1 low heat input welding alloys

Transcription

PREMIUM PRODUCT RANGE
Stronger, with
Castolin Eutectic
SOUTH EASTERN EUROPE
Castolin… past foundations, building for the future
A CENTURY OF HISTORY
1906: Foundation of Castolin in Lausanne, Switzerland by Jean-Pierre Wasserman.
His stroke of genius: to discover a way of welding cast iron at low temperature;
in the following years, his innovation was further developed for all industrial metals
including aluminium alloys.
1940: Foundation of Eutectic Welding Alloys Corporation in New York
1952: Foundation of Castolin France
1959: Foundation of Eutectic Japan Ltd
1962: Foundation of Eutectic India Ltd.
1960’s: International consolidation under Castolin Eutectic
1970’s: Creation of training centers for Maintenance & Repair technologies
1978: Establishment of World Head Quarters in St-Sulpice, Switzerland
2000: Merger with Messer Cutting & Welding and creation of the MEC Group - Messer
Eutectic Castolin
Today MEC - Messer Eutectic Castolin is:
A world-wide group with over 2300 collaborators
Established in all industrialised countries through subsidiaries
4 production plants in Europe
4 production plants on the American continent
2 production plants in Asia
4 complementary technologies: welding, brazing, cutting, thermal spraying
Continuous evolution and progress
The traditional core competence for Castolin is the constant fight against industrial wear
and tear using maintenance fusion technologies. Our long experience in research and development has created numerous patents and progress in the field of industrial materials and
metallurgy, surface engineered protective coatings and associated processes. Throughout
our hundred year history, Castolin has pioneered product developments at the leading edge
of technology with exceptional performance qualities for practical industrial applications
leading to conservation of valuable raw material and energy resources.
Castolin Eutectic is a registered BS EN ISO 9001:2000 Company.
Whilst every care has been taken in the preparation of the technical information contained in the publication, it is provided for guidance only and Castolin Eutectic will not accept any liability resulting from
its use.
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2
European Product Catalogue.
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YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS
Castolin Gesellschaft m.b.H.
Brunner Strasse 69
1235 Vienna, Austria
Phone: +43 - (0)1 - 869 45 41 - 0
Fax: +43 - (0)1 - 869 45 41 - 10
email: [email protected]
homepage: www.castolin.at
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European Product Catalogue
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TABLE OF CONTENTS
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1
LOW HEAT INPUT WELDING ALLOYS
6
11
EUTECTRODE MANUAL ELECTRODES
6
11.10
11.20
11.23
11.26
11.30
11.35
11.40
11.50
11.53
11.56
Welding Cast Irons
Welding Steels
Welding Stainless Steels
Welding Structural Steels
Welding Copper Alloys
Welding Aluminium Alloys
Gouging, Chamfering, Cutting
Carbide Alloy Coatings
Alloy Steel Coatings
Nickel Alloy and Cobalt Alloy Coatings
6
7
8
9
9
9
9
10
11
11
12
CASTOMIG-MAG WELDING WIRES
12
12.23
12.26
12.30
12.35
12.53
12.56
Nickel Alloy Coatings
12
13
13
14
14
14
13
CASTOTIG WELDING RODS
15
13.20
13.23
13.26
13.30
13.35
13.53
13.56
Welding Special Steels
15
15
15
16
16
16
17
14
ENDOTEC CORED WIRES (GAS SHIELDED)
18
14.10
14.20
14.23
14.50
14.53
14.56
Welding Cast Irons
Welding Steels
18
18
18
18
19
20
15
TEROMATEC CORED WIRES (SELF SHIELDED)
21
15.50
15.53
21
21
2
LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS
24
21
ECOBRAZ RANGES
24
21.10
22.10
23.10
23.20
24.10
27.10
28.10
Capillary Soldering Brazing Alloys
Self-Fluxing Brazing Alloys for Copper
Gas Welding and Brazing Alloys
Wearfacing Alloys
Soldering Alloys
Fluxes
Brazing Light Metal Alloy and Soldering Pastes
24
25
25
26
27
28
31
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TABLE OF CONTENTS
3
POWDERS AND WIRES FOR THERMAL SPRAYING
36
31
POWDERS FOR THERMAL SPRAYING
36
31.10
31.20
31.30
31.40
31.50
31.60
31.70
31.80
RotoTec – Alloy powders for "cold" spray process
ProXon – One-step alloy powders for "cold" spray process
Eutalloy – Self-fluxing powders for spraying with simultaneous fusion
Eutalloy SF – Self-fluxing powders for spraying with simultaneous fusion
Eutalloy RW – Self-fluxing powders for spraying with subsequent fusion
CastoPlast – Polymer powders for thermal spray process
MetaCeram – Ceramic and refractory powders for "cold" thermal spray process
EuTroLoy – Alloy powders for PTA (Plasma Transferred Arc) process
36
37
38
38
39
39
40
40
32
WIRES FOR THERMAL SPRAYING
41
32.10
EuTronic Arc spray wires – Alloy wires for arc spraying
41
4
COMPOSITE WEAR FACING MATERIALS
42
41
MECATEC - COLD SURFACING TECHNOLOGY POLYMERS
42
9
CASTODUR DIAMOND PLATES
44
91
WELD CLADDED PLATES
44
92
POWDER COATED PLATES
45
93
CASTOTUBES
45
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1 LOW HEAT INPUT WELDING ALLOYS
11 EUTECTRODE MANUAL ELECTRODES
11.10 WELDING CAST IRONS
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2-44
Ø 2.5 - 3.2 - 4.0
Special electrode with high nickel content for contaminated cast irons.
This electrode is highly recommended for welding without preheating
old and oil-soaked cast irons, whetever for joining or overlaying, as well
as for buttering before welding with bronze electrodes.
Rm: 330 MPa
Rp0.2: 300 MPa
XHD 2230
Ø 2.5 - 3.2 - 4.0
Nickel iron electrode with bimetallic core wire developed for welding
grey cast iron to steel or engineering cast iron grades with spheroidal
graphite. Deposits have highest mechanical properties and exceptional
crack resistance.
Rm: 490 MPa
Rp0.2: 330 MPa
A5: 13.5%
XHD 2480
Ø 2.5 - 3.2
Nickel based electrode developed for welding and repair of grey cast iron.
Regular deposits. Increased crack resistance.
Rm: 320 MPa
2-23
Ø 2.5 - 3.2 - 4.0
Nickel iron electrode developed for welding grey cast iron and ductile
cast iron. High crack resistance.
Rm: 325 MPa
Rp0.2: 310 MPa
2-24
Ø 2.5 - 3.2 - 4.0
Nickel based electrode developed for welding grey cast iron with soft,
machinable deposits. Very easy to use.
Rm: 480 MPa
Rp0.2: 230 MPa
2240
Ø 2.5 - 3.2 - 4.0
Nickel iron electrode with bimetallic core wire developed for welding cast
iron in all positions. High mechanical properties and crack resistance.
Rm: 345 MPa
Rp0.2: 305 MPa
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1
LOW HEAT
INPUT WELDING ALLOYS
11.20 WELDING STEELS
Designations
Properties
640
Ø 2.5 - 3.2 - 4.0
Electrode for fully austenitic steel deposits with exceptional hot crack
resistance. This alloy is developed for repair and assembly of high alloy
and carbon steels.
Rm: 650 MPa
Rp0.2: 450 MPa
A5: 38%
Work hardened: 400 HV30
XHD 646
Ø 2.5 - 3.2
Ø 4.0 - 5.0
High impact resistance. Rebuilding worn parts in 14% manganese steel.
Buttering layer before wear facing.
Rm: 680 MPa
Rp0.2: 510 MPa
A5: 32%
Xuper 680S
Ø 1.6 - 2.0 - 2.5
Ø 3.2 - 4.0
High alloy tool & die repairs and joining dissimilar steels. Highest tensile
strength and crack resistance. Exceptionally easy weldability.
Rm: 860 Mpa
Rp0.2: 690 MPa
A5: 20%
690 SF
Ø 2.5 - 3.2
Specifically designed for joining and buttering a wide range of steels
which are either of unknown composition or considered 'difficult - to weld' and where matching electrodes do not exist.
Rm: 820 MPa
Rp0.2: 620 MPa
A5: 25%
Xuper 690
Ø 2.5 - 3.2 - 4.0
Assembly, rebuilding, buttering layer for alloyed and hardenable steels
before wear facing. High resistance to cracking.
Rm: 675 MPa
Rp0.2: 550 MPa
A5: 40%
Xuper 2222
Ø 2.5 - 3.2
Ø 4.0 - 5.0
Electrode deposits a high nickel alloy with an austenitic structure for welding all kinds of steel and steel castings in thick sections. Welding nickel
alloys and Inconel 600®™. Working temperature: from cryogenic up to
980°C.
Rm: 670 MPa
Rp0.2: 420 MPa
A5: 45%
XHD 2222
Ø 2.5 - 3.2 - 4.0
High nickel alloy electrode producing deposits with excellent toughness,
capable of withstanding high stress even under impact loading.
Rm: 590 MPa
Rp0.2: 420 MPa
A5: 30%
XHD 6868
Ø 2.5 - 3.2 - 4.0
Electrode developed for high speed welding of difficult-to-weld, galvanised or dissimilar steels. Rebuilding and buttering layers before wear
facing. High metal recovery (170%).
Rm: 800 MPa
Rp0.2: 670 MPa
A5: 17.5%
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11.23 WELDING STAINLESS STEELS
Designations
Properties
E 307-17
Ø 2.5 - 3.2 - 4.0
Rutile electrode depositing a corrosion-resistant austenitic stainless steel.
The deposited metal can be work hardened combining good ductility and
toughness properties.
Rm: 610 MPa
Rp0.2: 445 MPa
A5: 40%
AWS A 5.4: E 307-17
E 308L-17
Ø 2.5 - 3.2 - 4.0
Electrode developed for assembly and repair of AISI 304 type stainless steel.
