TeroMatec® - Castolin Eutectic

TeroMatec ®Self shielding, welding cored wire technology for wear protection,rebuilding & repairEnduring Performance…Stronger, withCastolin EutecticSelf shielding peripheric arc system ensures :Fastest weld deposition ratesHigher welding duty cyclesOn site capability without shielding gas suppliesOptimised alloy weld properties for longer service lifeMaximum cost savings & productivity

TeroMatec®TeroMatec® CORED WELDING WIRESTeroMatec® is a self shielded arc welding process (Open Arc/FCAW) using specially formulated flux coredwire electrodes. The self shielded peripheric arc conception includes a wide range of custom made alloysoptimised for industrial wearfacing, rebuilding and repair solutions with many advantages :No shielding gas requirementsFastest weld deposition ratesHigher welding duty cyclesEfficient weld metal recoveryStock reduction opportunitiesEase of use by semi skilled operatorsMaximum savings & productivitySolidified slagMolten slagWire guide / contact tubeCored wireParticles-elements/compoundsGas shieldcreated by compoundsArc and Metal transferNO SHIELDING GAS REQUIREMENTSSolidified weld metalWeld poolSelf shielding peripheric arcThe TeroMatec® process requires no costly investments or complicated manipulation ofheavy gas cylinders, regulators, flowmeters, mixers, hoses etc. TeroMatec®’s autonomousself shielding peripheric arc is designed for outdoor use where on-site wind or draughtconditions would simply blow away any external protective gas (GMAW) causing porous,defective welds.FASTEST WELD DEPOSITION RATESHIGHER WELDING DUTY CYCLESThe deposition rate of TeroMatec® flux cored electrodesis remarkable reaching 4 kg/h with the Ø1.6mm and almost 10 kg/h with the Ø2.8 mm due toperipheric arc current density effects. Furthermore,by increasing the electrode “stick out” (distancebetween the contact tube tip and the workpiece)from 50mm to 75mm, the deposition rate can beboosted over 12 kg/h due to electrical resistanceheating effects whilst reducing heat input and dilutionwith the base metal.The welding duty cycle (X) is simply the % relationshipbetween the effective arc welding time(t1) and the total time involved (t1 + t2) where t2 isthe non productive time between the arc weldingcycles. Thus TeroMatec® duty cycles easily reachover 90% in automatic mode compared with MMAstick electrodes which peak around 40%. The higherduty cycle for TeroMatec® is due to :no need to keep stopping & changing electrodesrepetitive striking & restriking eliminatedless post weld slag cleaning requiredfewer stop-start weld crater defects to grindDeposition rate (kg/h)400%extra300%extraArc Ont1X = x 100 %t1 + t2Arc OffTimeHigh efficiency manual electrodeCurrent (A)TeroMatec® X≈ 80-90%Manual electrode X≈ 40%2Stronger with Castolin Eutecticwww.castolin.com

EFFICIENT WELD METAL RECOVERY ( %)The weld metal recovery (sometimes called yield orefficiency) is simply the ratio of the mass of weld depositedto the total mass of the original welding electrode.Thus TeroMatec® cored wires have an excellentweld metal recovery ratio reaching 90% to 95%whilst MMA stick electrodes only reach around 65%due to higher slag volumes and repetitive stub endlosses.In other words, TeroMatec® ensures that virtually allthe weight of purchased cored wire ends up as a usefulweld deposit thus reducing consumable costs.= 1000g= 1000g650 g950 gMMA- 65%TeroMatec- 95%STOCK REDUCTION OPPORTUNITIESAs a 15kg TeroMatec® spool represents around 22kg of MMA stick electrodes for the same quantity of requiredweld deposit, this represents a potential to cut welding consumable stocks by over 30% !Additionally, when a single spool Ø 1.2 or 1.6 mm TeroMatec® is considered, its all round application weldingcapabilities can eliminate the need to stock separate packs of stick electrodes in 2.4mm, 3.2mm, 4.0mm &5.0mm sizes thus further reducing inventory costs.EASE OF USE BY SEMI SKILLED OPERATORSRelatively little training is required for the TeroMatec® process (compared with MMA) which makes it easy tolearn by semi-skilled operators due to the self regulating nature of the arc, variable stick out capability, bettervisibility and absence of external shielding gases. Furthermore, powerful flux deoxidisers in the TeroMatec®cored wire enable direct welding on rusty or oxidised steel surfaces without the meticulous precleaningneeded for the GMAW process, especially when access is limited.MAXIMUM SAVINGS &PRODUCTIVITYNumerous studies by industry show thatlabour costs are the biggest single expense inwelding. As skilled labour rates continue to riseinexorably, cut and control your welding costswith TeroMatec®.TeroMatec® systems significantly increase cost savings and productivity over both Mig / Mag& MMA processes due to the ease of use by semi skilled operators, the incomparable welddeposition rates giving superior performance and service life.Stronger with Castolin Eutecticwww.castolin.com3

