tion spraying rates with simul- powder alloys has been developed Particle velocity: not relevant
taneous fusion capabilities. This to meet the precise granulometry
Deposition rate: 2 to 10 kg/h
creates wear resistant requisite and morphology tolerances of the
Coating material: Self-fluxing
coatings from 0.8 mm to 3 mm SF Lance system, thus ensuring
Ni, Co or Fe base in powder form
thickness with strong metallur- highest possible deposition rates
gical diffusion bonds to the steel combined with efficient yield, re- Coating thickness: 0.8 to 3 mm
substrate. liable deposit quality and ease of Coating density: 100%
application. This comprehensive Noise level: 70 - 80 dB(A)
Advantages range of corrosion resistant nickel
High deposition yield based Eutalloy® SF powder alloys
No dilution of the base material is available to meet different hard-
ness and machinability require-
ments when protecting industrial
machine parts in service against
Homogeneous and pore free wear by friction, abrasion, erosion,
coatings pressure etc.
Smooth surface for low Coating with densely packed
post machining hard tungsten carbides in
High bond strength a matrix to form an impenetrable
barrier to abrasive particles.
Good shock resistance
Thick coatings capabilities
Alloy Powder
Powder Injector
Cooling Water
Oxygen
Compressed
Acetylene Air
1014
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Powder Spray-Fusing
Eutalloy® SF Powders

Type
Eutalloy® SF 15211 Ni-Cr-B-Si- All round powder for anti-abrasion. ~60 HRC
Product N° Fe alloy and 60% tungsten carbides
202789 4.5kg tungsten Excellent resistance to erosion and
carbide abrasion by fine to coarse sized abra-
sives.
Eutalloy® SF PE 8213 Ni-Cr-B-Si- For thick coatings. Stabilizer in oil ~55 HRC
202536 12.5kg Fe alloy and and gas drilling industry. 55% tungsten carbides.
tungsten Excellent crack resistance.
202537 4.5kg
carbide Abrasion and corrosion resistance.
Eutalloy® SF PE 8215 Ni-Cr-B-Si- For smooth coatings and parts sub- ~850 HV30
202538 4.5kg Fe alloy and ject to severe abrasion such as agri- 60% tungsten carbides.
tungsten culture parts, centrifugal screws. Excellent abrasion resistance even by
carbide fine particles.
Eutalloy® SF PE 8217 Ni-Cr-B-Si- For parts needing a rough surface ~62 HRC
205951 12.5kg Fe alloy and and subject to severe abrasion such 70% tungsten carbides
tungsten as scraper blades, drill heads, scraper Best edge build-up capability.
carbide parts. Abrasion and corrosion resistance.
1014
www.castolin.com
Spray-Fusing
Eutalloy® SF Equipment & Accessories
CastoDyn SF Lance
The CastoDyn SF Lance kit increases the already wide range of applications by allowing the CDS 8000 to perform spraying
with simultaneous fusion.
Technical data Advantages

Standard Spray Module SSM 50 SSM 51 SSM 52 optional Increased energy output
for highest deposition rate
Deposition rate 4-9 kg/h 2-4 kg/h 1-2 kg/h
Advanced nozzle design delivers
Typical Yield >90 % >90 % >90 % exceptional yield (>90%)
Oxygen flow rate 2000 NI/h 1000 NI/h 500 NI/h Consumable : Eutalloy® SF powders
Acetylene flow rate-Flame 1900 NL/MN 950 NL/MN 475 NL/MN
Oxygen flow rate - Carrier gas 330 NL/MN 240 NL/MN 80 NL/MN
Flame power ~ 28 KW ~ 14 KW ~ 7 KW
Deposit thickness
1-3 mm 0,8-2,5 mm 0,8-2 mm
(one pass)
Schematic showing the assembly of SF Lance on CastoDyn DS 8000
Castolin Eutectic’s modular CDS 8000 torch performs more flame spraying processes, with more alloy powder types than
any other comparable system. Its robust, water-cooled design permits sustained high-intensity spraying, and is ideal for
both automated and manual applications.
1014
www.eutectic.com
Powder Spray-Fusing
Eutalloy® SF Equipment & Accessories
CastoDyn® SF Lance
The kit’s two Standard Spray Modules (SSM 50 and SSM 51) offer different
flame powers, so work elements of any mass or thickness can be coated.
Product N°
203766 CastoDyn SF Lance kit 500 mm
CastoDyn® DS 8000
The CastoDyn DS 8000 torch is de-
livered in a robust carrying and stor-
age case. This CDS 8000 kit is ready
to be used with an SF lance kit and
contains no Standard Spray Modul
(SSM).
Product N°
203754 CDS 8000 kit without SSM
CastoDyn® Extra-Flat SF Lance
The CastoDyn Extra-Flat SF Lance is the solution where access is a problem.

A minimum free opening of 60 mm is enough to enable the Extra-Flat SF
Lance to penetrate in the gap and to apply a coating. It is typically used to
apply wear resistant coatings on decanter screws.
The special Extra-Flat kit contains the SSM 51 and a SF Lance with a length
of 380 mm
Product N°
203763 CastoDyn Extra-Flat SF Lance kit
1014
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RotoTec®- ProXon®- MetaCeram®- Eutalloy® RW
Powder Cold or
Hot Flame Spraying
Simplified overview
Max
Heating Coating Coating Equipment
Coating Coating Base coating Coating Deposition Deposition Operating
of work- surface micro- Bonding rate yield
invest-
families material material thickness structure costs ment
piece size porosity
mm
Powder. Good.
RotoTec Metals & All Low 3 Medium Lamelar 5 to 15% Mechanical Medium to Medium to Combustion Low
polymer metals to large & micro- high high gases
diffusion
Good.
ProXon Powder. All Low 2 (5)* Medium Lamelar 5 to 15% Mechanical Medium Medium to Combustion Low
Metals metals to large & micro- high gases
diffusion
Good.
Meta- Powder. All Low 0,4 (1)* Medium Lamelar 5 to 15% Mechanical Low Medium Combustion Low
Ceram Ceramic metals & micro- gases
diffusion
Eutalloy Powder. Steels &
RW Self-fluxing cast iron High 2 (6)* Medium Homoge-
neous Negligible Very good. Medium to Medium to
Diffusion high high
Combustion
gases Low
alloys
Best Secondary choice
(...)* request special precaution or spray powder
1014
Powder Cold Flame Spraying
RotoTec®, ProXon® & MetaCeram® Processes - Cold Spraying
Function
RotoTec®, ProXon® & MetaCeram®
are «cold» processes whereby a new
alloy or ceramic is reliably coated
onto a cylindrical surface of a metal
workpiece or part. The sprayed coat-
ings are applied to the desired thick-
ness at temperatures that do not
overly stress, change the base metal
properties or create distortion. These
«cold» processes mean that the part
should not exceed about 150°C dur-
ing coating.
Rotor repair with RotoTec® «cold» spray process for lowest heat input
These thermal spray powders are
categorized into the following pro- «Cold» is key to simplicity, In particular, parts suitable for coat-
cesses: efficiency, speed and reliability. ing consist of those which can be ro-
ProXon® process where the Wide range of powders can tated and require repair due to wear
self-bonding powders are be sprayed. on surfaces which are cylindrical in
«cold» sprayed in «one-step». shape. This represents a wide range
Spraying equipment is
RotoTec® & MetaCeram® processes inexpensive. of applications, consisting of shafts,
where the powders are sprayed journals, rolls and bearings on areas
Easy to handle.
in «two-steps». such as bearing seats, press fits, seal
The low level of noise and fumes
The first step is to «cold» spray a and packing zones.
during spraying facilitates setting
bond coat to ensure the bonding
with the part. The second step is to
up a new low cost spraying facility. Technical data
Applications Flame temperature: 3200 °C
«cold» spray a final coating with
the required wear resistance Particle velocity: up to 50 m/s
«Cold» powder flame sprayed coat-
properties. ings have a very broad field of appli- Deposition rate: 1 to 6 kg/h
cations. Both metals and ceramics Coating material: Alloys and
Advantages ceramics in powder form
are sprayed for different application
Low heat input to the base Coating density: 85 - 95%
needs.
metal minimizes distortion, Noise level: 70 - 80 dB(A)
warping and changes in the
base metal.
These «cold» thermal spray powders are applied with

a flame powder spray system, such as the oxy-acety-
lene CastoDyn DS 8000. The powder is fed with help of Powder
injector effect or a carrier gas (nitrogen, argon or air)

Powder
into a gas flame (often acetylene/oxygen). The flame spray
stream
heats the powder particles and propels the droplets
towards the substrate forming a dense coating with
good bonding properties. Due to the moderate
transfer of heat to the powder particles
Oxygen
and to the workpiece, the base metal stays
relatively cool.
Acetylene
Compressed Air
Microstructure of a cold
sprayed coating
1014
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Powder Cold Flame Spraying Powder
Cold Flame Spraying
RotoTec® Powders
RotoTec® – Alloy powders for "cold" two step spray process