Rm: 590 MPa
Rp0.2: 430 MPa
A5: 40%
AWS A 5.4: E 308 L-17
E309MoL-17
Ø 3.2 - 4.0
Rutile type electrode depositing low carbon austenitic-ferritic stainless
steel. It has increased corrosion resistance, notably to intercrystalline corrosion up to 350°C and in air oxidation up to 1050°C.
Rm: 640 MPa
Rp0.2: 480 MPa
A5: 30%
AWS A 5.4: E 309 MoL-17
E 310-17
Ø 2.5 - 3.2 - 4.0
Electrode developed for assembly and repair of AISI 309 (25/12), 310
(25/20), and 314 type refractory steel. Excellent resistance to heat
(up to 1050 °C) and corrosion.
Rm: 600 MPa
Rp0.2: 400 MPa
A5: 35%
AWS A 5.4: E 310-17
E 316L-17
Ø 2.0 - 2.5
Ø 3.2 - 4.0
Rm: 590 MPa
Rp0.2: 440 MPa
A5: 40%
AWS A 5.4: E 316 L-17.
E 318-17
Ø 2.5 - 3.2 - 4.0
Rutile type electrode depositing austenitic stainless steel stabilized with
niobium. It has increased corrosion resistance, notably to intercrystalline
corrosion and pitting up to 400°C and in air oxidation up to 800°C.
Rm: 620 MPa
Rp0.2: 470 MPa
A5: 35 %
AWS A 5.4: E 318-17
E 385-17
Ø 2.5 - 3.2 - 4.0
Electrode developed for homogeneous welding of Z2 NCDU 25-20
(Uranus B6 ®™) type stainless steels. Assembly and repair of corrosion
resistant steel (sulphuric or phosphoric environments) or refractory steel (up to
1000°C)
Rm: 590 MPa
Rp0.2: 410 MPa
A5: 40 %
AWS A 5.4: E 385-17
Especially for Maintenance Welding of Stainless Steels
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Designations
Properties
33000
Ø 2.0 - 2.5 - 3.2
Rm: 615 MPa
Rp0.2: 450 MPa
A5: 42 %
AWS A 5.4: E 308L -17
33300
Ø 2.5 - 3.2
Electrode developed for assembly and repair of AISI 309 (25/12), 310 (25/20),
and 314 type refractory steel. Excellent resistance to heat (up to 1050 °C)
and corrosion.
Rm: 565 MPa
Rp0.2: 395 MPa
A5: 36 %
AWS A 5.4: E 310-16
33500
Ø 2.0 - 2.5 - 3.2
Rm: 700 MPa
Rp0.2: 535 MPa
A5: 30 %
AWS A 5.4: E 316L -17
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LOW HEAT
Especially for Maintenance Welding of Stainless Steels - Continued
Designations
Properties
Castinox D
Ø 2.5 - 3.2
Electrode developed for assembly and repair of AISI 309 (25/12), 310 (25/20),
and 314 type refractory steel. Excellent resistance to heat (up to 1200 °C)
and corrosion.
Rm: 555 MPa
Rp0.2: 399 MPa
A5: 33 %
11.26 WELDING STRUCTURAL STEELS
Designations
Properties
6601
Ø 2.5 - 3.2
Rutile electrode for welding usual structural steels in all positions.
Rm: 570 MPa
Re: 480 MPa
A5: 21 %
AWS A 5.1: E 6013
6666
Ø 2.5 - 3.2 - 4.0
Basic double extruded flux coated electrode for welding low alloy steel.
Rm: 570 MPa
Re: 420 MPa
A5: 20 %
AWS A 5.5: E 8018 G
11.30 WELDING COPPER ALLOYS
Designations
Properties
285
Ø 3.2 - 4.0
Bronze electrode developed for assembly and repair of copper based
alloys and resurfacing of steel or cast iron parts subject to frictional wear.
Rm: 380 MPa
A5: 18 %
Hardness: 125 HB
XHD 1855
Ø 3.2
Complex bronze electrode developed for marine applications needing
high strength / ductility properties and resistance to wear by cavitiation,
corrosion, friction.
Rm: 705 Mpa
A5: 24%
Hardness: 175 HV30
11.35 WELDING ALUMINIUM ALLOYS
Designations
Properties
2101S
Ø 2.5 - 3.2
Electrode developed for the assembly and repair of aluminium alloy castings.
Rm: 170 MPa
Rp0.2: 95 MPa
A5: 5 %
XHD 2100
Ø 3.2
Electrode developed for welding wrought aluminium alloys particularly
when anodisation is required .
11.40 GOUGING, CHAMFERING, CUTTING
Designations
Properties
CutTrode 01
Ø 3.2 - 4.0 - 5.0
Electrode developed for gas free, high speed cutting and piercing work on
all metals in all positions.
ChamferTrode
03 / 04
Ø 3.2 - 4.0
Electrode developed for fast metal removal and surface preparation by
chamfering, grooving and gouging.
Elimination of worn and cracked surfaces.
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11.50 CARBIDE ALLOY COATINGS
Designations
Properties
N 700
Ø 3.2
Electrode depositing chromium carbides for wear protection against
abrasion combined with pressure and moderate impact.
Hardness: 59-64 HRC.
XHD 6710
Ø 3.2 - 4.0
High metal recovery (215%) electrode developed for protection against
wear by abrasion and erosion. The hardness is obtained in a single pass.
XHD 6715
Ø 3.2
High metal recovery (255%) electrode developed for protection against
wear by abrasion and erosion. Maximum hot abrasion resistance up to
650°C. The hardness is obtained in a single pass.
Hardness: 65 HRC.
5006
Ø 2.5 - 3.2
Ø 4.0 - 5.0
High metal recovery (170%) electrode developed for anti-wear resurfacing of parts subject to combined stresses: abrasion, pressure and moderate impact by medium to fine particles.
N 6070
Ø 4.0
High metal recovery (250%) electrode developed for protective coatings
against wear by abrasion in the presence of very fine and very hard
abrasive materials. Maximum hot abrasion resistance up to 650°C.
Hardness: 900-1100 HV30
6088
Ø 5.0
Thanks to high density and good distribution of hard DIAMAX particles
in a hard nickel based matrix, the deposit obtained with this electrode is
highly resistant to abrasion, erosion and corrosion at high temperatures.
Hardness: 56 HRC
TECHNICAL NOTE
Microstructures of the primary EutecTrode alloys from the 11.50 carbide alloy coatings.
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XHD 6715
5006
N 6070
N 700
10
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1
LOW HEAT
11.53 ALLOY STEEL COATINGS
Designations
Properties
2
Ø 2.5 - 3.2
Electrode deposits a chromium, molybdenum, manganese alloy steel developed for anti-wear coating of parts to resist impact, pressure and abrasion.
Hardness: 55-60 HRC
6
Ø 2.5 - 3.2
Electrode for High Speed Steel type deposits developed for fabrication or
repair of damaged tools. Increased resistance to shock, pressure, cracking
and oxidation at high temperature.
Hardness: 62 HRC
N 102
Ø 3.2 - 4.0
High metal recovery (150%) electrode developed for anti-wear coatings
on parts or tools to resist high pressures, impacts and wear.
Hardness: 53-58 HRC
EC 3292
Ø 2.5 - 3.2
on parts subject to wear by fatigue (cutting tools), metal-to-metal
friction and by impacts with abrasion.
Hardness: 53-57 HRC
XHD 6804
Ø 2.5 - 3.2 - 4.0
on parts subject to elevated temperatures in combined wear regimes:
heat – corrosion – friction.
Hardness as welded: 470 HV30
6055
Ø 3.2 - 4.0
Electrode deposits a low temperature precipitation hardening martensitic steel (maraging steel) for making composite tools suitable for cold
working and cutting operations.
Hardness as welded: 36 HRC.
Hardness after heat treatment 480 °C for 4 hours: 52 HRC
35200
Ø 3.2 - 4.0
Electrode developed for coating parts to resist deformation and wear
by high pressure loading. Rebuilding and buttering layers before wear
facing.
Rm : 960 MPa
Rp0.2 : 810 MPa
A5: 13 %
Hardness: 320 HV30
11.56 NICKEL ALLOY AND COBALT ALLOY COATINGS
Designations
Properties
XHD 6865
Ø 2.5 - 3.2
High metal recovery (150%) electrode depositing a special nickel alloy,
developed for wear protective coatings on hot working tools and dies
Working temperature: up to 950°C.
Hardness as welded: 240 HB
Work hardened: 360-380 HB.
XHD 6817
Ø 3.2
High metal recovery (170%) electrode depositing a special nickel alloy,
developed for wear protective, creep resistant coatings on hot working
tools and dies.
Working temperature: up to 1100°C.
Hardness as welded: 200 HB
Work hardened: 350 HB.
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11.56 NICKEL ALLOY AND COBALT ALLOY COATINGS - CONTINUED
Designations
Properties
N 9025
Ø 3.2
Electrode deposits a cobalt based, work hardening alloy (Grade 25 type)
having high hot crack resistant mechanical properties and a superior
resistance to metal-to-metal friction, oxidation, pressure and thermal
fatigue.
N 9060
Ø 3.2
Electrode deposits a cobalt based alloy with lower hardness (Grade 6
type), intended for resurfacing for protection against wear combined
with corrosion, heat and abrasion. The deposited metal retains its
hardness at high temperature.
High resistance to impact and hot cracking.
Hardness: 40-45 HRC
N 9080
Ø 3.2 - 4.0
Electrode deposits a work hardening cobalt based alloy (Grade 21 type),
intended for resurfacing for protection against wear combined with
corrosion, heat and impact. The deposited alloy retains its properties at
high temperature.
12 CASTOMIG-MAG WELDING WIRES
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Designations
Properties
45500 S
(ER 316LSi)
Ø 0.8 - 1.2 - 1.6
15 Kg
MAG wire for assembly and repair of AISI 316 type stainless steel.