TeroMatec®TeroMatec® MANUFACTURING FACILITIESThe TeroMatec® range of high performance coredelectrodes are formulated, developed and manufacturedin Castolin Eutectic’s own modern plants usingspecially designed production equipment and proceduresin accordance with ISO 9001 and EN 29001quality assurance standards.Each TeroMatec® batch after wire drawing and baking,is weld tested for consistent chemistry, properties& operability before precision spiral spoolingand protective packaging for stock.metal strippre-forming rollfluxfinishing rollscore wireø 1,2 mmø 1,6 mmø 2,4 mmø 2,8 mmSelf shielding flux ingredients,arc ionising stabilisers, finegrain inoculants, powerful deoxidisers,metallurgical refiningagents, selected alloying elements,carbide compounds, etc.Steel stripSELF SHIELDED PERIPHERIC ARCUNIQUE ANTI-WEAR ALLOYSSolid Mag wires can only be manufactured in metallurgicalalloys which can be cast and easily drawndown to final diameters. The TeroMatec® cored electrodeconcept completely overcomes such limitationsand unique metallurgical alloys have been formulatedwith high density, ultra-hard micro constituantsin Fe matrices. Thus the wide TeroMatec® alloy rangeprovides cost effective solutions for most wear problemsfound in industry.Thanks to TeroMatec®’s self shielding and high current density characteristics,it can be welded at lower welding currents than a solid wire whilstkeeping a stable metal transfer across the arc due to ionising elementsin the core. Additionally, the lower heat input and presence of powerfuldeoxidising fluxes means that TeroMatec® weld deposits have better bonding,lower dilution, superior microstructure properties and minimal heataffected zones for maximum service performance.4Stronger with Castolin Eutecticwww.castolin.com

AbrasionErosionImpactFrictionHeatCorrosionCavitationRebuildingBase MetalTeroMatec® flux cored wiresTechnical Data690 Fe2010 Fe4226 FeEO 8340FeFor Joining, Buttering and RebuildingBucket blades, grabs, leveller blades, tooth-holders onmechanical shovelsFoundry defects in cast steel, shrinkage cavities orblowholes in semihard or cast steel.Repair of foundry defects in nodular or spheroidalgraphite grades of cast iron - porosity, blow holes orshrinkage cavities.For joining, fabrication & repair of mild and low alloysteels, galvanised steels, used for containers, vessels,hoppers, truck bodies, piping systems, machinerycast steel parts.Tensile strength : 600-670 N/mm²Elongation (l=d) : 45-55 %Hardness : 170-210 HVTensile strength : 560-640 N/mm²Hardness : 260-310 HVTensile strength ~475 N/mm2Hardness ~50 HRCAnnealed ~24 HRCTensile strength : 480 N/mm²Elongation (l=d) : 20%Yield stress= 400 N/mm2For anti-wear Coatings high resistant to Impact, metal/metal Friction, and slight Abrasion3205 Fe3206 Fe3220 Fe3302 FeES 4530FeRolling mill slide rods, shovel buckets, mobile cranewheels, rails.Crusher hammers, rolls, cranes, jaws, power shovel ordredge buckets, pump parts.Mechanical shovel teeth, crusher hammers and rolls,grab edges.For intermediate layers and multi-pass anti-wearcoatings, joining of large parts of dissimilar composition,rail points, crusher bars and jaws, drivesprockets.Railway retarder beams and wagon brakes, outsideparts in hydroelectric power stations, defects in chromiumcast steel. For submerged arc welding.Tensile strength : 710-790 N/mm²Elongation (l=d) : 20-30 %Hardness : 220-270 HVHardness after workhardening : 400HVHardness ~300 HVWork hardened ~45 HRCHardness : 230-280 HVTensile strength : 580-660 N/mm²Elongation (l=d) : 35-45 %Hardness : 180-220 HVTensile strength : 800-1000 N/mm²Hardness : 290-340 HVHardness after welding : 340-420 HVFor anti-wear Coatings resistant to moderate Abrasion combined with Impact and Pressure4327 Fe4415 Fe4625 FeCrusher hammers, bars, anvils, casings, mechanicalshovel bucket teeth & lips, dragline grab teeth,scraper blades.Ground augers, percussion grabs, dragline teeth andleading edges, gravel pumps, conveyor screws.Crusher bars and cylinders, feed screws, clay crushers,conveyor belts, waste disposal crusher hammers.Hardness ~59 HRCHardness : 52-57 HVHardness : 49-54 HV4923 FeCrusher hammers and bars, impact and casingscreens, bucket teeth and lips, scraper blades.Hardness : 54-59 HVFor anti-wear Coatings resistant to high Abrasion and ErosionNewProduct3952 Fe4395NFeSinter crushers and fans, hot sieves, screens and bells.Unique NanoAlloy for transport screws, furnacechutes, exhaust fans, cyclones, conveyor, mixers,scrapers, screws, screens.Hardness : 61-66 HVHardness ~70 HRC4601 FeConveyor screws, rolls, crusher pinions and grinders,dragline and pump parts.Hardness : 52-57 HV4630 FePress spindle segment heads, mixer segments, bladesand scraper, wear plates, induction fans, drag chains.Hardness : 65-70 HV4660 FeJaw crushers, mixer paddles, pump wheels, mouldscrews.Hardness : 59-64 HVMain applicationSecondary applicationStronger with Castolin Eutecticwww.castolin.com5