Type
RotoTec® 51000 Alloy Bond coat for RotoTec® 19000 and ~170 HV10 - Fusion reaction during
Product N° Ni-Al-Mo MetaCeram 28000 powder families, on spraying creates strong bond with subs-
100658 51000 1.25kg all metals except Cu and Mg. trate.
RotoTec® 19300 Alloy Pieces operating with metal-to-metal ~250 HV10 - Machinable with tools.
100639 19300 1.35kg Fe-Cr-Ni- friction such as shafts, bearing surfaces, Good coefficient of friction. Good resis-
Mo pistons, etc. tance to corrosion.
RotoTec® 19310 Alloy Pieces operating with metal-to-metal ~335 HV10 - Machinable with tools (very
100640 19310 1.35kg Fe-Cr-Ni friction. Wear sleeves for pumps. good machinability by turning). Good
resistance to frictional wear.
RotoTec® 19400 Alloy Protective couplings for shafts, press pis- ~420 HV10 - The best surface finish is
100641 19400 1.35kg Fe-Cr-Ni tons, motor casing. obtained by grinding.
RotoTec® 19404 Alloy Pieces operating with metal-to-metal ~400 HV10 - Excellent combination
202903 19404 1.35kg Fe-Cr-Co- friction and corrosion such as bearing of corrosion, wear resistance and low
Mo seats, etc. For replacing hard-chrome. friction. Machinable with nice surface
finish.
RotoTec® 19800 Alloy Guides, slides, journal bearings, bearings. ~100 HV10 - Very good machinability by
202905 19800 1.35kg Cu-Sn-Zn turning. Excellent coefficient of friction.
Low sensitivity to residual stress.
RotoTec® 19850 Alloy Compressor pistons, trunnions and pul- ~120 HV10 - Very good machinability by
202907 19850 1.35kg Cu-Al leys. turning. Low coefficient of friction.
RotoTec® 19868 Alloy Interior coatings of chocks, ram slides, ~150 HV10 - Good machinability by
202909 19868 1.35kg Cu-Al-Ni foundry models. turning. Low coefficient of friction and
good pressure resistance. Good corro-
sion resistance.
RotoTec® 19940 Alloy Wear sleeves for pumps, cylinder rods, ~370 HV10 - The best surface finish is
100643 19940 1.35kg Ni-Cr-Fe- drying cylinders for papermaking. obtained by grinding. Good resistance to
Mo friction under pressure.
RotoTec® 19985 Alloy Bearing seatings, pistons. ~200 HV10 - Very good machinability by
100644 19985 1.35kg Ni-Cr-Fe Used in rebuilding worn parts. turning.
RotoTec® 19999 Alloy Ni- Drag roll, wear plates, gripping finger. ~250 HV10 - 50% carbides. High resis-
100646 19999 1.35kg Cr-Fe and tance to abrasion. Rough deposit.
carbides
RotoTec® LT 29230 Zn base Sign panels, pylons, gantries, metallic Zn >99% - Low melting temperature.
203013 29230LT 1.35kg structures, machine casing, port equi- Sacrificial layers ensuring cathodic pro-
pment, repair of accidental damage to tection of ferrous supports against cor-
galvanized structures. rosive atmospheric phenomena.
RotoTec® LT 29240 Alloy Antifriction alloys. Resurfacing bearings. Excellent behavior under friction.
203014 29240LT 1.35kg Sn-Sb-Cu The best adhesion is obtained by prepara- Low melting temperature.
tory tinning using CastoTin # 1.
1014
www.eutectic.com
Powder Cold Flame Spraying
ProXon® & MetaCeram® Powders
ProXon® – One-step alloy powders for "cold" one step spray process
Type
ProXon® 21021 Alloy Mechanical seats, feathering sides. ~170 HV10 - Used without bonding
Product N° Ni-Al-Mo Thin and thick anti-wear coatings. layer.
100648 1.25kg The best surface condition is obtained by
100649 2.5kg grinding.
ProXon® 21023 Alloy Bearing seatings, guides, slides, feathe- ~200 HV10 - Used without bonding
202940 2.5kg Fe-Ni-Al ring sides. layer.
Max. service temperature 800 °C.
Thick deposit capability (<3mm).
ProXon® 21031 Alloy For components subject to wear and ~280 HV10 - Used without bonding
100671 2.5kg Ni-Cr-Al- corrosion such as fan blades, shaft slee- layer.
Fe-Mo ves and roller bearing seats Thick deposit capability (<3mm).
ProXon® 21071 Alloy Compressor pistons, trunnions and ~120 HV10 - Used without bonding
202941 1.25kg Cu-Al pulleys. layer.
Good machinability. Low coefficient of
friction. Thick deposit capability (<4mm).
MetaCeram® – Ceramic and refractory powders for "cold" two step spray process
MetaCeram® Cr2O3 On RotoTec 51000 bonding layer. Microhardness ~2400 HV10g
28010 Cable gland seatings, shaft protector Max. service temperature 500 °C
Product N° sleeves, seam ring joint seatings, plun- Product density 5.2 kg/dm
203004 1.2kg gers, pump shafts, feed chutes. High hardness, excellent resistance to
corrosion, low coefficient of friction.
MetaCeram® Al2O3 On RotoTec 51000 bonding layer. Microhardness ~1950 HV10g
28020 TiO2(2.2%) Seam ring joint seatings, cable gland Max. service temperature 1000 °C
203005 1.2kg seatings, shaft protector sleeves, elec- Product density 4.0 kg/dm
trical isolation of machine parts, press High hardness, excellent resistance to
rings for making radial tyres, sifting corrosion.
plate. Good electrical insulation (dependent on
deposit thickness).
MetaCeram® Al2O3 On RotoTec 51000 bonding layer. Microhardness ~1600 HV10g
28030 TiO2(13%) Printer cylinders, paper transport rol- Max. service temperature 1000 °C
203006 1.2kg lers, thread guide, wear and sliding pla- Product density 4.0 kg/dm
tes, induction oven parts. Good resistance to corrosion and good
friction properties.
MetaCeram® Mo Used without bonding layer. Microhardness ~900 HV10g
28095 Sliders, bearings, spindle guide, cable Max. service temperature 400 °C
203009 0.7kg gland seatings, pistons for high-pres- Product density 10.2 kg/dm
sure pumps. Good resistance to abrasion and excel-
lent coefficient of friction.
Non-magnetic deposit.
1014
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Powder Hot Flame Spraying Powder
Hot Flame Spraying
Eutalloy® RW Process - Two Step Spray & Fuse

Function
Eutalloy® RW is a 2-step hot flame spraying process.
The first step is to «cold» spray a thin, regular layer of «RW» self-fluxing quality powder onto a precleaned,
preheated steel substrate using a oxy-acetylene powder spray system such as the CastoDyn DS® 8000.
First step: Cold spraying with CastoDyn® DS 8000
The second step is then to heat the “RW” powder deposit “red hot” using a flame torch, such as the Casto-
Fuse torch, until a reflective fused surface finish is visible locally. An induction system or an oven can also be
used. Strong metallurgical diffusion bonding of the resultant wear resistant coating is thus achieved without
melting or dilution with the substrate. The coating thickness may then be further increased by continuing to
spray & fuse the powder simultaneously followed by controlled slow cooling to ambient temperatures.
Microstructure of a 2-step
sprayed & fused coating
Advantages
Smooth surface for low
or no post machining
Second step: red hot fusion using the CastoFuse® flame torch
No dilution of the base material
Applications
The Eutalloy® RW process is designed to hot flame spray a range of wear
Homogeneous and pore
resistant powder coatings onto fast rotating or stationary even sur-
free coatings
faces.Final «RW» pure precision coatings are characterised by smooth
surface finish requiring little or no post machining operations for opti- High bond strength
mum service performance. Good shock resistance
1014
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Powder Hot Flame Spraying
Eutalloy® RW Powders

Type
Eutalloy® RW 12112 Ni-Cr-B-Si- Recoating wear pieces of agricultu- ~710 HV30
Product N° Fe alloy and ral machines, mixer blades, ceramic 35% tungsten carbides.
100627 3.5kg tungsten press feeder plungers. Excellent resistance to erosion and
carbide Resurfacing pump wear sleeves, abrasion.
steel industry transport rollers.
Eutalloy® RW 12494 Alloy Coating incineration boiler tubes. ~310 HV30
100629 3.5kg Ni-Cr-B-Si-Fe Machine elements in food and Very good resistance to corrosion.
chemistry industry. Suitable for friction under light
loads.
Machinable with cutting tool.
Eutalloy® RW 12495 Alloy Coating of wear sleeves for pumps, ~390 HV30
100630 3.5kg Ni-Cr-B-Si-Fe glassworks feed plunger, valve parts: Suited for impact and friction.
seats, flaps, etc. Machinable with cutting tool.
Eutalloy® RW 12496 Alloy Coating cylinder rods, wear sleeves, ~680 HV30
100632 3.5kg Ni-Cr-B-Si-Fe pump pistons and faucet parts. Very low coefficient of friction and
103352 50kg Resurfacing coal dust separators, good abrasion resistance.
etc. Excellent resistance to corrosion
and especially to seawater.
Eutalloy® RW 12497 Alloy Coating protective couplings, cylinder ~740 HV30
100634 3.5kg Ni-Cr-B-Si- rods, wear and seal sleeves, Pelton Excellent frictional and corrosion
Fe-Mo-Cu turbine, injection needle valves, etc. resistance.
Coating stainless steel pieces. Excellent corrosion resistance.
Eutalloy® RW 12999 Ni-Cr-B-Si- Coating fan blades, mixers, trans- ~760 HV30
100637 3.5kg Fe alloy and port screws, tensioning pulleys, 40% tungsten carbides.
tungsten guides. Excellent resistance to abrasion.
carbide Wear parts for agricultural
equipment, etc
Eutalloy® RW 17535 Alloy Coating paper mill and household ~480 HV30
202878 3.5kg Ni-Cr-B-Si waste boiler tubes. Resurfacing High Cr alloy.
machine parts operating in corro- Well suited for metal-to-metal
sive environments. friction.
Excellent resistance to oxidation
while hot.
Good resistance to cracking.
Machinable with cutting tool.
Eutalloy® RW 53606 Alloy Boiler tubes, shafts and sleeves in ~600 HV30
100662 3.5kg Ni-Cr-Mo-Si- waste incineration, chemical, pulp Excellent wear and corrosion
B-Cu and paper industries. resistance to both reducing and
oxidizing environments.
1014
www.castolin.com
Powder Flame Spraying Powder
Flame Spraying
Flame Equipment & Accessories

CastoDyn® DS 8000
Technical data
CastoDyn® DS 8000 is an advanced modular oxy-acetylene thermal spray system,
designed to spray a wide range of alloys and other materials for many different appli-
cations, from anti-abrasion coatings to thermal shielding. The CDS 8000 can be inte-
grated into automated installations for large-scale mass-production applications.
For «hot» thermal spraying of Eutalloy® RW powders
For «cold» thermal spraying of RotoTec® and Proxon® alloy powders
For «cold» thermal spraying of MetaCeram® alloy powders
For «cold» thermal spraying of CastoPlast thermoplastic powders
Advantages
Outstanding operator safety and ease-of-use
Ready-for-use CDS 8000 kit in a robust
carrying/storage case
Standard Spray Modules (SSM)
Product N° Unique rapid shut-off lever for safety and
203756 CDS 8000 complete kit with SSM10, for relighting without touching any other control
SSM20, SSM30 and SSM40
Oxygen flow rate - Flame Acetylene flow rate-Flame Oxygen flow rate - Carrier gas
Module NL/MN NL/MN NL/MN
SSM10 1000 950 240
SSM20 1000 950 240
SSM30 2000 1800 80
SSM40 1000 950 330
Accessories for CastoDyn® DS 8000
Extension Neck
Spray extension neck for coating internal surfaces or difficult access areas.
Product N° Length 465 mm
203758 CDS 8000 Extension neck
CastoFuse®
Technical data
The advantage of local heating using the CastoFuse® torch is obvious compared
with an oven. Local preheating and fusing prevents the dispersion of heat in the
rest of the workpiece, to the surrounding area and into the oven walls. CastoFuse®
offers the heat where needed. Furthermore, only a small investment is required.
Advantages
Performance: nozzles designed specifically to fuse self-fluxing
powder coatings
Safety and ease-of-use: unique rapid shut-off lever
Full line: assortment of lances to ensure optimum flame power
CastoFuse Lance 20 30 40
Kit with optional lances Oxygen consumption 0.8 - 1.1 m3/h 1.5 - 1.66 m3/h 2.3 - 3.3 m3/h
Acetylene consumption 0.7 - 1.0 m3/h 1.05 - 1.5 m3/h 2.1 - 3.0 m3/h
Product N°
290020 CastoFuse complete kit with lances Flame power ~ 11 KW ~ 20 KW ~ 40 KW
20, 30 and 40 Required acetylene cylinders 1 2 4
Length 270 mm 320 mm 590 mm
1014
www.eutectic.com
Powders Flame Spraying
Flame Equipment & Accessories
Accessories for CastoFuse®
Konstantherm
Heat resistant heating tip for acetylene and hydrogen.
Available on request, please ask your local Castolin Eutectic company.
Line Heating Torch