Rm: 560 MPa
Rp0.2: 370 MPa
A5: 35 %
AWS SFA 5.9: ER 316 LSI
45503 S
(ER 308LSi)
Ø 0.8 -1.0
Ø 1.2 - 1.6
15 Kg
MAG wire for assembly and repair of AISI 304 type stainless steel.
Rm 600 MPa
Rp0.2: 360 MPa
A5: 40 %
AWS SFA 5.9: ER 308 LSI
45513 S
(ER 310)
Ø 1.0 - 1.2
15 Kg
MAG wire for assembly and repair of refractory (AISI type 310) stainless
steel that needs to resist corrosion and oxidation in air up to 1150°C.
Rm: 580 Mpa
Rp0.2: 380 Mpa
A5: 42 %
AWS SFA 5.9: ER 310
45516 S
(ER 309LSi)
Ø 1.0
15 Kg
MAG wire for heterogeneous welding of steels that are difficult to weld
and for welding 309 type stainless steel.
Rm: 600 MPa
Rp0.2: 400 MPa
A5: 40 %
AWS SFA 5.9: ER 309LSi
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1
LOW HEAT
12.23 WELDING STAINLESS STEELS - CONTINUED
Designations
Properties
45552 S
(ER 347)
Ø 0.8 - 1.0 - 1.2
15 Kg
MAG wire for welding 304 type stainless steels stabilized with Ti or Nb
(321 and 347).
Rm: 660 MPa
Rp0.2: 460 MPa
A5: 42 %
AWS A 5.9: ER 347
45554 S
(ER 307 Si)
Ø 0.8 - 1.0
Ø 1.2 - 1.6
15 Kg
MAG wire for welding austenitic steels with manganese and welding
steels that are difficult to weld or with thick sections.
Rm: 620 MPa
Rp0.2: 420 MPa
A5: 40 %
Designations
Properties
45250
Ø 0.8 - 1.0 - 1.2
15 Kg
MAG wire for welding non-alloyed or low alloyed steel in general use.
Rm: >570 MPa
Rp0.2: >420 Mpa
A5: >19 % EN 440: G4Si1
45252
Ø 0.8 - 1.0 - 1.2
15 Kg
MAG wire for welding steel resistant to heat and creep up to 570 °C.
Rm: >600 MPa
Rp0.2: >500 MPa A5: >20%
45257
Ø 0.8 - 1.0 - 1.2
15 Kg
MAG wire for welding high yield strength steel (up to 700MPa) used in
highly stressed parts of fabrication-welded structures.
Rm: 830 MPa
Rp0.2: 760 MPa
A5: 18 %
AWS A 5.28: ER 100S-G
Designations
Properties
45703
Ø 1.0 - 1.2
15 Kg
MIG wire for assembly and coating of plain bronze (copper-tin) parts.
Rm: 260 MPa
A: 20 %
DIN 1733 SG-CuSn6
45706
Ø 1.0 - 1.2
15 Kg
MIG wire for assembly and coating of copper and its alloys.
Copper-Silicon alloy (3%).
Rm: 350 MPa
Rp0.2: 150 MPa
A5: 40 %
DIN 1733: SG Cu Si 3
45751
Ø 0.8 - 1.0
Ø 1.2 - 1.6
15 Kg
MIG wire for welding copper-aluminum alloys and coating parts subject
to wear by metal-to-metal friction. Very good resistance to corrosion by
sea water.
Rm: 430 MPa
A: 40 %
Hardness: 100 HB
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12.35 WELDING ALUMINIUM ALLOYS
Designations
Properties
45802
Ø 0.8 - 1.0 - 1.2
7.5 Kg
MIG wire (type AG5, 5356) for welding aluminium alloys.
Homogeneous welding of aluminum-magnesium alloys with 5% Mg.
Rm: >235 MPa
Rp0.2: >110 MPa A5: >17 % EN: AW–AlMg5(A)
45803
Ø 1.0 - 1.2 - 1.6
7.5 Kg
MIG wire (type AS5, 4043) for welding aluminum-magnesium alloys and
reclamation of defective foundry castings.
Rm: >120 MPa
Rp0.2: >40MPa
A5: >8 %
EN: AW-AlSi5(A)
45806
Ø 1.0 - 1.2
7.5 Kg
MIG wire (type AG4MC, 5183) for welding aluminum-magnesium alloys.
Rm: >275 MPa
Rp0.2: >125 MPa A5: >17 % EN: AW-AlMg5Mn1(A)
Designations
Properties
45351
Ø 0.8 - 1.0
Ø 1.2 - 1.6
15 Kg
MIG wire for producing anti-wear coatings on parts subject to combined
pressure, moderate abrasion and significant impacts.
Hardness: 60 HRC DIN 8555: SG 6-60-GTZ
45365
Ø 1.0 - 1.2
15 Kg
MIG wire for producing anti-wear coatings on parts subject to combined
pressure and abrasion, which is only machineable by grinding.
Hardness: 58 HRC MSG 3-GZ-60
12.56 NICKEL ALLOY COATINGS
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Designations
Properties
45654
Ø 1.0 - 1.2
15 Kg
MIG wire for welding Inconel 625 ® and nickel based alloys.
Austenitic alloy for assembly of dissimilar steels.
Rm: > 700 Mpa
Rp0.2: > 420 Mpa
A5: >25 %
AWS 5.4 14: ER NiCrMo-3
14
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LOW HEAT
13 CASTOTIG WELDING RODS
13.20 WELDING SPECIAL STEELS
Designations
Properties
45507 WS
(ER 312)
Ø 1.0 - 2.0
Ø 2.4 - 3.2
TIG rod for assembling or coating tool steel or dissimilar steels. Buttering
layer before surfacing.
Rm: 750 Mpa
Rp0.2: 530 Mpa
A5: 25 %
AWS SFA 5.9: ER 312
45612W
Ø 1.0 - 1.6
Ø 2.0 - 2.4
TIG rod for welding Inconel 600 ®, nickel based alloys and tool steels or
low to highly alloyed steels that are difficult to weld. Assembly of copper
with steel.
Rm: >620 Mpa
Rp0.2: >380 Mpa
A5: >35 %
AWS SFA 5.14: ER NiCr–3
45654W
Ø 1.6 - 2.0 - 2.5
TIG rod for welding Inconel 625 ® and nickel based alloys. Austenitic alloy
for assembly of dissimilar steels.
Rm: > 700 Mpa
Rp0.2: > 420 Mpa
A5: >25 %
AWS 5.4 14: ER NiCrMo-3
Designations
Properties
45500 WS
(ER 316L)
Ø 1.6 - 2.0 - 2.4
TIG rod for assembly and repair of AISI 316 type stainless steel.
Rm: 560 Mpa
Rp0.2: 370 Mpa
A5: 35 %
AWS SFA 5.9: ER 316 L
45503 WS
(ER 308L)
Ø 1.0 - 1.6 - 2.0
Ø 2.4 - 3.2
TIG rod for assembly and repair of AISI 304 type stainless steel.
Rm: 600 MPa
Rp0.2: 360 MPa
A5: 40 %
AWS SFA 5.9: ER 308 L
45513 WS
(ER 310)
Ø 1.6 - 2.0
TIG rod for welding refractory stainless steel (AISI type 310) that needs to
resist corrosion and oxidation in air up to 1150°C.
Rm: 580 MPa
Rp0.2: 380 MPa
A5: 42 %
AWS SFA 5.9: ER 310
45552W
(ER 347)
Ø 1.0 - 2.0
Ø 2.4 - 3.2
TIG rod for welding 304 type stainless steel stabilized with Ti or Nb (321 and
347).
Rm: 660 MPa
Rp0.2: 460 MPa
A5: 42 %
AWS SFA 5.9: ER 347
Designations
Properties
45252W
Ø 2.0 - 3.0
TIG rod for the assembly and resurfacing of 15 CD 4 type steel.
Resists heat up to temperatures of 550°C.
Rm : >510 MPa
Rp0.2: >355 MPa
A5: >20 %
AWS A 5.28-29 : ER80 S-G
45255W
Ø 2.0 - 2.4 - 3.0
TIG rod for fabrication welding mechanical structural steel assemblies.
Rm : > 530 MPa
Rp0.2: > 385 MPa A5: > 20 % AWS A 5.18 : ER 70 S 6
Tel:+43 1 869 45 41
15
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Designations
Properties
45701W
Ø 2.0
TIG rod for assembly and coating of parts subject to marine corrosion
and notably the 70/30 or 90/10 copper-nickel alloys.
Rm: 420 MPa
Rp0.2: 240 MPa
A5: 36 %
DIN 1733: SG-Cu Ni 30 Fe
45703W
Ø 2.0 - 2.5
TIG rod for assembly and coating of plain bronze (copper-tin) parts.
Fights against wear by metal-to-metal friction.
Rm: 260 MPa
Hardness: 80 HB A: 20 %
DIN 1733: SG-Cu Sn 6
45704W
Ø 2.0 - 3.0
TIG rod for assembly and coating of pure copper. The deposited metal
provides high electrical conductivity. Particularly recommended for
copper that is difficult to weld.
Rm: 200 Mpa
Hardness: 60 HB A: 30 %
DIN 1733: SG-Cu Ag
45706W
Ø 2.0
TIG rod for assembly and coating of copper and its alloys.
Copper-silicon alloy (3%).
Rm: 350 MPa
Hardness: 80 HB Din 1733: SG Cu Si 3
13.35 WELDING ALUMINUM ALLOYS
Designations
Properties
45801W
Ø 2.0 - 3.2
TIG rod for welding aluminum (up to 99.5%) and its alloys.
Rm : >65 MPa
Rp0.2: >20 MPa
A5: >35 % AWS A 5.10: ER 1100
DIN 1732 : SG Al99.5Ti
45802W
Ø 2.0 - 2.5
Ø 3.2 - 4.0
TIG rod for welding aluminum-magnesium alloys and similar types of
aluminum alloys.