TeroMatec®THE COMPLETELY MOBILE TeroMatec® SYSTEMWire Feeder developed specially for heavy dutywear protection applications.Unit powered by the open arc voltage.Fitted contactor (up to 400A) for safe operation,live torch>400AFitted solenoid for gas shielding.Designed for wires from 1.2mm to 2.8mmwith a simple combination of rollers.High feeding force: 4 wheel drive knurled rollers.Fully protected feeding system.Self regulating wire speed. Accepts 15kg and 25kg spooltypes.Easy to maintain.Euro connection to accept any torch( water coolingoption).Front panel of the TeroMatec® Wire feeder 600TeroMatec® Wire Feeder 600 is designed for coatingand joining with open-arc wires in the field. Connecteddirectly to the arc voltage. No mains connection isneeded. It operates with any welding power source(with any DC power source)*. TeroMatec® Wire Feeder600 is easier to use than a manual electrode as aconstant arc length is assured by self regulation ofthe variable wire speed. Any arc length changes areautomatically compensated via the arc voltage drivingthe wire speed. This feature is unique to Tero-Matec®.* Suitable are CE marked welding power sources orthose with OCV

TeroMatec® applicationsFor your critical applicationsWear phenomena Industry PartsAbrasion + Pressure +ImpactCementRollers ofvertical rollermillAbrasion + erosionSugar caneTeeth of a sugarcane crusherAbrasionOpen castminingBucket teethImpact + abrasion Glass works HammerImpact + hot abrasionIron andsteel worksSinter CrushtoothFriction + abrasionPulp andpaperCounter-knifeStronger with Castolin Eutecticwww.castolin.com7

TeroMatec® applicationsFor your critical applicationsWear phenomena Industry PartsFriction + abrasion +impact + erosionCivilengineeringDrill sleevecutterAbrasionThermalpowerplantsCoal screwvanesImpact + abrasionQuarryLimestonehammerImpact + abrasionRefuserecyclingCrushing clawsFrictionForgingHydrauliccasingFriction + abrasion+ corrosionPulp andpaperScrew conveyor8Stronger with Castolin Eutecticwww.castolin.com

TeroMatec® applicationsApplicationCement IndustryA cement plant installed two new waste feeding lines into the kiln burner. Waste is pumped at 32 m/s speedthrough 60m and 90m long feeding lines. Previous OEM solutions consisted of standard mild steel straighttubes with internally basalt protected elbows which lasted only 3 weeks. When the installation was operating,the noise of multiple impacts could be heard due to scrap metal or stone particles in the waste feedstock. Thiscaused high wear rate failures of the basalt lining.Wear is usually localized at the elbow entryFirst line installation (passing through platform floor).Second line awaiting installation.SolutionAfter a successful month’s testing on one CastoTube®elbow coated on the inlet side with NanoAlloy® TM4395N and on the remaining section with a TM 4666coating, the customer decided to build the whole linewith CastoTube®. Critical parts of the line such as theelbow inlets had NanoAlloy® protection, while therest of the installation including the straight tubes,had the TM 4666 internal coating.Cost savingSample of a NanoTube, yellow sectionwearfaced with NanoAlloy® TM 4395Nand red one coated with standardCastoTube® alloy TM 4666BeforeWith Castolin Eutectic procedureDowntime cost perCost of Castolin99 600 € 62 300 €dayEutectic procedurePrevious service life 21 days Actual service life 300 daysElbows above the platform constructed from CastoTubes withNanoAlloy TM4395N coating have yellow inscriptions. StandardTM 4666 CastoTubes have red inscriptions.LPF *+1329 %* Life Prolonging FactorApplication part of the Polish TeroLink®databseStronger with Castolin Eutecticwww.castolin.com9