For heating, brazing, forming, hardening, stress relieving.
Ring Torches
For pre and post heating, soldering and brazing, forming.
RotoTec® 800
RotoTec® 800 is an advanced modular oxy-acetylene thermal spray system, designed
to spray a wide range of alloys and other materials for many different applications,
from anti-abrasion coatings to thermal shielding. The RotoTec® 800 can be integrated
into automated installations for large-scale mass-production applications.
For «hot» thermal spraying of Eutalloy® RW powders
For «cold» thermal spraying of RotoTec® and Proxon® alloy powders
For «cold» thermal spraying of MetaCeram® alloy powders
For «cold» thermal spraying of CastoPlast thermoplastic powders
Technical data
Connections
Fuel gas (acetylene): LH 3/8" left, Oxygen: RH 1/4" right,
Compressed air: M10 x 1
Spraying efficiency
Powder throughput: ~ 3.0 – 6.0 kg/h (depending on powder type,
instrument adjustment, etc.)
Operating pressures and gas consumption values
Oxygen, 3.0 bar: 1400 NL/h ± 50 NL/h,
Acetylene, 0.7 bar: 1130 NL/h ± 50 NL/h
Fuel gas-oxygen mixture, Injection principle (gas-mixing squirting and heat-
Product N° ing nozzle) Weight approx. 1.25 kg (without powders and gas hoses)
307100 RotoTec 800 complete kit
1014
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HVOF® PTA
HVOF LIQUID FUEL
Simplified overview
Max
Coating Coating Base coating Coating Deposition Deposition Operating Equipment
families material material thickness structure costs
piece size porosity
mm
Powder Excellent Liquid fuel,
HVOF - Metals All Low 0.5 Small to Lamelar > 1% mechanical Medium Low combustion Medium to
Tungsten metals Large gases High
Carbide bond
Best Secondary application
1014
HVOF
HVOF Process
CastoJet® CJK5
From our history and DNA, Castolin Eutectic’s CJK5 HVOF is the easy-to-use route to the highest coating quality.
During the early 1990s Castolin Eutectic Research & Development were involved in the development of a converging/
diverging nozzle for its CDS 8000 torch to accelerate the particles and improve coating quality.
In 1996, the world’s leading technology of the day was integrated into the Castolin Eutectic history with the pur-
chase of the company TAFA and the JP 5000 HVOF technology, which has been a reference since this date. In 2009
we launched the CJK5, which embodies all that we learned from this period of coating innovation and to which was
added the Castolin Eutectic DNA of ease-of-use and high quality.
CJK5 HVOF Function

The CJK5 HVOF is a high pressure, A powder feed stock is injected into
high velocity thermal spray pro- the gas stream, which accelerates ment of kerosene fuelled high pres-
cess, using liquid fuel (kerosene) the powder up to 800 m/s. The sure HVOF (High-Velocity Oxy-Fuel)
and oxygen which are fed into a stream of hot gas and powder is systems. The CJK5 developments
combustion chamber, where they directed towards the surface to be have focused on the gun, pow-
are ignited and continuously com- coated. The powder partially melts der feeder and operator interface.
busted. The resultant hot gas at a in the stream, and deposits upon The operator interface is simple to
pressure close to 1 MPa, emanates the substrate. The resulting coating
use with a touch screen interface.
through a converging – diverg- consists of thin overlapping plate-
ing nozzle and travels through a lets, has low porosity and high bond The powder feeder has mass flow
straight section. The jet velocity at strength. controlled carrier gas and closed
the exit of the barrel (>1000 m/s) The CastoJet® Kerosene 5 - CJK5 - is loop motor control for reliability and
exceeds the speed of sound. the latest Castolin Eutectic develop- repeatability of powder feed rates.
HVOF Schematic Diagram

1014
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HVOF HVOF
HVOF Advantages
Advantages:
The value is in the technology - to make it intuitive to operate, to reduce operator errors, to simplify the mainte-
nance and to obtain repeatable high quality coatings.
High-pressure of the combus- High Bond strength and low po- Simple gun maintenance for re-
tion chamber is typically at least rosity coatings. duced downtime when changing
double that of gas fuelled HVOF, Manual or fully sequenced start- consumables.
which improves the gas speed by up, operation and shut-down. Steel powder feed tubes for reli-
20% over gas fuelled HVOF. able operation – do not melt in
Kerosene start-up / no hydrogen /
PC control with touch screen op- improved safety. operation.
erator interface. Robust chamber pressure trans-
Liquid fuel = thick, low stressed
Multilanguage software / ease of coatings. ducer provides accurate feed-
use. back directly from the chamber.
High hardness, low oxide level
Reversable nozzle design/ pro- Repeatable process control.
coatings.
vides increased life and reduced Control can either be via the op-
spares costs. Optimised, single point fuel erator interface or directly at the
injection system to promote a powder feeder for stand-alone
Reduced footprint compared to complete, clean burn within the
others systems with unbundled operation.
combustion chamber. Superior
options. coating quality.
Optional keyboard control or op- Three nozzle lengths available,
erator interface unit. 100mm, 150mm and 200mm,
Unlimited recipes and parameter enable a wide range of coating
recording. properties to be achieved.
The CJK5 control system is shown screen operator interface and a gas
with the operator interface mount- box. The PC provides a means of op-
ed onto the gas box for pictorial erator interface and overall system
purposes only. In a typical installa- control. For reliability of operation,
tion, the gas box would be inside the actual control of the individual
the spray booth. The powder feeder operations of the system are con-
would either be inside or outside the trolled by PLC’s in the gas box and
spray booth. The operator interface powder feeder. The PC and PLC’s
would be outside the spray booth. are all linked by serial bus to mini-
The control system for the CJK5 mise wiring and increase reliability.
HVOF consists of a PC with a touch-
1014
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HVOF
HVOF Applications and Technical
Applications:
Hard chrome plating alternative
CGL mill rolls - steel industry
Oil andGas - ball and gate valves
Down hole tools used in the oil and gas industry
Paper rolls
Hydraulic rams
Aircraft Landing gear
Suspension components
Hydro-electric turbines
Automotive valves
Ball Valve Finished
Aero Engine Components
Mud Motor Rotors Aircraft Landing Gear HVOF HVOF coating on steel roll
Technical
Windows
Familiar
Unlimited recipe storage
Industrial PC
Stainless steel enclosure
Dust/water ingress protection
Standard interfaces (USB, ETHERNET, RS232)
Connected to main control PLC by industrial serial link
Rapid response to changes
Mass flow control of carrier gas = repeatability.
Volumetric feed via hopper and rotating disc design.
Two disc variants to allow optimum feeding of a wide
range of powders.
Feed disc rotational speed is controlled via a closed loop
AC inverter for improved feeding accuracy.
Robot mounting interface.
1014
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HVOF HVOF
HVOF Powders
SEM image of HVOF WC-Co-Cr powder SEM image of HVOF NiCrBSi powder SEM image of CrC-NiCr powder
Castojet HVOF Typical Material Hardness Maximum Environment Typical

Powder Hv operating Application
temperature
(°C)
55586C WC86/Co10/Cr4 1100/1200 Hv 500°C Excellent resistance to wear Rotors, Valves,
757474 5kg and corrosion Mandrels
55588C WC88/Co12 1000/1100 Hv 540°C Good wear and thermal Steel rolls,
757476 5kg shock resistance Wear Plates
55583C WC83/Co17 1000/1100 Hv 540°C Excellent in severe impact/ Steel rolls,