Rm: >235 MPa
Rp0.2: >110 MPa A5: >17 % AWS A 5.10: ER 5356
DIN 1732 : SG Al Mg 5
45806W
Ø 2.0
TIG rod for welding aluminum-magnesium alloys. Excellent mechanical
properties.
Rm: >275 MPa
Rp0.2: >125 MPa A5: 17 %
AWS A 5.10: ER 5183
DIN 1732: SG AlMg 4.5 Mn
Tel:+43 1 869 45 41
Designations
Properties
45301W
Ø 1.0 - 1.6
Ø 2.0 - 2.4
TIG rod for coating parts subject to heat, thermal shock and plastic
deformation.
Hardness as welded: 46 HRC
45303W
Ø 1.0 - 1.6
Ø 2.0 - 2.5
TIG rod for HSS coating of parts subject to combined mechanical wear:
adhesion, friction, shock or contact fatigue at elevated temperatures.
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LOW HEAT
13.53 ALLOY STEEL COATINGS - CONTINUED
Designations
Properties
45305W
Ø 1.0 - 1.6
TIG rod for preventive and repair coating of hot working tools.
45351 W
Ø 1.0 - 1.6
TIG rod for coating parts subject to heat, impact, sliding and rolling
abrasion.
45355 W
Ø 1.0 - 1.6 - 2.0
TIG rod Maraging type. Martensitic precipitation hardening
Ni-Co-Mo steel for cold metal working applications.
Hardness after heat treatment 480°C for 4 hours: 51 HRC
Designations
Properties
45406W
Ø 3.0 - 4.0
TIG rod cobalt based alloy (Grade 6 type). Excellent resistance to heat,
corrosion, wear, cavitation and metal-to-metal friction.
45412W
Ø 3.0
45421W
Ø 3.0
45612W
Ø 1.0 - 1.6
Ø 2.0 - 2.4
TIG rod for welding Inconel 600 ®™, nickel based alloys and tool steels or
low to highly alloyed steels that are difficult to weld. Assembly of copper
with steel.
Rm: >620 Mpa
Rp0.2: >380 MPa A5: >35 % AWS A 5.14: ER NiCr–3
45654W
Ø 1.6 - 2.0 - 2.5
TIG rod for welding Inconel 625 ®™ and nickel based alloys.
Austenitic alloy for assembly of dissimilar steels.
Rm: > 700 Mpa
Rp0.2: > 420 Mpa A5: >25 % AWS A 5.14: ER
Tel:+43 1 869 45 41
17
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14 ENDOTEC CORED WIRES (GAS SHIELDED)
14.10 WELDING CAST IRONS
Designations
Properties
DO*23
Ø 1.0 - 1.2
15 Kg
Metal cored nickel-iron wire developed for welding cast iron assemblies
or rebuilding.
Joining cast iron to steel.
Hardness: 200 HV30
14.20 WELDING STEELS
Designations
Properties
DO*02
Ø 1.2 - 1.6
15 Kg
Metal cored wire developed for welding difficult-to-weld steels, armour
plate and manganese steel.
Rm: 650 Mpa
Rp0.2: 390 Mpa
A 35 %
DO*22
Ø 1.6
15 Kg
Inconel 600®™ type metal cored wire developed for weld surfacing nickel
alloys, low or high alloy steel, and refractory steel and alloys.
Rm: 650 Mpa
Rp0.2: 370 Mpa
A5: 40%
DO*266 S
Ø 1.6
15 Kg
Copper-coated cored wire electrode providing fast solidification, rutiletype slag characteristics.
Rm: 510 Mpa
A5: 22%
Designations
Properties
DO*28 S
Ø 1.2
15 Kg
Metal-flux cored wire intended for welding AISI 316 L type steel.
Rm: 500-600 Mpa
Rp0.2: 380-450 Mpa
A5: 35-45 %
AWS A 5.9: E 316 LT-1
Tel:+43 1 869 45 41
Designations
Properties
DO*11
Ø 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings (tungsten
carbides in a nickel based matrix) on parts subject to severe abrasion in
combination with heat and corrosion.
Hardness (matrix): 55 HRC
Hardness (carbides): 2400 HV0.4
DO*48
Ø 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings (tungsten
carbides in an iron base matrix) on parts subject to severe abrasion or
erosion combined with moderate pressure and impacts.
Hardness (matrix): 55 HRC
Hardness (carbides): 2300 HV0.3
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LOW HEAT
14.50 CARBIDE ALLOY COATINGS - CONTINUED
Designations
Properties
DO*390 N
Ø 1.6
15 Kg
NanoAlloy patended, gas shielded, metal cored alloy wire, ideal for maintenance and repair applications or batch manufacturing where highest
integrity welding, efficiency and productivity are required.
Hardness (one layer): 70 HRC
DO*395 N
Ø 1.2
15 Kg
The slag-free deposit contains a high volume fraction of ultra-hard phases which ensures an excellent performance against abrasion, erosion
combined with moderate impact.
Hardness (one layer): 69 HRC
Designations
Properties
DO*04
Ø 1.2 - 1.6
15 Kg
Metal cored wire develped for producing anti-wear coating depositing steel
alloyed with chromium, cobalt and molybdenum. Excellent resistance to
wear by metal-to-metal friction, mechanical properties stable up to 500°C.
Hardness: 48 HRC
DO*05
Ø 1.6
15 Kg
Metal cored wire developed for producing work hardening anti-wear coatings,
having an excellent resistance to impacts, pressure and high stress abrasion.
DO*06
Ø 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings with High
Speed Steel properties for fabrication or repair of damaged tools. Increased
resistance to shock, pressure, cracking and oxidation at high temperature.
Hardness: 63 HRC
DO*13
Ø 1.2 - 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings,
having a high resistance to pressure, impacts and moderate abrasion.
Hardness: 58 HRC
DO*15
Ø 1.2 - 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings on parts
subject to impact, abrasion and contact fatigue.
Hardness: 58 HRC
DO*16
Ø 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings having
excellent resistance to shocks and to pressures up to 550°C.
Hardness: 48 HRC.
DO*30
Ø 1.2 - 1.6
15 Kg
Metal cored wire developed for producing single pass, anti-wear coatings
on parts subject to abrasion and erosion by small particles.
Hardness: 67 HRC
DO*33
Ø 1.6
15 Kg
Metal cored wire developed for producing anti-wear coatings having
excellent resistance to abrasion and erosion at high temperatures up to 650°C.
Hardness: 68 HRC
DO*55
Ø 1.6
15 Kg
Metal cored wire Maraging type (Martensitic Ni-Co-Mo steel with
precipitation hardening) developed for producing anti-wear coatings
on parts subject to compression, creep and cold cutting.
Hardness after heat treatment 480°C for 3 to 7 hours: 58 HRC
Tel:+43 1 869 45 41
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14.53 ALLOY STEEL COATINGS - CONTINUED
Designations
Properties
DO*322
Ø 1.6
15 Kg
Metal cored wire developed for producing multi pass, anti-wear coatings
on parts subject to abrasion and erosion by small particles.
Hardness: 65 HRC
DO*327
Ø 1.6
15 Kg
Metal cored wire developed for producing multi pass, crack-free coating of
parts subject to wear by combined abrasion and impact with high pressures.
Hardness: 58 HRC
DO*332
Ø 1.6
15 Kg
Metal cored wire developed for multi pass, anti-wear coatings having
excellent resistance to abrasion and moderate impact.
Hardness: 60 HRC
CaviTec GMA
Ø 1.2 - 1.6
15 Kg
Metal cored wire developed with a patented alloy system producing
anti-wear coatings with outstanding cavitation resistance on hydraulic
turbines and pumping equipment.
Tel:+43 1 869 45 41
Designations
Properties
DO*60
Ø 1.2 - 1.6
15 Kg
Metal cored wire depositing a Grade 6 type cobalt base alloy. Excellent
resistance to heat, corrosion, wear, cavitation and metal-to-metal friction.
Hardness: 41 HRC
DO*70
Ø 1.6
15 Kg
resistance to heat, corrosion, abrasion, cavitation and metal-to-metal friction
Hardness: 48 HRC
DO*80
Ø 1.6
15 Kg
resistance to heat, corrosion, wear, cavitation and metal-to-metal friction.
DO*85
Ø 1.6
15 Kg
resistance to thermal shocks and pressures, as well as abrasion at temperatures up to 950°C and oxidation up to 1200°C.
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1
LOW HEAT
15 TEROMATEC CORED WIRES (SELF SHIELDED)
Designations
Properties
3952
Ø 1.6 - 2.8
15 kg
Self shielded cored wire developed for coating parts subject to hot
abrasion up to service temperature of 600°C.
Hardness: 65 HRC
4395 N
Ø 2.8
15 Kg
Self shielded cored wire developed for coating parts subject to abrasion
and erosion combined with moderate impact.
Hardness: 69 HRC
4601
Ø 1.2 - 1.6 - 2.8
15 Kg
without impact.
Hardness: 60 HRC
4660
Ø 1.2 - 1.6 - 2.8
15 Kg
by medium and large bodies
Hardness: 63 HRC
Designations
Properties
3205
Ø 1.6 - 2.4 - 2.8
15 Kg
Self shielded cored wire developed for anti-wear coating of low or alloy
steel parts with work hardening properties against heavy impact, pressure and friction.
4415
Ø 1.6 - 2.8
15 Kg
Self shielded cored wire developed for anti-wear coating of low or alloy
steel parts to resist impact and abrasion up to service temperature of 500°C.
Hardness: 55 HRC
4630
Ø 2.8
15 Kg
Self shielded cored wire developed for anti-wear coating of low or alloy steel
parts in single pass to resist severe abrasion and erosion by fine particles.
Hardness: 67 HRC
4923
Ø 1.2 - 1.6 - 2.8
15 Kg
Self shielded cored wire developed for crack-free coating of parts subject
to wear by combined abrasion and impact with high pressures.