TeroMatec®Castolin EutecticTrainingCastolin Eutectic LocationsThe unique Terolink database ofCastolin Eutectic contains more than8,000 fully documented approvedapplications from around the globe.The case studies include photographs,technical data, detailed descriptionsand cost-saving analyses.To increase customer knowhowin wear technology andrepair techniques, wehave developed a full lineof seminars and trainingprograms, teaching allrelevant personnel fromwelders and engineers tosales teams and managingdirectors.ManufacturingR&D-Wear Test LaboratoryProduct Portfolio - Widest in the IndustryTogether with our sister company, the MesserGroup, we can offer our customers a very powerfulrange of products and services. Being «Part of theMesser World» means:Investment of over €420 millionMore than 6,000 motivated employeesOver 100 factories to meet customer needsTechnical sales support in over 120 countries2,000 technical sales people in the field with ourcustomers every dayMetallurgical LaboratoryMicrograph of Wear Phenomena10Stronger with Castolin Eutecticwww.castolin.com

History of Castolin Eutectic1906: Foundation of Castolin in Lausanne, Switzerland by Jean-PierreWasserman. His stroke of genius: to discover a way of weldingcast iron at low temperature; in the following years, this innovationwas further developed for all industrial metals includingaluminium alloys.1940: Foundation of Eutectic Welding Alloys Corporation in New York1952: Foundation of Castolin France1959: Foundation of Eutectic Japan Ltd1962: Foundation of Eutectic India Ltd.1960’s: International consolidation under Castolin Eutectic1970’s: Creation of training centers for Maintenance & Repair technologies1978: Establishment of World Head Quarters in St-Sulpice, Switzerland2000: Merger with Messer Cutting & Welding and creation of theMEC Group - Messer Eutectic Castolin2005: Part of the Messer World2006: 100 years of innovation, service and quality.Addresses of Castolin Eutectic Companies in EuropeAustria, Hungary, South East EuropeCastolin GmbHBrunner Strasse 691235 Wien+43 (0)1 869 45 41 0BelgiumMEC Benelux nv / sa – Castolin EutecticRue des Ateliers, 117850 Enghien (Edingen)+32 (0)2 888 24 51Czech RepublicMesser Eutectic Castolin spol.s.r.o.Trojska 80/12218200 Praha 8+420 2-830 900 77FranceMesser Eutectic Castolin SARL22, Av. du Québec BP 325Z.A. Courtaboeuf 1- Villebon91958 Courtaboeuf Cedex+33 (0)1 69 82 69 82GermanyCastolin GmbHGutenbergstrasse 1065830 Kriftel+49 (0)6192 403 0NetherlandsSA Messer Eutectic Castolin Benelux NVRotterdamseweg 4062629 HH Delft+31 (0)15 256 92 03NorwayCastolin Scandinavia NUFHammaren 134056 Tananger+47 (0)516 925 10PolandMesser Eutectic Castolin Sp.z.o.o.P.O. Box 502, ul. Robotnicza 244-100 Gliwice+48 (0)32 230 67 36RussiaMesser Eutektik Castolin Ltd.Ul. Bolschaja Tulskajya 10/9, Office9506115191 Moscow+7 (0)495 771 74 12SpainCastolin Iberica S.A.P. I. de Alcobendasc/ San Rafael, 628108 Alcobendas (Madrid)+34-(0)91 490 03 00Sweden, Denmark, FinlandCastolin Scandinavia ABTransportgatan 3742204 Hisings-Backa, Sweden+46 (0)31 570 470SwitzerlandMesser Eutectic CastolinSwitzerland SASwiss Market CenterIndustriestrasse 348108 Dällikon+41(0)44 847 17 17TurkeyCastolin Kaynak San. Ve Tic. Ltd. Sti.Yukari Dudullu MahallesiBostanci Yolu Sehit Sokak 5334775 Ümraniye / Istanbul+90 (0)216 313 28 00United Kingdom & IrelandCastolin Eutectic Ltd.Unit 10, Merse RoadNorth Moons MoatRedditch B98 9NZ+44 (0)1527 582 200Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggestproduct applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantabilityor of fitness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance withapplicable law and non-infringement of the rights of others, and Castolin Eutectic and its affiliates shall have no liability in respect there of.Your resource for protection, repair and joining solutionswww.castolin.comwww.eutectic.comStronger with Castolin Eutecticwww.castolin.com11

Stronger with... Castolin EutecticWEAR & FUSION TECHNOLOGYAsk for a demonstrationfrom our ApplicationSpecialists.-> www.castolin.com