757475 5kg sliding wear resistance Impellers, Shafts
55580C CrC -NiCr 80/20 900/1000 Hv 870°C Excellent in high tempera- Aero Engine
757972 3kg ture, corrosion and wear, components and
resists flame impingement Furnace rolls
55396C NiCrBSi 750 Hv 800°C Good corrosion and wear Hydraulic shafts,
757810 5kg properties, hard machinable pump sleeves,
coating. Good build up mate- wear rings,
rial armature shafts.
Castolin Eutectic provides powders Applications requiring improved cor- Important powder characteristics
for High Velocity Oxy-Fuel (HVOF) sys- rosion resistance, such as in the oil that Castolin Eutectic control include:
tems. These HVOF tungsten carbide and gas industry, would need a matrix carbide grain size in the powder
powder materials offer high density, of cobalt-chromium. For high service particle
low porosity, and high bond strength. temperatures above 550 °C (1000 °F),
we would recommend chromium homogeneity of carbide dispersion
For the best wear protection and tem- within the powder particle
peratures up to 550 °C (1000 °F) we carbide materials, commonly used in
would recommend Tungsten carbide the aerospace industry. All our carbide density of the powder particle
in a cobalt matrix. based powders are agglomerated and shape of the powder particle
sintered and the metallic powders gas
Materials with a higher percentage of atomized and gas cooled. particle size distribution
cobalt produce coatings with better Check out our powder products above
ductility, and a lower percentage of The powder manufacturing process,
which determines the powder charac- to find out more including typical
cobalt offers greater hardness, resul- applications
ting in superior wear resistance. teristics, will therefore influence the
properties of the deposited coating.
1014
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HVOF
HVOF Equipment & Accessories
The CastoJet® CJK5 kit comprises:
CJK5 Gun
CJK5 Control interface and gas box
CJK5 Touch screen PC
CJK5 Mass flow powder feeder
Input supplies package 5 m
Output supplies package available in 5,
10 or 14 m
Tool kit and accessories
Flashback arrestor
Options
High pressure oxygen regulator
Nitrogen regulator
CJK5 Powder feeder cabinet
Robot interface
Chiller
Spares kits (100 hours, 500 hours,
powder feeder change over kit)
Description Characteristics
Canister capacity 2750cc
Electrical supply 240/110V 1ph
Weight 40kg
Dimensions (mm) W-400 x D-400 x H-700
Product N° Description
753912 CastoJet® CJK5 kit - 5 m
753908 Toolkit and accessories
754390 CJK5 Gun with 100 mm nozzle
1014
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Laser Technology PTA
LASER TECHNOLOGY
Simplified overview
Max
piece size porosity
mm
Powder
Laser MetalsTungsten All Low 5 (15) Small to Homoge 0% Excellent High Medium Electricity High
Cladding Carbides
metals Very Large -neous Fusion
Best Secondary application
1014
Laser Cladding
Laser Process
In the laser coating process, the
filler alloy in powder form is in-
jected into the laser beam, sprayed
and welded onto the component
in a single step.
This process uses a laser beam to
fuse completely the desired mate-
rial onto a substrate material for
superior wear resistance or for re-
pair. A shielding gas protects the
weld pool from the atmosphere.
The rapid cooling rate gives the
coating a homogeneous and fine
microstructure that is character-
ised by toughness as well as hard-
ness. The laser beam spot and
the heat input can be far better
controlled than a conventional
electric arc. The energy is almost
completely used to fuse the filler
powder, leaving the least heat to
melt the surface of the substrate,
reducing the heat input, the Heat
Affected Zone (HAZ) and dilution
to the minimum.
The melt pool, formed when the
laser fuses the powder, is precisely
controlled in comparison to other
welding or hardfacing processes.
Laser powder coating nozzles

Coaxial ring nozzle MultiJet Nozzle Off-Axis Nozzle
Powder Spot ≥ 0,3 mm Powder Spot ≥ 1,5mm 2D Nozzle for geometries with
Laser Power ≤ 2000 W Laser Power ≤ 6000 W limited access
Oxygen Contamination ≤ 20 ppm Oxygen Contamination ≤ 50 ppm Laser Power ≤ 2000 W
1014
www.castolin.com
Laser Cladding Laser
Advantages
The laser coating process is one
of the cladding processes which
is used to fuse a desired alloy on
a substrate material. The clad
material may be similar to the Coating direction
substrate material in the case of
repairs and rapid prototyping. The
clad material may have a higher
Feeding gas and powder
performance to offer enhanced Laser beam
corrosion resistance or wear re- Coating
sistance to protect a multitude of material
Melt Pool
components.
The laser process is at the cut- Shielding Gas
ting edge of technology in many
industrial fields where modern Work piece
production lines require reliable,
automated and flexible systems
with little maintenance that ways to protect against wear, re- constraints. Below, a simplified
achieve optimum profitability. pair and rebuild parts, each with overview of different coating pro-
There are many different coating their respective advantages and cesses.
Coating Heating of Distorsion of Coating Deposition Deposition Max coating Precision Noise
Bonding
Processes workpiece workpiece micro-porosity rate yield thickness mm of coating level
Low Low Negligible Excellent High Medium 5 (15)* High Low
Laser
Fusion
High High Negligible Excellent High Medium 5 (40)* Medium Medium
Welding
Fusion to high
Medium Medium Negligible Excellent Medium High 2 (10)* Medium Low to
PTA to high Fusion to high medium
Thermal Medium High Negligible Very good Medium Medium 2 (6)* Medium Medium
to high to low Diffusion to high
spraying
with fusion
Low Low 1 to 10% Good Medium Medium 0.3 (10)* Medium Medium
Thermal Mechanical to high to high to high
spraying & micro-
diffusion
Best choice
Second choice
Laser coating: metallurgical fused bonding with Conventional welding process with strong dilution
minimum dilution, low heat input and controlled which degrades the purity of the coating.
coating thickness.
1014
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Laser Cladding
Advantages
The laser coating process provides pieces than conventional welding. quality.
a wide range of benefits compared Metallurgical fused bonding re- Unlimited coating thickness for
with conventional arc and PTA weld- sulting in high bond strength. rebuilding, repair or rapid proto-
ing processes: Very rapid coating solidification, typing.
Heat input localised and process- producing very fine wear resistant Precise coating thickness control
ing time short. microstructures. and smooth surface for least post-
Lowest dilution of 2 to 5% for Dense, hard and smooth surface weld machining.
maximum purity of the coating. finish coating for high coating High process stability, reliable and
Distortions and HAZ smaller than quality. consistent results ideal for auto-
any other welding processes. It Dense, hard and smooth surface mated processes.
can coat smaller and thinner finish coating for high coating Low noise level.
Applications
There is a wide range of applica- The laser coating process is used to quire adapted wear or friction prop-
tions which address the corrosion repair and restore worn machine erties.
and wear protection in the automo- components, such as shafts, shaft Over the decades, Castolin Eutectic
tive industry (such as valve seats), ends, linings, bearing seats and oth- has developed many innovative
the wear protection for tools in offer parts prone to wear. powders for our established
shore oil drilling, for hydraulic cyl- Eutalloy and PTA processes. Many
inders in mining and for reworking The method is also used for new of these industry proven powders
expensive tools. manufacture of components where have been formulated for use with
the component - or parts of it - ire- the laser technology.
Mixer Screw Housing end plate Stabilizer Sleeve

1014
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Laser Cladding Laser
Laser Powder range
Laser Powder Catalogue

The complete laser powder range is
available in a separate catalogue cov-
ering the latest chemistry and pow-
der specification.
Laser Powder
The laser coating process requires coating technology
high-quality powders with spherical
solid particles to achieve a constant
flow in the automated laser system Enduring Performance…
and high coating performance.
The powder should be without satel-

lites which are fine particles attached
to the spherical surface. These can
detach during the laser process and
increase the amount of fines in the
Stronger, with
Castolin Eutectic
feedstock. These fines will melt more
quickly and can affect the coating
quality. These fines will also modify
the feeding rate through the laser
equipment. The particles must also
be solid without internal pores in or-
der to avoid porosity in the coating.
Castolin Eutectic powders give you Precise coatings with fine wear
the best results. Solid and spherical resistant microstructure, metallurgical
satellite free particles with lowest
oxygen content and constancy, batch
bonding and lowest heat input
after batch, are key features of Casto-
lin Eutectic powders. Free flow in all
powder feeding systems is enhanced
and achieves consistent high produc-
tivity.
1014
www.eutectic.com
Laser Cladding
Our offer
Laser Powders, Laser Clad- Metallic powders and Blends op- If you need laser cladding work to
ding Service, Laser Clad- timised for the Laser Cladding be done in Europe or Asia do not
process hesitate to contact us and can han-
ding Systems dle very large and heavy parts.
Laser Cladding Service Work-
The laser source and the head are shops (in Europe and Asia) If you are looking to buy a complete
the only equipment in the Castolin integrated laser cladding facility,
System Integration of Laser Clad-
Eutectic Coating Equipment range including laser source, head, pow-
ding component for customers
that are not designed, manufac- der feeder, optimised powder and
tured and sold under our control. parameters, tailored automation,
However, we have been involved The broad range of metallic pow- off line programing and booth that
with laser technology and cladding der and blends that have proven complies with all safely standards,
for several decades, ever increas- themselves against wear and corro- Castolin Eutectic is able to also offer
ing our experience, as the technol- sion in the toughest environments, this service, as we have successfully
ogy itself has rapidly progressed previously deposited with the well- put several systems together for
through advances in the solid state/ established PTA and Eutalloy pro- our own workshops and can offer
diode lasers. cesses, can also be modified and this know how to such customers.
optimised for the laser cladding
Our welding and PTA backgrounds is process. This is being done in our
ideally suited to optimisation of the dedicated laser R&D facilities and
laser cladding process and today we also in several of our CastoLab Ser-
have a broad offer consisting of: vices workshops.
Consumables
Putting a reliable, performing Package together for OEMs and Workshops
Equipment
System integration CastoLab Services

1014
www.castolin.com
EuTroLoy® PTA
PTA Coating
Simplified overview
Max
piece size porosity
mm
Powder or Steels,
EuTroLoy wire. cast iron, Medium 2 (10)* Large Homoge- Negligible Excellent. Medium to High Electricity & Medium
Metals (aluminium to high neous Fusion high shielding gas
bronze) *
Best Second choice
(...)* request special precaution or PTA powder
1014
PTA Welding
Plasma Transferred Arc Process
Plasma Transferred Arc
(PTA)
Function
In the PTA process, the plasma is fo-
cused while forced through the heat
resistant anode, causing a conside-
rable increase of the arc density, Smooth surface and spatter free coating
energy and temperature. The filler
alloy in powder form is conveyed
into the plasma arc column where a
shielding gas protects the weld pool
from the atmosphere. The plasma
arc and the heat input can be far
better controlled than a conventio-
nal electric arc and the energy is al-
most completely spent to melt the
filler metal, reducing the heat input Wear resistant coating with metallurgi-
and dilution to the minimum. cal bonding and minimum dilution.
Advantages Technical data Coating material: Metals in

powder or wire form
PTA technology provides a wide Plasma arc temperature:
range of benefits compared with up to 20 000 °C Coating thickness: 0.1 to 20 mm
conventional arc welding processes: Particle velocity: not relevant Coating density: 100%
Lowest dilution, heat input, Deposition rate: up to 6 kg/h
distortions and HAZ than any
other arc welding process
Maximum purity and perfor
mance of the coating alloy
Extra smooth surface for least
post-weld machining
Higher bond strength
Pore free coating
Thicker coatings capabilities
Applications
The EuTronic® GAP is the Castolin
Eutectic Plasma Transferred Arc
(PTA) process. GAP is ideal for coa-
ting and joining operations. Casto-
lin Eutectic has developed special
EuTroLoy powders for applications
1) Cathode holding device 6) Feeding gas and powder
carried out with the EuTronic® GAP. 2) Plasma gas 7) Welding direction
3) Cathode 8) Ignition
4) Cooling water 9) Double power supply
5) Shielding gas
1014
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PTA Welding PTA Coating
PTA
EuTroLoy® - PTA Powders
Designations Product Type Applications Properties