Hardness: 57 HRC
Tel:+43 1 869 45 41
21
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TECHNICAL NOTE
Sample photographs of wearfacing applications using Castolin Maintenance &
Repair welding alloys.
We have a Terolink technical library describing many application case studies (process,
alloy used, context of the part and application, operating procedure, precautions, etc.).
This electronic database makes it possible for us to better solve the wear problems
encountered and to propose practical solutions as part of our technial service to
industry.
Tel:+43 1 869 45 41
CRUSHER ROTOR / QUARRY
CROWN GEAR RING – SUGAR REFINERY
TONGS / STEEL INDUSTRY
ROTARY CUTTER / CIVIL ENGINEERING
MOULD / AUTOMOTIVE
ROTOR DISCS / CEMENT PLANT
HAMMERS / WASTE RECYCLING
HYDROPULPER ROTOR / PAPER MILL
22
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1
LOW HEAT
Tel:+43 1 869 45 41
23
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2 LOW TEMPERATURE BRAZING AND SOLDERING ALLOYS
21 ECOBRAZ RANGES
21.10 CAPILLARY SILVER BRAZING ALLOYS
Cadfree® Silver Alloys
Designations
Properties
1020 B - T - XFC
Castolin 1020 is a CADFREE® quaternary Ag-Cu-Zn-Sn brazing alloy for
capillary joining of ferrous metals, plus Cu and Ni alloys. Very high Ag
content gives excellent fluidity, low joining temperature and increased
mechanical strength in joints. Water/gas-tight sealing of joints.
Deposit colour: stainless steel.
1666
1666 XFC
A high silver-copper-zinc-tin alloy. Formulated for maximum fluidity and
wettability on the metals specified. High fluidity, low heat input and very
good mechanical properties make this latest silver alloy exceptional.
181 - 181 F
Maximum Safety Margin, thanks to its high silver content: either by
capillary attraction, in the case of close-fitting components, or by moulding in the case of large joint gaps. Joints built up with Castolin 181 are
especially resistant to impact and vibrations.
Silver Alloys with Cadmium
Tel:+43 1 869 45 41
Designations
Properties
1010 XFC
Castolin 1010 XFC is a brazing alloy for capillary joining of ferrous metals,
plus Cu and Ni alloys. High Ag content plus Cd gives outstanding fluidity, lowest joining temperature and high mechanical strength in joints.
Water/gas-tight sealing of joints.
1030 XFC
The high silver content of this filler alloy promotes joining by capillarity,
and makes this product ideal for joining dissimilar metals.
1030 XFC is recommended for all maximum safety margin applications.
1802 - 1802 L
1802 XFC
1802 is a quaternary Ag-Cd-Cu-Zn brazing alloy for capillary joining
of ferrous metals, plus Cu and Ni alloys. High Ag content plus Cd gives
outstanding fluidity, lowest joining temperature and high mechanical
strength in joints. Water/gas-tight sealing of joints.
1810 XFC
Versatile and economical, this low temperature brazing alloy is designed
for application on copper, brass, bronze and steels. Especially recommended for dissimilar metal combinations such as carbon or alloy steels to
copper, brass or bronze.
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2
BRAZING & SOLDERING ALLOYS
22.10 SELF-FLUXING BRAZING ALLOYS FOR COPPER
Self-Fluxing Copper Alloys
Designations
Properties
1803D
Self-fluxing brazing alloy for copper to copper joining.
1805
Self-fluxing brazing alloy for copper to copper joining.
RB 5246
RB 5246 is a copper-phosphorus brazing alloy in bare rod form, for capillary
joining of copper and copper alloy parts. It is designed to deliver low-cost,
watertight joints and is particularly for mass production applications. When
joining copper to copper with this product, a separate flux is not required.
RB 5280
RB 5280 is a Cu P Ag brazing alloy with 2% Ag, designed for joining Cu
and Cu alloys. Ag content gives increased fluidity and better penetration
of joints, Water/gas-tight sealing of joints.
RB 5283
RB 5283 is a Cu Ag P brazing alloy with 15% Ag, for capillary joining of Cu
and Cu alloys. Ag content gives improved fluidity and increased mechanical strength in joints. Water/gas-tight sealing of joints.
RB 5286
RB 5286 is a Cu P Ag brazing alloy with 5% Ag, designed for joining Cu
and Cu alloys. Ag content gives increased fluidity and better penetration
of joints. Water/gas-tight sealing of joints.
Product form: bare alloy rod
Deposit colour: copper (after cleaning)
23.10 GAS WELDING AND BRAZING ALLOYS
Brazing-Brass/Bronze Alloys
Designations
Properties
146 MF - 146 XFC 146 is a bronze type alloy for use with cast-iron and carbon steel components, also recommended for galvanised steels and copper base alloys.
16 XFC
Tel:+43 1 869 45 41
A silver containing alloy for producing high strength joints by either thin
flowing or bead formation on carbon and alloy steel applications, and
especially suitable for joining carbide tips. A copper base alloy producing
high fluidity or bead forming characteristics by simply controlling the
heat input combination. Deposits are of exceptional joint strength and
crack resistance, and are fully machinable and will work harden under
impact loading conditions.
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Brazing-Brass/Bronze Alloys - CONTINUED
Designations
Properties
18 - 18 MF
18 XFC
Application designed welding rod for the repair and maintenance of brass,
bronze and copper parts. An economical silver bearing brazing type alloy for
use on a wide range of brasses and bronzes, and a combination of these, also
suitable for dissimilar combinations of copper alloys to ferrous materials.
A bronze alloy producing maximum strength and fluidity. The addition of
deoxidising elements aid in eliminating zinc oxidation and fuming.
185 XFC
Cu-Zn-Ni braze welding alloy for repair and rebuilding of metal components.
80 MF
80 XFC
The Castolin alloy 80 is recommended for high strength joints on tubulars chassis and bronze bearings and excellent frictional resistance overlays on shafts etc.
23.20 WEARFACING ALLOYS
Wearfacing with Carbides
Designations
Properties
CastoDrill 8800
A flux coated bronze/tungsten carbide rod for use with the oxyacetylene
process for applications requiring excellent cutting properties along with
abrasion and impact resistance in media such as sand, gravel, earth,
minerals etc., also recommended for tools to remove drill rods in well
drilling. A composite torch rod; consisting of hard carbide particles dispersed through a tough alloy matrix.
TeroCote® 7888 T 7888 T is a high performance anti-wear product in the form of a flexible
cord, comprising a nickel core wire, covered with an elastic binder
with carbides
containing a mixture of carbides and nickel alloy powder. The latter has
a uniquely effective self-fluxing action, which gives 7888 T outstanding
wetting properties. As a result, a smooth, even protective coat can be
deposited quickly and easily, greatly reducing the risk of overheating
the base material. Each spool of 7888 T carries one continous length of
cord of rigorously consistent diameter and without joints, for improved
reliability with automated or robotic feeder systems. 7888 T deposits
an extremely durable protective coating comprising a dense mass of
ultrahard tungsten carbides embedded in a tough nickel-chromium
alloy matrix. This structure offers extremely effective protection against
erosive and abrasive attack by a wide variety of materials. The matrix
composition helps to absorb moderate impact and improves resistance
to corrosion, while the angular profile of the finely crystallised carbides
makes them very difficult to dislocate.
Ultimium® 8811
Tel:+43 1 869 45 41
A carbide containing rod for producing the ultimate in abrasion resistance
due to the high concentration of hard, wear resistant carbides within a self
fluxing metallic matrix. For use on steels, stainless steel and cast iron
components utilising the Oxyacetylene, TIG and Eutalloy processes.
This unique alloy form provides a welded protective coating without dilution
of the base material. High density of carbide hard phases. Sound, crack free
deposit. No deformation of workpiece. Rod identification: Dark grey coating.
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2
Wearfacing with Carbides - CONTINUED
Designations
Properties
Ultimium 8888
Ultimium 8888 is a nickel based composite rod containing a high quantity
of tungsten carbides. This functional coating is designed for cutting and
drilling applications.
The coating thickness of 5-10mm guarantees great wear and corrosion resistance.
Castolin 8888 Cutter was specifically designed to be have the «Ultimate
Cutting Performance». Only high grade tungsten carbides are used,
insuring consistant cutting performance.
Ultimium 8888
Cutter
E 7650
Castolin 7650 CR has excellent flow and wetting characteristics.
It is designed to coat, repair and protect low alloyed steels as well as cast
iron parts with up to 0.5% carbon.
Wearfacing without Carbides
Designations
Properties
CastoDur® N 901
Cobalt base alloy for use with either oxyacetylene or the TIG process, for
applications subject to wear by abrasion, impact and pressure in both
hot and cold service conditions. Deposits also provide corrosion and heat
resistance with excellent hot hardness properties. Excellent resistance to
corrosion and abrasion. High hardness properties. Good heat resistance.
CastoDur® N 906
CastoDur 906 is a cobalt base filler metal. This alloy is used in applications
where lower hardness with abrasion and corosion resistance are needed.
24.10 SOLDERING ALLOYS
Soft Soldering
Designations
Properties
157 - 157 T
157 is a solder alloy containing silver but no lead or cadmium, and particularly recommended for applications in the food processing industry.
The mechanical properties of assemblies made with 157 are superior to
those of any conventional (lead-tin) alloys, making it especially preferable
in harsh service conditions.
1827
1827 is a cadmium based soft solder containing silver. It is recommended
for joining aluminium to copper.
Tel:+43 1 869 45 41
27
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Light Metal
Designations
Properties
190 - 190 FBK
Recommended for good strength joints in sheet and wrought aluminium
and some aluminium alloys. Ideal for brazing furniture and fittings,
window frames, aluminium utensils and applications within the aircraft
and radio industries. Castolin 190 can be used in conjunction with the
Oxyacetylene and Tungsten inert gas shielded (TIG) processes. An aluminium silicon alloy producing good strength joints and good resistance
to corrosion. Not suitable for parts requiring anodised finishes or aluminium alloys containing more than 1.5% magnesium.