EuTroLoy® 16006.04 Alloy Valve seats, protective shaft sleeves, ~40 HRC
Co-Cr-W-Ni-Fe shaft seal surfaces, tools in the wood High abrasion resistance under pressure
Product N°
(Gr. 6 Type) and plastic processing industry, stir- and impact stress (cavitation). Heat and
420005 16006.04 4kg rer components, valve parts, extruder corrosion resistant. Low coefficient of
420004 16006.04 12.5kg screws, buffer layer for EuTroLoy® sliding metal friction, insensitive to
16001 alloy powders. adhesive wear.
For operating temperatures up to 750°C.
EuTroLoy® 16008.04 Alloy Calibration matrices for steel forming, ~30 HRC
Co-Cr-Mo-Ni hot working tools such as dies and Corrosion, oxidation, heat, cavitation,
420006 16008.04 4kg
(Gr. 21 Type) shearing blades, valve seats, seal thermal shock and creep-resistant weld
103704 16008.04 12.5kg surfaces of shafts and spindles, pump metal. Workhardening. Low coefficient
and turbine parts. Buffer layers for of sliding metal friction, insensitive to
EuTroLoy® 16001, 16006, 16012 alloy adhesive wear. Nonmagnetic, easily
powders. machined and polished coatings.
EuTroLoy® 16012.04 Alloy Slide valve seats, extruder screws for ~46 HRC
Co-Cr-W-Ni-Fe plastic masses, feed screws for sawdust High abrasion resistance under pressure
420008 16012.04 4kg
(Gr. 12 Type) and hydropulpers in the paper industry, and impact stress (cavitation). Heat and
103651 16012.04 12.5kg tools in the timber industry, segments corrosion-resistant. Low coefficient of
of nose rings and clinker cooling plates, sliding metal friction, insensitive to
tools for the paper, plastics and timber adhesive wear.
processing industries. For operating temperatures up to 750°C.
EuTroLoy® 16221.04 Alloy Highly suitable for use with molten ~30 HRC
Ni-Cr-B-Si-Al glass. Mould bottoms, tailstocks, Excellent bonding with lamellar and
205144 16221.04 4kg
blowheads in cast iron and Cu-Al. spheroidal graphite grey cast iron, as
205146 16221.04 12.5kg Drawing matrices in cast iron, coke well as steel. Excellent resistance to heat
oven door. Bonding layer on flake and and thermal shock.
spheroidal graphite cast iron parts.
EuTroLoy® 16223.04 Alloy Gray cast iron forming tools, gray cast ~34 HRC
Ni-Cr-B-Si-Al iron and bronze glass moulds, valve and Good wetting of the base metals. Creep
205145 16223.04 4kg
slide valve parts, dies, anti-corrosion resistant, thermal fatigue resistant and
205147 16223.04 12.5kg hardfacings on gray cast iron workpiec- cavitation resistant hardfacings. Low
es, buffer layers on gray and nodular coefficient of sliding metal friction. Good
cast iron. adhesive strength and corrosion resist-
ance. Polishable.
EuTroLoy® 16316.04 Alloy Workpieces in the chemical industry ~170 HV30
Fe-Cr-Ni-Mo and food processing industry and buff- Austenitic weld metal with ~9 % -ferrite
103693 16316.04 4kg
er layers for hard-facing. and low carbon content. Resistant to
103443 16316.04 12.5kg pitting and intercrystalline corrosion
up to temperatures of 400 °C, also scale
resistant up to 800 °C. May be polished
to a mirror finish.
EuTroLoy® 16454.04 Self-fluxing Ni Hardfacing of seal surfaces in valves, ~53 HRC
base alloy sliding seals and slideways, forming Highly creep resistant, heat and corro-
205839 16454.04 4kg
tools, valves, valve flaps, pump rotors, sion resistant weld metal.
205838 16454.04 12.5kg cams and worm screw parts. Low coefficient of sliding metal friction.
High adhesive strength.
The suffix “.04” indicates the particle size distribution 150+53 µm
1014
www.eutectic.com
PTA Welding
EuTroLoy® - PTA Powders
Designations Product Type Applications Properties

EuTroLoy® 16496.04 Self-fluxing Ni Hardfacing of seal surfaces in valves, ~58 HRC
base alloy sliding seals and slideways, forming Highly creep resistant, heat and corro-
204549.4kg
tools, valves, valve flaps, pump rotors, sion resistant hardfacing. Low coefficient
cams and worm screw parts. of sliding metal friction. High adhesive
strength.
EuTroLoy® 16604 Alloy Tools for hot and cold metal shaping: ~45 HRC
Fe-Co-Cr-Mo clipping bed, rolling mills, bending Work-hardening deposit with very fine
202863 4kg
machines Gate components. Sealing martensitic structure. Ecellent resistance
joints. to heat, thermal shock and corrosion.
Buttering layer before coating with Good resistance to cracking.
cobalt based alloys.
EuTroLoy® 16606A.04 Alloy Temperature-stressed dies and man- ~58 HRC
Fe-W-Cr-Mo-V drels, cutting tools, also for natural Martensitic weld metal based on cold
103713 4kg
fibres, punching, compression moul- work tool steel. Wear-resistant to
103714 12.5kg ding and drawing dies, forging inserts, abrasion and fatigue stress as well when
worm screw parts, valves, barrel extru- subject to a combination of abrasion and
ders. fatigue stress. Hot wear resistant. Good
tempering properties. Heat treatable.
EuTroLoy® 16625M.04 Alloy Marine engine components, power ~210 HV30
Ni-Cr-Mo-Nb-Fe plant components, installations on High ductility. Very good corrosion resist-
750152 4kg
drilling rigs, valve components for min- ance (e.g. seawater). Tough at subzero
750153 12.5kg eral oil, tools for underwater work and temperatures, suitable for cryogenic use.
low-temperature equipment.
EuTroLoy®16800 Alloy Mixer arms, components in the paper ~260 HV30

Ni-Mo-Cr-W industry, hot shears, hot trimming dies, Very high resistance to intercrystalline
103419 4kg
extrusion dies, valve seats, pump com- corrosion, interfacial corrosion and
ponents in the chemical industry. stress corrosion cracking. Excellent
corrosion resistance to oxidising media
such as nitric, phosphoric, sulphuric
and sulphurous acid. Also resistant to
ethanoic, lactic, citric and fatty acids,
caustic soda as well as media containing
chloride.
EuTroLoy® Ni-B-Si-Fe alloy Decanting and transport screw. Mixer ~60 HRC
PG 6503 and tungsten pieces. Drilling tools. Brick or tile dies. 60% tungsten carbides.
carbide Protective sleeves. Wood-working tools. Excellent resistance to abrasion.
202434 4kg
202433 12.5kg
EuTroLoy® Self-fluxing Ni Gray cast iron and bronze glass moulds, ~270 HV30
PG 8426.04 base alloy Floodfilling of WC/Co Tiles, buffer layers Low energy input for the fusion. Good
on gray cast iron and nodular cast iron. wetting of the base metals. Good adhe-
750556 12.5kg sive strength and corrosion resistance.
Polishable.
The suffix “.04” indicates the particle size distribution 150+53 µm
1014
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PTA
EuTronic GAP® - PTA Equipment

EuTronic GAP® 2501 DC
Plasma welding, TIG welding, MMA welding
For joining, coating and brazing
Designed for manual & automated applications
Versatile unit with strong 250A inverter
User friendly touch screen control panel
Fully compatible with all Eutronic GAP accessories
Why Eutronic® GAP 2501 DC?
The EuTronic GAP is the Castolin Eutectic Plasma Transferred Arc (PTA)
process, ideal for joining and coating operations.
A stream of accelerated ionized gas in electric arc is focused in
plasma nozzle and generates plasma. PTA process can be started by
preliminary use of inner pilot arc. The pilot arc is burn between the
gas cooled cathodic tungsten electrode and liquid-cooled anodic cop-
per nozzle. The welding filler alloy, in microatomised powder or cold
wire form is conveyed into the plasma beam where the shielding gas
protects the weld pool from the atmosphere. The plasma arc and the
heat input can be far better controlled than a conventional electric
arc and the energy is almost completely spent to melt the filler metal,
reducing the heat input and dilution to the minimum.
The well-arranged designed operating touch panel of the machine
allows the easy adjustment of the welding parameters also with
protective gloves.
PTA technology provides a wide range of benefits compared with conventional arc welding
processes Major factors are:
• High energy density in an extremely focussed arc
• High deposition rates for shorter welding times
• Lowest dillution, heat input, distortions and HAZ
• Possible multipass overlays
• Smoother surface for lower machining costs
• Maximum purity and performance of the applied alloy even in the first layer.
• Metallic bond strength and impact resistance
• Optionally suitable for fully automated processes (electronically controlled gas valves and separate interface to link the unit with external
controllers is giving outstanding flexibility for automation)
Focoused plasma arc allows extra control, that results also in lowest dilution among all the arc welding process.
PTA process produces extra smooth and spatter free deposits, minimizing machining and filler alloy costs.
Application examples: EuTronic GAP® 2501 DC

Mains voltage: 3x 400V+N ±10%
• Repairs on tool steels, rebuilding of cutting edges, forging, stamp-
ing dies, aluminium die casting moulds Mains frequency: 50/60 Hz
• Repairs on cast iron, glass moulds Mains fuse: 32 A
• Feeding screws repairs
• Hard-facing on drilling tools Max. power consumption: 18 kVA
• Hard-facing on valve seats and valves RMS value of the largest main current: 20 A
• Hard-facing of mining machinery
• Hard-facing of milling tools Cos phi: 0.99
Protection class: IP 23 S
Article numbers:
Open Circuit Voltage - main inverter: 80V DC
ESC Designation
Open Circuit Voltage - pilot inverter: 100V DC
758614 EuTronic GAP 2501 DC
Max. welding current (100% duty-cycle): 160 A
260056 Trolley incl. footprint for gas bottles and hol-
ders for several accessories Max. welding current (60% duty-cycle): 200 A
260058 Cooling GAP Max. welding current (35% duty-cycle): 250 A
754273 Cooling GAP Chiller Max. pilot current (100% duty-cycle): 30 A
260229 Powder Feeder EP 2 Adjustment range for plasma welding: 2 ÷ 250 A
260231 Remote control (hand operated) RC-H Adjustment range of the pilot current: 0.5 ÷ 50 A
260232 Remote control (foot operated) RC-F Dimensions (L x W x H): 815 x 445 x 635 mm
758633 X30 Automation Interface extended Weight: 70 kg
1014
www.eutectic.com
PTA Welding
EuTronic GAP® - PTA Equipment
GAP® Unicoating V2.0
Advantages
Provides repeatable precision for plasma joining, coating and braz-
ing
Turn-key robotic cell to increase productivity
Complete modular for immediate, tailor made configuration and
cost effective adaption to application
Why GAP UniCoating V2.0?
Castolin Eutectic´s GAP UniCoating V2.0 integrates all components
necessary for the overlay welding of round parts.
Well suited to the Glass Mould industry for baffle and bottom plates.
Also very efficient at welding various forge dies and moulds as well as
engine valves
With the 200kg table the machine is capable of handling the smallest
parts as well as moderately lage ones.
The GAP UniCoating V2.0 incorporates a complete Plasma power source.

This unit uses the latest technology in plasma welding. With fully programmable gas controls, pilot arc settings,
powder delivery and welding current the GAP UniCoating can deliver a completely repeatable, precisely engi-
neered weld overlay.
The power source is fully integrated with the oscillation and arc length controller to work with the tilting turn
table for simple, fast setup of welding parameters.
All parameters are programmed using the dedicated control. There is no programming code to learn, all param-
eters are set in common welding terms for the optimum in operator friendly set-up and operation.
GAP UniCoating V2.0 ESC: 757008

Mains voltage: 3x 400V+N
Mains frequency: 50/60 Hz
Mains fuse: max. 35 A
Max. power consumption: 20 kVA
RMS value of the largest main current: 25 A
Cos phi: 0.99
Protection class: IP 23
Open Circuit Voltage - main inverter: 85V DC
Max. pilot current (100% duty-cycle): 30 A
Adjustment range for plasma welding: 6 ÷ 250 A
Adjustment range of the pilot current: 3 ÷ 60 A
Turn table Ø: Ø 400 mm
Turn table - Load: max. 200 kg
Dimensions L x W x H (mm): 2270 x 1000 x 2200
Weight: ca. 650 kg
1014
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PTA
EuTronic® GAP - Accessories
Cold Wire Feeder WF

For GAP® 2501 series / 3001 and 3002
Degree of protection IP23
Weight 25 Kg
Dimensions L x W x H (mm) 725 x 230 x 450
Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feeder
for 16 Kg wire coils.
Product N° Special designed pressure arms care for a smooth and reproducible pressure
260395 Cold Wire Feeder WF of the wire onto the feeder rolls within the drive.
Powder Feeder EP2

Carrier gas Ar, Ar-H2
Carrier gas flow rate 0 - 4 l/min
Powder reservoir 2 l capacity
Degree of protection IP 23
Weight (without powder) 7.5 kg
Dimensions L x W x H (mm) 200 x 170 x 470 mm
Stepless feeding rate control via feeding wheel speed directly from GAP unit.
Powder feed rate 1,5 - 95 g/min, depending on feeding wheel configuration,
torch, anode and powder density.
Two EP2 units can be driven in parallel (optional second motor control card)
for applications that require feeding of different powders into the weld pool:
i.e. matrix and carbides.
Product N°
260229 Powder Feeder EP2
Cooling GAP® *
Weight 40 kg
(*) Use only Castolin Eutectic dedicated cooling liquid
Cooling with air/water heat exchanger.

additional water-water heat exchanger available.
Product N°
260058 Cooling GAP® (*)
754315 Xuper Cool, 5l tank
Cooling GAP® Chiller

Weight 50 kg
(*) Use only Castolin Eutectic dedicated cooling liquid
Cooling with integrated chiller.
Product N°
754273 Cooling GAP® chiller
754315 Xuper Cool, 5l tank
1014
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PTA Welding
EuTronic® GAP - Accessories
GAP® E12N
Construction horizontal
Max current at 100% 100A
Weight with hose pack 1.9 kg (4m)
Product N°
400900 GAP® E12N 4m Liquid cooled manual torch, available also with 70° and 180° neck
Hose pack: 4 metres; longer hose packs on request Cold wire holder available
GAP® E15N
Weight with hose pack ca. 2.5 kg (4m)
Liquid cooled manual torch, available also with 70° and 180° neck
Product N° Hose pack: 4 metres; longer hose packs on request
260581 GAP® E15N Cold wire holder available
GAP® E20N
Powder flow rate N.A
Product N°
Liquid cooled manual torch, available also with 70° and 180° neck
752873 (4m)
GAP® E150P
Powder flow rate 5-20 g/min
Product N°
260434 GAP® E150P 3m
260435 GAP® E150P 4m 3m hose pack Liquid cooled Powder manual torch
GAP® E54 S-M-D-DL

Powder flow rate 10 - 40 g/min
Product N° Powder machine torch for inner coatings of parts with diameter > 80mm
400861 GAP® E54 (length: 330 mm) 4m
Available in four different lengths (models): 330(S), 550(M), 920(D) and 1770(DL)mm
402272 GAP® E54 (length: 550 mm) 4m
Longer hose packs on request Built on request, please ask for delivery time
GAP® E52
Construction vertical
Powder flow rate 3 - 80 g/min
Liquid cooled powder machine torch for general applications
Cold wire holder available
Product N° Hose pack: 4 metres; longer hose packs on request
400204 GAP® E52 4m Wide range of anodes and powder nozzles
GAP® E200P
Construction vertical
Powder flow rate** up to 80 g/min
Liquid cooled powder machine torch for general applications
Hose pack: 4 meters; longer hose packs on request
Wide range of anodes and powders nozzles
Product N°
755952 GAP® E52 (4m)
1014
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EuTronic® Arc
Wire Spraying
Simplified overview
Max
piece size porosity
mm
Good. Electricity &
EuTronic Wire. All Low 1 to 2 Very large Lamelar 1 to 10% Mechanical High Medium compressed Medium
Arc Metals metals & micro- air
diffusion
Best Second choice
(...)* request special precaution or coating material
1014
Wire Spraying
EuTronic® Arc Process
Function
EuTronic® Arc is the highest productivity thermal spraying process. EuTronic® Arc is an Arc Spray Process using a
pair of wires which are melted by an electric arc.
The arc has a temperature of 5,000 - 6,000°C that melts the wires continuously. Compressed gas - most often air - is
used to atomise the molten wire tips and to propel the droplets towards the substrate at velocities exceeding 100
meters per second. This molten material is atomised by compressed gas and propelled towards the workpiece to
form a coating. This combination of high temperature and high particle velocities gives arc sprayed coatings very
good coating properties with high bond strengths and low porosity.
Arc spraying often produces large amounts of fume and high noise levels.
Arc spraying is a cold thermal spraying process where the temperature of the substrate is held below 150°C. Be-
cause of the low temperature, the work piece is not exposed to any metallurgical changes or distortion.
Arc Spraying Structure of cold arc sprayed coating
Advantages Applications Technical data

The arc spraying process is the ther- The main applications of the arc Arc temperature: up to 6000 °C
mal spraying process that has the spray process are anti-corrosion Particle velocity: 150 - 300 m/s
highest spray rates and lowest run- coatings of zinc and aluminium
Deposition rate: 2.5 to 40 kg/h
ning costs. and spraying work on large compo-
nents. The material to be sprayed Coating material: Metals or
Safe process must be electrically conductive. The metal alloys in solid and cored
most common materials are me- wires form
No flammable gases used tallic material or cored wires. Low Coating thickness: 0.1 to 20 mm
Cold spray process running costs, high spray rates and Coating density: 90 - 97%
efficiency make it a good tool for
Noise level: 100 - 120 dB(A)
Does not require the use of spraying extensive areas or a large
oxygen, kerosene or a number of parts.
combustible gas which means
more economic coatings
Operator can use two different

wires during spraying to
produce new suitable coatings.
Schematic of Arc Spray process

1014
www.castolin.com
Wire Spraying Wire
Spraying
EuTronic® Arc Spray Wires

Type
EuTronic® Arc 502 Alloy Cement cooler plates, boiler water Hardness ~860 HV0.3
Product N° Fe-Cr-Ti-Si-Mn wall protection, pulp production Self bonding alloy with enhanced
205375 Arc 502 1.6mm 15kg digesters, steam turbine casings, surface wear resistance properties
cracking installations, high tempe- to combat erosion, thermal shock up
rature cyclone, fume extractors etc. to 650°C.
EuTronic® Arc 509 Alloy Corrosion and erosion resistant Hardness ~260 HV0.3
205373 Arc 509 1.6mm 15kg Fe-Cr-Al-Mo protective coatings in boiler equip- Self bonding alloy with enhanced
ment up to 900°C. surface wear resistance properties
to combat corrosion, erosion up to
900°C and oxidation.
EuTronic® Arc 532 Alloy Alternative to 13%Cr-steel. Hard Hardness ~640 HV0.3
103129 Arc 532 1.6mm 15kg Fe-Cr-Mn-C chrome replacement on hydraulic Self bonding alloy with enhanced
pistons. Wear resistant layers for surface wear resistance properties
rollers in paper machines, bearing- to combat metal-to-metal friction,
and sealing seats. corrosion and oxidation.
EuTronic® Arc 579 Alloy Worn general engineering compo- Hardness ~230 HV0.3
331426 Arc 579 1.6mm 15kg Fe-Ni-Cr-Si-Mn nents, undersize external or internal Self bonding alloy for thick or thin
diameters, bearing seats and faces, coatings with good corrosion resis-
housings, shrink or force fit areas, tance. Easy machinabillity, like
flat surfaces etc. Hot gas corrosion machining solid mild steel.
protective coatings in heat exchan-
gers, process piping, etc.
EuTronic® Arc 595 Alloy Exhaust fans, pump components, Hardness ~965 HV0.3
206118 Arc 595 1.6mm 15kg Fe-Cr-B-Si- coal-fired boilers, super-heaters, Self bonding alloy with enhanced
Mn-C economiser waterwalls, boiler surface wear resistance properties
tubes, boiler installations, lamella to slurry erosion, corrosion and low
seals and «Füller» cooler plates in stress abrasion. Withstands service
cement works etc. environment up to 925°C.
1014
www.eutectic.com
Wire Spraying
EuTronic® Arc Spray Equipment
EuTronic® Arc Spray 4 system
The EuTronic® Arc Spray 4 is motor in the gun. Instead, the Gun Sealed 350 amp power source
robust, reliable and easy to use. 4 uses a patented ‘Synchrodrive’ for reliability
The Arc Gun and the drive sys- system, where a single, sealed mo- 1.6 mm wires standard. From
tem are coupled to a 350 amp, tor with a flexible drive arrange- 1.6 mm to 2.5 mm optional
switched voltage power source. ment, powers a reliable, positive
Air cooled cables for low weight
drive push / pull up to a distance of
This power source features sealed Excellent gun manoeuvrability
20 m.
electronics for excellent reliabil-
5 m / 10 m supplies packages
ity in the harshest spray environ- This results in a long reach and
standard
ments. lightweight flexibility of the gun
Steel reinforced, PTFE lined wire
and supplies.
The wire feeder unit is neatly conduits
mounted on the power source, For the operator, working condi-
Easy to maintain for lower
leaving it free to swivel and follow tions are more comfortable and
downtime costs
the operator whilst spraying. productive.
Wire spool, coil and drum feeder
Other options include either floor option capabilities
or trolley mounting. There is no
Soft start for smooth start ups
EuTronic® Arc Spray Supplies Setup
WIRE FEEDER ELECTRIC DRIVE UNIT ARC SPRAY GUN Standard Configuration
(Push / Pull)
• Power source, push / pull
drive & wire feeder.
• Arc Spray Gun.
• Drive unit position :
On power source or floor.
• 5 m / 10 m Push / Pull from
POWER SOURCE
Wire.
• Supplies package includes
power and control cables,
air hose, wire conduits and
flexible drive.
CONDUITS
FLEXIBLE DRIVE CABLE
SUPPLIES PACKAGE
Product N°
263000 complete kit 5m
758558 complete kit 10 m
1014
www.castolin.com
Wire Spraying Wire
Spraying
EuTronic® Arc Spray Equipment