190: Bare rod
1185 MF
Mini-flux filler rod for overlays, repairs and fabrication of parts made
from copper and its alloys such as York-Albro, cupro-aluminium, and the
joining of these to nickel alloys, or cast iron which must have high corrosion resistance.
Castolin 1185 MF is recommended particularly for its excellent resistance
to corrosion from sea water and mineral and organic acids, such as sulphuric, acetic, hydrofluoric and hydrochloric acid diluted to 5%, saline
and alkaline solutions.
1902
1902 is a magnesium aluminium alloy. Specially designed for braze welding of magnesium motor-blocks and castings.
21F
An extruded flux coated aluminium alloy for low heat input, high
strength welding repairs and fabrication of wrought and cast aluminium
and some aluminium alloys. Not suitable for parts requiring an anodised
finish. Uniform flux coating. Rapid solidification ideal for butt joints.
AluTin 51
Soft solder especially suited for joining aluminium to other metals.
27.10 FLUXES
Brass/Bronze Fluxes
Designations
Properties
16
Paste brazing flux for capillary brazing with copper - zinc - nickel based alloys.
At elevated temperature the flux reduces the metal oxides on the base
metal and activates the surface. This results in an optimal wetting of the
filler metal and increase of the capillary effect in the gap between the
two surfaces to be joined. The development of a surface alloy between
the filler metal and the base metal ensures the metallic continuity.
Paste brazing flux for capillary brazing with copper - zinc - nickel based alloys.
two surfaces to be joined. The development of a surface alloy between
the filler metal and the base metal ensures the metallic continuity, eliminating zinc oxidation and fuming.
18
Tel:+43 1 869 45 41
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2
Brass/Bronze Fluxes - CONTINUED
Designations
Properties
185 A
Paste brazing flux for braze coating with copper - zinc - nickel based
alloys. At elevated temperature the flux reduces the metal oxides on the
base metal and activates the surface. This results in an optimal wetting
of the filler metal and increase of the capillary effect in the gap between
the two surfaces to be joined. The development of a surface alloy
between the filler metal and the base metal ensures the metallic continuity. The brazing flux 185 A is designed for use with the following heating methods: oxyacetylene flame and furnace without gas protection.
Light metal fluxes
Designations
Properties
190
Recommended Castolin 190 flux in powder for use with Castolin 190 filler alloy.
Its power as a deoxidising agent makes in-position joining much easier,
as well as repairs presenting difficult access. The corrosive flux residue
must be removed. Alloys containing not more than 1.5% magnesium.
Other Fluxes
Designations
Properties
14
Flux for 14, cast iron filler rod typical of a flake cast iron structure, where
deposits require high strength for the repair of cracks, blow-holes, casting
defects and building up of worn and missing sections.
Soldering Fluxes
Designations
Properties
157 NC
157 NC is a solder flux in paste form ready for use.
AluTin 51
Silver Fluxes
Designations
Properties
1020
Flux for Castolin 1020 a CADFREE® quaternary Ag-Cu-Zn-Sn brazing alloy
for capillary joining of ferrous metals, plus Cu and Ni alloys. Very high Ag
content gives excellent fluidity, low joining temperature and increased
mechanical strength in joints. Water/gas-tight sealing of joints.
Powder brazing flux for capillary brazing with high silver content alloys.
two surfaces to be joined. The surface active Atmosin helps to obtain an
even thickness of the brazing flux, which adheres strongly with the base
metal during the heating phase.
1802 Atmosin
Tel:+43 1 869 45 41
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Silver Fluxes – CONTINUED
Designations
Properties
1802 HF
Powder brazing flux for capillary brazing with high silver content alloys.
metal and activates the surface. This result in an optimal wetting of the
two surfaces to be joined. The brazing flux 1802 HF is designed for use
with induction heating.
1802 PF Atmosin Paste brazing flux for capillary brazing with high silver content alloys.
metal and activates the surface. The surface active Atmosin helps to
obtain an even thickness of the brazing flux, which adheres strongly with
the base metal during the heating phase. The brazing operation is easier,
this increases the productivity specially for large series of parts.
Tel:+43 1 869 45 41
181 Atmosin
Paste with Powder brazing flux for capillary brazing with silver containing
alloys. At elevated temperature the flux reduces the metal oxides on the
base metal and activates the surface. The surface active Atmosin helps to
181 PF Atmosin
Paste brazing flux for capillary brazing with silver containing alloys.
metal and activates the surface. The surface active Atmosin helps to
ActivaTec® 1000
Paste flux for all high-silver content brazing.
Albro
Silver brazing flux with long continuous activity and high heat resistance.
It is recommended for parts in aluminium bronze.
AluTin 51
30
www.castolin.com
2
28.10 BRAZING LIGHT METAL ALLOY AND SOLDERING PASTES
Brazing-Light Metal Alloy Pastes
Designations
Properties
190 AL
This alloy in paste form is designed for immediate use without
preparation, and provides high-strength assemblies and re-pairs.
Combining the filler alloy 190 and 190 NH flux into a ready-to-use paste,
this product has been designed for use with automatic metering devices,
having a consistency suitable for most such systems.
Brazing-Soldering Alloy Pastes
Designations
Properties
157 PA
A flux and solder alloy powder combined in paste form, offering
non-toxic deposits free from lead, antimony.
CastoTin® 1
CastoTin 1 is a tin-lead soldering paste with a corrosive flux.
It can be used on stainless, ferrous and copper alloys.
CastoTin® 2
CastoTin 2 is a tin soldering paste with a corrosive flux.
It can be used on stainless, ferrous, nickel and copper alloys.
CastoTin® 3
CastoTin 3 is a tin-lead soldering paste with a non-corrosive flux.
It can be used on copper alloys.
Cadfree® Silver Alloy Pastes
Designations
Properties
1800 PA
Silver-zinc-copper-tin brazing alloy in paste form for capillary joining of
stainless steel, ferrous, copper and nickel alloy parts. Very high silver content for improved wetting and very strong joints. This ready-to-use-paste
contains a mixture in ideal proportions of atomised filler alloy powder and
optimized flux, held together by a special inert organic binding agent.
Silver Alloy Pastes with Cadmium
Designations
Properties
1802 PB
Silver-zinc-cadmium-copper brazing alloy in paste form, for capillary
joining of ferrous-, copper and nickel alloy parts. High silver content for
improved wetting and very strong joints. Paste contains a mixture of
ideal proportions of atomised filler alloy powder and compatible flux,
held together by a special inert organic binding agent in a stable, readyto-use compound.
CastoSil
A silver -zinc-cadmium-copper brazing alloy in paste form, water based.
Tel:+43 1 869 45 41
31
www.castolin.com
TECHNICAL NOTE
BRAZING ALLOYS WITH HIGH SILVER CONTENT HAVE MANY ADVANTAGES:
• The fluidity of the filler alloy makes brazing easier.
• The working temperature of these alloys is below 650°C which requires low thermal energy input. Grain growth during heating cycles reduces the mechanical properties of metal,
so it is important to limit heat input. Brazing with high silver alloys therefore only slightly
affects the parts in the joint (see picture below, left), and so preserves their properties.
• The ductility of the filler alloys provides better performance of the brazed joints in service
(resistance to vibrations, clamping, tensile stress, fatigue, etc).
• Reducing the time for heating, making the joint and cleaning the residues by using these
alloys, significantly reduces the labour and energy costs.
• The appearance of the brazed joint ensures a high quality image.
MAGNIFICATION 200 X
MAGNIFICATION 200 X
Capillary silver brazed joint using
Xuper 1802 alloy.
Grain growth observed after brazing using
a Cu-P-Ag alloy.
TYPES OF COATED RODS
Tel:+43 1 869 45 41
F
STANDARD QUALITY COATING
XFC
XUPER FLEXIBLE COATING
NF
THIN COATING
ZF
ULTRA-THIN COATING
MF
MINI-FLUX / PARTIAL COATING
32
www.castolin.com
2
21 ECOBRAZ RANGES
Melting
Range in °C
Composition in %
Product
Ag
Cu
Zn
Sn
Cd
Si
Ni
Other
Product Form
Flux
Coating
Colour
Colour
Solidus
Liquidus Form
625
625
660
660
740
740
665
665
700
700
835
835
F Coated
XFC® Coated
Bare Rod
XFC® Coated
Bare Rod
F Coated
Pink
Pink
615
625
595
595
604
670
695
630
630
683
XFC® Coated
XFC® Coated
Bare Rod
XFC® Coated
XFC® Coated
White
Purple
740
740
740
680
680
680
630
630
630
650
650
650
815
815
815
760
760
760
730
730
730
710
710
710
Castolin range - Cadfree® Silver Alloys
1020 F
1020 XFC®
1666
1666 XFC®
181
181 F
56,7
56,7
45,1
45,1
19,6
19,6
21,9
21,9
25,3
25,3
46,0
46,0
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
5.3
5.3
2
2
Green
White
Castolin range - Silver Alloys with Cadmium
1010 XFC®
1030 XFC®
1802
1802 XFC®
1810 XFC®
37,9
35
40
40
29,8
20,3
25,7
18,3
18,3
27,5
Bal.
Bal.
Bal.
Bal.
Bal.