EuTronic® Arc Spray Gun 4
The Gun has been designed to give consistent throughputs with high
coating quality. It is a lightweight, heavy-duty unit with robust but com-
pact construction.
Optional conversions of wire size

The Gun can also be converted to use other wire diameters by using the
following parts in the front end assembly :
Wire Size Nozzle X 1 Air Cap 1 Contact Tubes X 2

1.6 mm 263245 263063 263252
Product N°
263266 Gun 4 complete for 1.6 mm wires 2.0 mm 263244 263242 263133
2.3 mm 263071 263241 263134
2.5 mm 263072 263241 263144
Power Source
Power & air requirements
Power Requirements 380 / 440 V 50-60 Hz 3 Phase
Power Option 220 V 50-60 Hz 3 Phase
Fuses Required 32 A / Phase (415 V input)
Fuses Required Option 40 A/Phase (220 V input)
Max Power Consumption 18 KVA
Duty cycle (100%) 0-350 Amps
Output Voltage 0-50 Vdc (nominal) Switched High/Low & 1 - 5
Air Requirements 1.56 m3 / min @ 6 bar (55 cfm @ 90 psi)
Power source specification

Product N° Weight 215 Kg
263227 Power source 4 for Inverter Drive
Width 665 mm
Length 900 mm
Height 913 mm
Wire Feeder and Drive
Wire Drive Unit The wire feeder unit can be neatly mounted on the power source, leaving
it free to swivel and follow the operator whilst spraying.
Spool Feeder
Product N°
263223 Wire Feeder for Spools with drive
1014
www.eutectic.com
Wire Spraying
EuTronic® Arc Spray Accessories
Accessories for EuTronic Arc
 Power, Air and Supplies packages

Control Cables
 Flexible Drive Standard Supplies Package includes
   Cable The supplies packages consisting
 Wire Conduits of cables and conduits are available
in different lengths 5, 10 and 20 meters.
Product N°
263273 5 m supplies package
263275 Extension from 10 to 20 m supplies package
ArcJet
The ArcJet fits on the gun to inject air in front of the nozzle. The ArcJet constricts
the spray pattern thus reducing overspray and allowing more confined areas
such as deep slots, to be sprayed. Therefore significant improvements in deposit
efficiency can be made especially on small diameter components.
«ArcJet mounted on the Gun»
Technical overview
• Reduces Arc Spray footprint • Finer coatings.
• Improved deposit efficiency when • Less apparent porosity.
spraying onto small components. • Improved hardness.
Product N° Maximum Current 350 Amps

263270 Arcjet 4 for 1.6 mm wires Compressed Air 0.7 m3 / min @ 3.5 Bar
Arc Spray Extension neck

The Arc Spray extension neck enables an improved access to awkward areas such as
It is available in 3 different
deep bores with a minimum diameter of 75 mm and rear sides of welded stiffeners
lengths 500, 1000 and 1500 etc. The extension neck allows for spraying either straight ahead or at an angle and
mm. for applications using power up to 200 amps.
Product N° Description Characteristics

263269 Extension neck 0.5 m long
263267 Extension neck 1 m long
Maximum Current 200 Amps
263268 Extension neck 1.5 m long Compressed Air 0.6 m3 / min @ 4.5 Bar
Remote Control
The 5 meters remote control allows a remote operation of the EuTronic Arc® Spray
4 system with robust design for use on semi-automatic installations. The remote
control buttons and switch mimic those of the Gun.
Product N°
263326 EAS remote control
1014
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Integrated Systems
Integrated Systems / Putting a reliable, performing Package together for OEMs
and Workshops
Castolin Eutectic has been at the forefront of the coatings industry for more than 30 years. Industry demand for
better coating consistency, enhanced safety and lower costs continues to drive the trend towards system integra-
tion.
There is an increasing requirement to utilize computer technology to improve consistency and system perfor-
mance. There is also a need to mitigate risks associated with direct operator contact which further supports this
trend toward automated turnkey systems.
Castolin Eutectic Turnkey Systems

Castolin Eutectic has designed, manufactured and commissioned many Turnkey Integrated Systems on a global
basis. We have serviced several industries and applications with tailored made system solutions that are fully en-
gineered, cost efficient, flexible and have state of the art safe operating features. Typical designs include control
equipment, sound-proof cabins, robots, turn tables, extraction, etc.
These components are fully integrated for operation in automatic mode. As well as providing full monitoring with
operational status and alarms, the systems also allow manual intervention for further development and optimisa-
tion of parameters.
Safety and Quality

Castolin Eutectic is committed to the highest safety and quality standards
for the design, manufacture and installation of our turnkey systems.
The software design ensures a user-friendly interface that can be easily
upgraded. Following installation we provide engineering support, risk
assessments and training on a global basis.
PTA system
PTA system Laser Cladding System
HVOF fully integrated system

1014
www.eutectic.com
Services
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1014
www.castolin.com
CastoLab® Services
CastoLab® Services
We believe in making our exten-
sive know-how fully available
to our customers, but for situa-
tions where technology transfer
is complex or requires a rapid
turn-around, we have our own
maintenance service workshops.
These fully resourced skill centers
develop advanced procedures for
transfer to end users.
CastoLab Austria
Castolin Eutectic workshops
are located in several countries
around the world, and are best
contacted via our website. In
countries without CastoLabs,
Castolin Eutectic collaborates
with approved workshops who
are in close contact with Castolin
Eutectic’s specialists and techno- Arc Wire Spraying CastoLab Team
logies.
These are some coating

applications examples from the
wide range of services provided
by our CastoLab® Services.
Remachining Weld overlay for Roller Press
Training
At Castolin Eutectic, we offer For more information about Contact information can be
a wide range of welding, braz- training, please contact your lo- found in our website.
ing, and thermal spray training cal Castolin Eutectic company.
courses. These courses can be
designed according to the needs
of each customer. There are
training sessions for managers,
engineers and technicians.
Each course is composed of both

theoretical as well as practical
training. Castolin Eutectic can
offer these courses in almost
every European country. The
courses are carried out in our
own in-house training facilities,
with qualified instructors or
with our trainers at your loca-
tion. Thermal spray training course
1014
www.eutectic.com
Information
Technical data & Table
Hardness Conversion Table in accordance with DIN 50150 (Extract)
Tensile Hardness in accordance with Tensile Hardness in accordance with Tensile Hardness in accordance with
strength Vickers Brinell Rockwell strength Vickers Brinell Rockwell strength Vickers Brinell Rockwell
[MPa] [HV] [HB] [HRC] [MPa] [HV] [HB] [HRC] [MPa] [HV] [HB] [HRC]
320 100 95 800 250 238 22.2 1630 500 (476) 49.8
335 105 100 820 255 242 23.1 1665 510 (485) 50.5
350 110 105 835 260 247 24.0 1700 520 (494) 51.1
370 115 109 850 265 252 24.8 1740 530 (504) 51.7
385 120 115 865 270 257 25.6 1775 540 (513) 52.3
400 125 119 880 275 261 26.4 1810 550 (523) 53.0
415 130 124 900 280 266 27.1 1845 560 (532) 53.6
430 135 128 915 285 271 27.8 1880 570 (542) 54.1
450 140 133 930 290 276 28.5 1920 580 (551) 54.7
465 145 138 950 295 280 29.2 1955 590 (561) 55.2
480 150 143 965 300 285 29.8 1995 600 (570) 55.7
495 155 147 995 310 295 31.0 2030 610 (580) 56.3
510 160 152 1030 320 304 32.2 2070 620 (589) 56.8
530 165 156 1060 330 314 33.3 2105 630 (599) 57.3
545 170 162 1095 340 323 33.4 2145 640 (608) 57.8
560 175 166 1125 350 333 35.5 2180 650 (618) 57.8
575 180 171 1155 360 342 36.6 660 58.3
595 185 176 1190 370 352 37.7 670 58.8
610 190 181 1220 380 361 38.8 680 59.2
625 195 185 1255 390 371 39.8 690 59.7
640 200 190 1290 400 380 40.8 700 60.1
660 205 195 1320 410 390 41.8 720 61.0
675 210 199 1350 420 399 42.7 740 61.8
690 215 204 1385 430 409 43.6 760 62.5
705 220 209 1420 440 418 44.5 780 63.3
720 225 214 1455 450 428 45.3 800 64.0
740 230 219 1485 460 437 46.1 820 64.7
755 235 223 1520 470 447 47.7 840 65.3
770 240 228 20.3 1550 480 (456) 48.4
785 245 233 21.3 1595 490 (466) 49.1
Particle size conversion table