21.4
19.5
24.1
24.1
23.6
White
White
EcoBraze Cadfree® Silver Alloys
38220 B
38220 F
38220 T
38225 B
38225 F
38225 T
38234 B
38234 F
38234 T
38240 B
38240 F
38240 T
38244 B
38244 F
38244 T
38245 B
38245 F
38245 T
38245 XFC®
38249 B
38249 T
38255 B
38255 F
38255 T
38256 B
38256 F
38256 T
38256 XFC®
19,4
19,4
19,4
25,9
25,9
25,9
34
34
34
40,7
40,7
40,7
45
45
45
45
49
49
54,3
54,3
54,3
56,8
56,8
56,8
56,8
43,8
43,8
43,8
39,7
39,7
39,7
36,6
36,6
36,6
29,3
29,3
29,3
26,7
26,7
26,7
26,7
16,3
16,3
21,1
21,1
21,1
22,3
22,3
22,3
22,3
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
0.2
0.2
0.2
2.1
2.1
2.1
2.2
2.2
2.2
2
2
2
2.7
2.7
2.7
2.7
4.7
4.7
7.6
7.6
2.2
2.2
2.2
5.3
5.3
5.3
5.3
640
640
640
640
680
680
630
630
630
625
625
625
625
680
680
680
680
705
705
660
660
660
665
665
665
665
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
XFC® Coated
Bare Rod
Wire
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
XFC® Coated
610
610
610
610
610
610
610
610
610
610
610
595
595
595
595
605
605
605
690
690
690
690
680
680
680
670
670
670
670
630
630
630
630
620
620
620
Bare Rod
F Coated
Wire
XFC® Coated
Bare Rod
F Coated
Wire
Bare Rod
F Coated
Wire
XFC® Coated
Bare Rod
F Coated
Wire
XFC® Coated
Bare Rod
F Coated
Wire
White
White
White
White
White
White
White
White
White
White
EcoBraze Silver Alloys with Cadmium
38330 B
38330 F
38330 T
38330 XFC®
38334 B
38334 F
38334 T
38335 B
38335 F
38335 T
38335 XFC®
38340 B
38340 F
38340 T
38340 XFC®
38345 B
38345 F
38345 T
Tel:+43 1 869 45 41
30,4
30,4
30,4
30,4
33,9
33,9
33,9
34,7
34,7
34,7
34,7
39,8
39,8
39,8
39,8
44,3
44,3
44,3
27,2
27,2
27,2
27,2
22,6
22,6
22,6
25,2
25,2
25,2
25,2
19,4
19,4
19,4
19,4
15
15
15
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
Bal.
20.5
20.5
20.5
20.5
19.6
19.6
19.6
18.2
18.2
18.2
18.2
20.5
20.5
20.5
20.5
23.5
23.5
23.5
33
White
White
White
White
White
White
White
White
www.castolin.com
22.10 SELF-FLUXING BRAZING ALLOYS FOR COPPER
Composition in %
Designation
Ag
Cu
Other
Castolin range - Self-Fluxing Copper Alloys
1803D
15
Remainder
1805
2
Remainder
RB 5246
Remainder
RB 5280
2
Remainder
RB 5283
15
Remainder
RB 5286
5
Remainder
Melting Range °C
Solidus
Liquidus
P
5
6,2
7
7
5
6
645
645
715
650
650
650
800
825
805
820
802
810
23.10 AUTOGENOUS WELDING OF CONSTRUCTION STEEL
Composition in %
Product
Ag
Cu
Zn
Cd
Castolin range - Brazing-Brass/Bronze Alloys
146 MF
60
39
146 XFC®
60
39
16 XFC®
1
48,1
Bal.
18
1
57,8
Bal.
18 MF
1
57,8
Bal.
18 XFC®
1
57,8
Bal.
185 XFC®
47,5
Bal.
80 MF
54,2
Bal.
80 XFC®
54,2
Bal.
Castolin range - Fuctional Coatings
CastoDrill 8800
1
47,6
42,6
Si
Others
1
1
1
,5
,5
,5
,5
,3
,3
Melting Range °C
Solidus
Liquidus
885
885
885
879
879
879
890
885
885
905
905
915
895
895
895
915
910
910
885
910
Composition in %
Designation
Ni Fe
Sn
Si
C Co
Cr
W Other WC% Hardness
Castolin range - Wear-Facing Alloys
CastoDur® 901
1,1 1,1
1,1 2,53 Bal. 32.2 12,21
,2
55-57 HRC
CastoDur® 906
2,56
2,68 1,48 1,26 Bal. 29 4,7
,2
43,5 HRC
TeroCote® 7888 T
Bal.
3,1
11
3.2 65% 400-430 Hv
Ultimium® 8811
Bal.
2
,69
12 74% 350-450 Hv
Ultimium 8888
Bal.
3,7
9
5
N.A.
Ultimium 8888 Cutter Bal.
3,7
9
5
N.A.
E 7650
Bal.
30
10
N.A.
Melting Range °C
Solidus Liquidus
1080
1050
1120
1120
24.10 SOLDERING AND LIGHT METAL ALLOYS
Composition in %
Product
Ag
Cu
Zn
Al
Sn
Castolin range - Soldering and Light Metal Alloys
1185 MF
90
9
157
3,5
157 T
3,5
1827
1,6
16,3
190
88
1902
8,5
21 F
Remainder
AluTin 51
31,6
Tel:+43 1 869 45 41
Pb
Si
12
5,3
Bal.
34
Melting Range °C
Solidus
Liquidus
1020
221
221
270
570
443
570
160
1040
221
221
280
580
599
630
240
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2
27.10 FLUXES
Melting Range °C
Product
Solidus
Liquidus
Castolin range - Brass/Bronze Fluxes
16
700
1000
18
700
1000
185 A
700
1000
Castolin range - Light metal fluxes
190
500
700
Castolin range - Other Fluxes
14
700
1000
Castolin range - Silver Alloy Fluxes
1020
450
850
1802 Atmosin
400
780
1802 HF
450
850
1802 PF Atmosin
420
820
181 Atmosin
550
900
181 PF Atmosin
550
900
ActivaTec® 1000
400
800
Albro
400
820
Castolin range - Soft Solder Fluxes
157 NC
150
450
AluTin 51
120
300
Flux Appearance
Residue Properties
Dark Grey Paste
Yellow Paste
Blue Paste
Non-Corrosive
Non-Corrosive
Non-Corrosive
White Powder
Corrosive
Pink Powder
Corrosive
White Powder
White Powder
White Powder
Pink Paste
White Powder
White Paste
White Paste
White Paste
Corrosive
Corrosive
Corrosive
Corrosive
Corrosive
Corrosive
Corrosive
Corrosive
Yellow Paste
Yellow Liquid
Corrosive
Corrosive
28.10 BRAZING AND SOLDERING PASTES
Composition in %
Product
Ag
Cu
Zn
Cd
Other
Al
Castolin range - Brazing-Light Metal Alloy Paste
190 AL
88
Castolin range - Brazing-Soft Solder Alloy Pastes
157 PA
3,5
CastoTin® 1
CastoTin® 2
,2
CastoTin® 3
,5
Castolin range - Cadfree® Silver Alloy Pastes
1800 PA
56,8
21,9
Bal.
Castolin range - Silver Alloy Pastes with Cadmium
1802 PB
40
18,3
Bal.
24,1
CastoSil
40,2
18,7
Bal.
19,9
Tel:+43 1 869 45 41
Si
Sn
Pb
12
50
99,8
39,5
5,3
35
50
60
Melting Range °C
Solidus
Liquidus
570
570
221
183
232
183
221
216
232
238
625
665
595
595
630
630
www.castolin.com
3 POWDERS AND WIRES FOR THERMAL SPRAYING
31 POWDERS FOR THERMAL SPRAYING
31.10 ROTOTEC – ALLOY POWDERS FOR "COLD" SPRAY PROCESS
Tel:+43 1 869 45 41
Designations
Product
Type
Applications
Properties
RotoTec
51000
Alloy
Ni-Al-Mo
Bond coat for RotoTec 19000 and
MetaCeram 28000 powder families,
on all metals except Cu and Mg.
~170 HV10
Fusion reaction during spraying creates
strong bond with substrate
RotoTec
19300
Alloy
Fe-Cr-Ni-Mo
Pieces operating with metal-to-metal
friction such as shafts, bearing surfaces, pistons, etc.
~250 HV10
Machinable with tools. Good coefficient
of friction. Good resistance to corrosion.
RotoTec
19310
Alloy
Fe-Cr-Ni
friction. Wear sleeves for pumps.
~335 HV10
Machinable with tools
(very good machinability by turning).
Good resistance to frictional wear.
RotoTec
19400
Alloy
Fe-Cr-Ni
Protective couplings for shafts, press
pistons, motor casing.
~420 HV10
The best surface finish is obtained
by grinding.
RotoTec
19404
Alloy
Fe-Cr-Co-Mo
friction and corrosion such as bearing
seats, etc. For replacing hard-chrome.
~400 HV10
Excellent combination of corrosion,
wear resistance and low friction.
Machinable with nice surface finish.
RotoTec
19800
Alloy
Cu-Sn-Zn
Guides, slides, journal bearings,
bearings.
~100 HV10
Very good machinability by turning.
Excellent coefficient of friction.
Low sensitivity to residual stress.
RotoTec
19850
Alloy
Cu-Al
Compressor pistons, trunnions
and pulleys.
~120 HV10
Low coefficient of friction.
RotoTec
19868
Alloy
Cu-Al-Ni
Interior coatings of chocks, ram slides, ~150 HV10
foundry models.
Good machinability by turning.
Low coefficient of friction and good pressure resistance. Good corrsion resistance.
RotoTec
19910
Alloy
Ni-Cr-Si-Fe
Bearingseats and wherever a hard
and corrosive resistand layer is
needed.
36
~350 HV10
Machinable with tools.
Excellent coefficient of friction.
www.castolin.com
3
POWDERS
FOR THERMAL SPRAYING
31.10 ROTOTEC – ALLOY POWDERS FOR "COLD" SPRAY PROCESS - CONTINUED
Designations
Product
Type
Applications
Properties
RotoTec
19940
Alloy
Ni-Cr-Fe-Mo
Wear sleeves for pumps, cylinder rods, ~370 HV10
drying cylinders for papermaking.
The best surface finish is obtained by
grinding. Good resistance to friction
under pressure.
RotoTec
19985
Alloy
Ni-Cr-Fe
Bearing seatings, pistons
Used in rebuilding worn parts.
RotoTec
19999
Alloy
Ni-Cr-Fe and
carbides
Drag roll, wear plates, gripping finger. ~250 HV10
50% carbides
High resistance to abrasion.