Microns Inches Mesh per inch Microns Inches Mesh per inch Microns Inches Mesh per inch
US* Tyler BS* US* Tyler BS* US* Tyler BS*
1 12500 (theoritical) 76 0.003 200 200 200 315 0.0124
2 6250 (theoritical) 80 0.0032 350 0.0139 45 42 44
5 2500 (theoritical) 90 0.0035 170 170 170 400 0.0158
10 1250 (theoritical) 106 0.0041 140 150 150 417 0.0164 35
15 800 (theoritical) 125 0.0049 120 115 120 420 0.0165 40 35 36
20 625 (theoritical) 149 0.0059 100 100 100 495 0.0195 32
25 500 (theoritical) 152 0.006 100 500 0.0197 35 32 30
33 0.0013 (425) 160 0.0063 600 0.0234 30 28 25
38 0.0015 400 177 0.0069 80 80 85 630 0.0248
41 0.0016 180 0.007 80 85 699 0.0275 22
45 0.0017 325 (325) 200 0.0079 701 0.0276 24
50 0.002 208 0.0082 65 710 0.0278 25 24 22
53 0.0021 270 (270) (300) 210 0.0083 70 65 72 800 0.0315
56 0.0022 246 0.0097 60 60 60 833 0.0328 20
63 0.0025 230 (250) 250 0.0098 60 60 60 850 0.0331 20 20 18
66 0.0026 240 251 0.0099 60 853 0.0336 18
71 0.0028 259 0.0116 48 52 991 0.039 18
75 0.0029 200 200 200 300 0.0117 50 48 52 1000 0.0394 18 16 16
* standard
1014
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Information
Periodic Table of the Elements
Periodic Table of the Elements
1014
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Information
Contact
Global with local support
Castolin Eutectic has a presence in Our 350 sales engineers are sup- For more information or addresses of
almost all European countries. ported by over 50 process and ap- Castolin Eutectic companies, please
plication experts. These experts are visit our websites www.castolin.com
With over 350 sales engineers trav-
multi-lingual and communicate or www.eutectic.com
elling around Europe everyday,
daily with our 4 production centers
we are able to provide unbeatable
and research laboratories.
service to our customers. We can
literally be at 90% of customers in
Europe within 2 hours; this allows
us to give unsurpassed service and
support.
We supply all technical documenta-
tion and material safety data sheets
in local languages. Our salesmen all
live locally and speak the language
of our customers, understand the
local cultures. We manage ware-
houses and keep stocks adapted to
local requirements in every Euro-
pean country.
Contact
For more information or contact

addresses, please visit our website
www.castolin.com/contact
1014
www.castolin.com
Information
Index
Total Coating Solutions RotoTec 19850 p. 25 EuTroLoy PTA Welding
Overview of the wear phenomena p. 4 RotoTec 19868 p. 25 EuTroLoy Process p. 44
R&D Technical support p. 4 RotoTec 19940 p. 25
RotoTec 19985 p. 25 EuTroLoy Powders
Wear testing labs p. 5
Integrated production p. 5 RotoTec 19999 p. 25 EuTroLoy 16006.04 p. 45
Stringent quality controls p. 5 RotoTec LT 29230 p. 25 EuTroLoy 16008.04 p. 45
Coating Overview p. 6 RotoTec LT 29240 p. 25 EuTroLoy 16012.04 p. 45
Quality Assurance p.7-8 ProXon 21021 p. 26 EuTroLoy 16221.04 p. 45
Powder production p. 9 ProXon 21023 p. 26 EuTroLoy 16223.04 p. 45
Spray Wire Production p. 10 Proxon 21031 p. 26 EuTroLoy 16316.04 p. 45
Equipment Production p. 11 ProXon 21071 p. 26 EuTroLoy 16454.04 p. 45
Our offer p. 12 MetaCeram 28010 p. 26 EuTroLoy 16496.04 p. 46
MetaCeram 28020 p. 26 EuTroLoy 16604 p. 46
Eutalloy Spray and Fuse EuTroLoy 16606A.04 p. 46
MetaCeram 28030 p. 26
Eutalloy Process p. 14 MetaCeram 28095 p. 26 EuTroLoy 16625M.04 p. 46
EuTroLoy 16800 p. 46
Eutalloy® Powders Eutalloy® RW EuTroLoy PG 6503 p. 46
Eutalloy 10009 p. 15 Hot Spray Process - 2 step p. 27 EuTroLoy PG 8426.04 p. 46
Eutalloy 10011 p. 15
Eutalloy 10112 p. 15 Eutalloy® RW Powders EuTronic GAP® PTA Equipment
Eutalloy 10185 p. 15 Eutalloy RW 12112 p. 28 EuTronic GAP 2501 DC with touch screen p. 47
Eutalloy 10224 p. 15 Eutalloy RW 12494 p. 28 GAP® Unicoating V2.0 p. 48
Eutalloy 10611 p. 15 Eutalloy RW 12495 p. 28 EuTronic GAP® Accessories
Eutalloy 10680 p. 15 Eutalloy RW 12496 p. 28
Eutalloy 15999 p. 15 Eutalloy RW 12497 p. 28 Cold Wire Feeder p. 49
Eutalloy LT PE 8418 p. 16 Powder Feeder EP2 p. 49
Eutalloy RW 12999 p. 28
Eutalloy LT PE 8422 p. 16 Cooling GAP p. 49
Eutalloy LT PE 8426 p. 16 Cooling GAP chiller p. 49
Eutalloy LT PE 8431 p. 16 GAP E12N p. 50
Eutalloy LT PE 8435 p. 16 Flame Thermal Spray Equipment GAP E15N p. 50
Eutalloy LT PE 8440 p. 16 CastoDyn DS 8000 p. 29 GAP E20N p. 50
RotoTec 800 p. 30 GAP E150P p. 50
Eutalloy® Equipment GAP E54 S-M-D-DL p. 50
SuperJet-S - Eutalloy® p. 17 CastoDyn DS 8000® Accessories GAP E52 p. 50
SuperJet-S - Eutalloy® kit p. 17 Extension Neck p. 29 GAP E200P p. 50
KoolTip p. 17 CastoFuse p. 29 EuTronic Arc Spray
Eutalloy® Accessories CastoFuse Accessories EuTronic Process p. 52
C6 Air Cooled Tip p. 18 Konstantherm p. 30 EuTronic Arc Spray Wires
Nozzles p. 18 Line Heating Torch p. 30
Heavy duty Nozzles p. 18 EuTronic Arc 502 p. 53
Ring Torches p. 30
Compact heavy duty tip p. 18 EuTronic Arc 509 p. 53
Compact heavy duty tube p. 18 HVOF Thermal Spray EuTronic Arc 532 p. 53
EuTronic Arc 579 p. 53
Eutalloy SF HVOF Process p. 32-33
EuTronic Arc 595 p. 53
HVOF Applications p. 34
Eutalloy SF Process p. 19
EuTronic Arc Spray Equipment
HVOF Powders
Eutalloy® SF Powders EuTronic Arc Spray 4 system p. 54
55586C p. 35
Eutalloy SF 15211 p. 20 EuTronic Arc Spray Gun 4 p. 55
55588C p. 35
Eutalloy SF PE 8213 p. 20 Power Source p. 55
55583C p. 35
Eutalloy SF PE 8215 p. 20 Wire Feeder and Drive p. 55
55580C p. 35
Eutalloy SF PE 8217 p. 20 55396 C p. 35 EuTronic Arc Accessories
Eutalloy® SF Equipment HVOF Thermal Spray equipment Supplies packages p. 56
CastoDyn SF Lance p. 21-22 ArcJet p. 56
CastoJet CJK5 p. 36 Arc Spray Extension neck p. 56
CastoDyn Extra Flat SF Lance p. 22
CJK5 Accessories Remote Control p. 56
RotoTec®, ProXon® & MetaCeram®
Toolkit p. 36
Cold Spray Process p. 24 Integrated Systems p. 57
CJK5 Gun p. 36
Industry partners p. 58
RotoTec & ProXon® powders Terolink p. 58
Laser Cladding
RotoTec 51000 p. 25 CastoLab Services p. 59
Laser Process and advantages p. 38-40
RotoTec 19300 p. 25 Training p. 59
RotoTec 19310 p. 25 Laser Powders p. 41 Hardness Conversion p. 60
RotoTec 19400 p. 25 Particle Size Conversion p. 60
Powders p. 41
RotoTec 19404 p. 25 Periodic table p. 61
RotoTec 19800 p. 25 Laser Offer, Service, Systems p. 42 Contact Adresses p. 62
CE200114EC
Other coating consumables and equipment

This brochure contains only a selection of Castolin Eutectic coating products. Other materials or services are available. Please ask your local Castolin Eutectic company.
1014
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Castolin Eutectic

Global Coating Technology

1906 Foundation of Castolin Eutectic in Lausanne, Switzerland

Automated PTA Laser Cladding HVOF

Powder Cold or Hot Flame Spraying

HVOF Liquid fuel

Overview of the wear phenomena

Abrasion Erosion Impact Friction Heat & Corrosion Cavitation

R&D / Technical Support

Wear Testing labs

Integrated Production performance

Stringent Quality Controls

Simplified thermal spray

Heat Source Acceleration Impact

(...)* request special precaution or coating material Best Second choice

The quality control of sprayed parts

Wear test methods

Unique wire production unit

Quality wire awaiting baking Unique wire characteristics

In keeping with the Swiss tradition

Testing of each torch Assembly

Accessories, kits and spare parts Modelling

Integrated Laser system Castolab Services

Equipment Powders System integration CastoLab Services

Best Second choice

(...)* request special precaution or coating powder

Designations Product Applications Properties

Designations Product Applications Properties

SuperJet-S- Eutalloy® Kit

C6 water-cooled tip assembly kit contents:

C6 Air cooled Tip

Heavy duty Nozzles

Compact heavy duty tip

Compact heavy duty tube

Designations Product Applications Properties

Eutalloy® SF Equipment & Accessories

Technical data Advantages

Schematic showing the assembly of SF Lance on CastoDyn DS 8000

CastoDyn® Extra-Flat SF Lance

The CastoDyn Extra-Flat SF Lance is the solution where access is a problem.

Best Secondary choice

(...)* request special precaution or spray powder

These «cold» thermal spray powders are applied with

injector effect or a carrier gas (nitrogen, argon or air)

RotoTec® – Alloy powders for "cold" two step spray process

Eutalloy® RW Process - Two Step Spray & Fuse

First step: Cold spraying with CastoDyn® DS 8000

Designations Product Applications Properties

Flame Equipment & Accessories

Accessories for CastoDyn® DS 8000

Available on request, please ask your local Castolin Eutectic company.

Line Heating Torch

Available on request, please ask your local Castolin Eutectic company.

Available on request, please ask your local Castolin Eutectic company.

HVOF LIQUID FUEL

Best Secondary application

CJK5 HVOF Function

HVOF Schematic Diagram

Castojet HVOF Typical Material Hardness Maximum Environment Typical