Rough deposit.
RotoTec LT
29230
Zn base
Sign panels, pylons, gantries, metallic
structures, machine casing, port
equipment, repair of accidental
damage to galvanized structures.
~200 HV10
Zn >99%
Low melting temperature.
Sacrificial layers ensuring cathodic protection of ferrous supports against corrosive
atmospheric phenomena.
31.20 PROXON – ONE-STEP ALLOY POWDERS FOR "COLD" SPRAY PROCESS
Designations
Product
Type
Applications
Properties
ProXon
21021
Alloy
Ni-Al-Mo
Mechanical seats, feathering sides.
Thin and thick anti-wear coatings.
~170 HV10
Used without bonding layer.
The best surface condition is obtained
by grinding.
ProXon
21031
Alloy
Ni-Cr-Al-FeMo
For components subject to wear and
corrosion such as fan blades, shft
sleeves and roller bearing seats
~280 HV10
Thick deposit capability (<3mm).
ProXon
21071
Alloy
Cu-Al
Compressor pistons, trunnions
and pulleys.
~120 HV10
Good machinability. Low coefficient of
friction. Thick deposit capability (<4mm).
Tel:+43 1 869 45 41
37
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31.30 EUTALLOY – SELF-FLUXING POWDERS FOR SPRAYING WITH SIMULTANEOUS FUSION
Designations
Product
Type
Applications
Properties
Eutalloy
10009
Alloy
Ni-Cr-B-Si-Fe
Resurfacing cams, pushers, stops,
guide wheels, filterpress cake stone
remover for sugar mill, decanting
screw, steam gate components.
Coating elements subject to friction.
~63 HRc.
Low friction coefficient. Good resistance
to corrosion, erosion and abrasion under
light load.
Eutalloy
10011
Ni-Cr-B-Si-Fe
alloy and
tungsten
carbide
Coating elements of chains, transport
screw, wiper segments, brick die frames, claw excavators, rock drill, brush
cutter rake, debarking knives
~65 HRc.
80% tungsten carbides
Excellent resistance to abrasion by fine
to coarse sized abrasives
Eutalloy
10112
Ni-Cr-B-Si-Fe
alloy and
tungsten
carbide
Coating of machine parts used in
the transport, handling and processing of minerals: transport screws,
clay mixers, dies, segments, wipers,
turbine impeller, fan impeller, pump
screw, etc.
~64 HRc.
Excellent resistance to erosion and
abrasion by fine to coarse sized abrasives
Eutalloy
10185
Alloy
Ni-B-Si
Coating of cast iron and steel molds
for plastic material and glass.
Recoating shafts, eccentrics, bearings
Soldering tungsten carbide biscuits
on drilling stabilizers, etc.
~390 HV30.
Well suited for metal-to-metal friction.
Excellent corrosion resistance.
Machinable with cutting tool.
Eutalloy
10224
Alloy
Ni-B-Si
Repairing glass mold edges, gear
teeth, exhaust manifolds, pump
bodies, brakes on drawing tools.
Bonding layer before welding with
electrode on cast iron that is difficult
to weld, etc.
~260 HV30.
Appropriate for new or worn cast iron.
Good resistance to corrosion.
Eutalloy
10611
Co-Ni-Cr-BSi alloy and
tungsten
carbide
Resurfacing chemical transport
screws, fan blades at cement works,
augers, and extrusion screws. Blades
and segments of mixers, etc.
~55 HRc
Excellent resistance to abrasion under
pressure and to corrosion.
Eutalloy
10680
Alloy
Ni-B-Si
Repair of gears, cast iron valve seats,
molds, keyways, bearing seating.
Renewing drawing tools Correction of
machining errors, etc.
~240 HV30.
Good resistance to shocks and oxidation
while hot.
Eutalloy
15999
Ni-Cr-B-Si-Fe
alloy and
tungsten
carbide
Coating of molds for ceramics, rasps.
Distributor blades for fertilizer spreaders, cyclone blades, hopper for sand
spreading machines, mouths of baggers, etc.
~65 HRc.
abrasion by fine abrasives.
31.40 EUTALLOY SF – SELF-FLUXING POWDERS FOR SPRAYING WITH SIMULTANEOUS FUSION
Tel:+43 1 869 45 41
Designations
Product
Type
Applications
Properties
Eutalloy SF
15211
Ni-Cr-B-Si-Fe
alloy and
tungsten
carbide
All round powder for anti-abrasion.
~60 HRc
abrasion by fine to coarse sized abrasives.
38
www.castolin.com
3
POWDERS
31.50 EUTALLOY RW – SELF-FLUXING POWDERS FOR SPRAYING WITH SUBSEQUENT FUSION
Designations
Product
Type
Applications
Properties
Eutalloy RW
12112
Ni-Cr-B-Si-Fe
alloy and
tungsten
carbide
Recoating wear pieces of agricultural
machines, mixer blades, ceramic press
feeder plungers.
Resurfacing pump wear sleeves, steel
industry transport rollers.
~710 HV30.
abrasion.
Eutalloy RW
12494
Alloy
Ni-Cr-B-Si-Fe
Coating incineration boiler tubes.
Machine elements in food and
chemistry industry.
~310 HV30
Very good resistance to corrosion.
Suitable for friction under light loads.
Eutalloy RW
12495
Alloy
Ni-Cr-B-Si-Fe
Coating of wear sleeves for pumps,
glassworks feed plunger, valve parts:
seats, flaps, etc.
~390 HV30.
Suited for impact and friction
Eutalloy RW
12496
Alloy
Ni-Cr-B-Si-Fe
Coating cylinder rods, wear sleeves,
pump pistons and faucet parts.
Resurfacing coal dust separators. etc.
~680 HV30.
Very low coefficient of friction and good
abrasion resistance.
Excellent resistance to corrosion and
especially to seawater.
Eutalloy RW
12497
Alloy
Ni-Cr-B-Si-FeMo-Cu
Coating protective couplings, cylinder
rods, wear and seal sleeves, Pelton
turbine injection needle valves, etc.
Coating stainless steel pieces.
~740 HV30
Excellent frictional and corrosion
resistance.
Excellent corrosion resistance.
Eutalloy RW
12999
Ni-Cr-B-Si-Fe
alloy and
tungsten
carbide
Coating fan blades, mixer, transport
screw, tensioning pulleys, guides.
Wear parts for agricultural
equipment, etc
~760 HV30.
Excellent resistance to abrasion.
Eutalloy RW
53606
Alloy
Ni-Cr-Mo-SiB-Cu
Boiler tubes, shaft and sleeves in
waste incineration, chemical, pulp
and paper industries
~600 HV30
Excellent wear and corrosion resistance
to both reducing and oxidizing environments
Eutalloy RW
PE 8040.02
Alloy
Ni-Cr-Si-Fe-B
Plungers and other rotating parts.
~40 HRC
Good resistance against friction and
impact. Excellent corrosion resistance.
31.60 CASTOPLAST – POLYMER POWDERS FOR THERMAL SPRAY PROCESS
Designations
Product
Type
Applications
Properties
CastoPlast
103
Polyamide
Thermoplastic coatings.
Protection of parts that need to
resist urban, rural, marine and
chemical corrosion.
Good resistance to UV.
Good electrical insulation.
Well suited for mechanical rebuilding
even in thick layers.
Stands up well to friction and abrasion
~75 ShD
Breakdown voltage ~30 kV/mm
Max. service temperature 100°C.
Max. peak temperature 140°C
Melting temperature 185°C.
Good resistance to alkaline or saline
solutions and to hydrocarbons and
solvents.
Tel:+43 1 869 45 41
39
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31.70 METACERAM – CERAMIC AND REFRACTORY POWDERS FOR "COLD" THERMAL SPRAY PROCESS
Designations
Product
Type
Applications
Properties
MetaCeram
28010
Cr2O3
On RotoTec 51000 bonding layer.
Cable gland seatings, shaft protector
sleeves, seam ring joint seatings
Plungers, pump shafts, feed chutes.
Microhardness of the particles ~2400 HV10g
Max. service temperature 500 °C.
Product density 5.2 kg/dm
High hardness, excellent resistance
to corro3
sion, low coefficient of friction.
MetaCeram
28020
Al2O3
TiO2(2.2%)
seam ring joint seatings, cable gland
seatings, shaft protector sleeves,
electrical isolation of machine parts,
press rings for making radial tyres,
sifting plate
Product density 4.0 kg/dm .
3
High hardness, excellent resistance
to corrosion.
Good electrical insulation (dependent
on deposit thickness).
MetaCeram
28030
Al2O3
TiO2(13%)
Printer cylinders, paper transport
rollers, thread guide, wear and sliding
plates, induction oven parts.
Product density 4.0 kg/dm.
Good resistance to corrosion and good friction properties.
MetaCeram
28085
ZrO2
CaO (30%)
Combustion chamber thermal insulation parts, crucibles, foundry machine
parts, ladle for steel and iron works,
guide wheels for wire zinc baths,
pyrometer tubes.
Product density 5.4 kg/dm3.
Excellent thermal insulation and stands up to
thermal shocks.
3
Non wetting for liquid metals.
3
31.80 EUTROLOY – ALLOY POWDERS FOR PTA (PLASMA TRANSFERRED ARC) PROCESS
Tel:+43 1 869 45 41
Designations
Product
Type
Applications
Properties
EuTroLoy
16006.04
Alloy
Valve seats, protective shaft sleeves,
Co-Cr-W-Ni-Fe shaft seal surfaces, tools in the wood
(Gr. 6 Type)
and plastic processing industry, stirrer
components, valve parts, extruder
screws, etc.
~40 HRC
High abrasion resistance under pressure
and impact stress (cavitation). Heat and
corrosion resistant. Low coefficient of
sliding metal friction, insensitive to
adhesive wear.
For operating temperatures up to 750 °C.
EuTroLoy
16008.04
Alloy
Co-Cr-Mo-Ni
~28 HRC
Excellent resistance to high-temperature
oxidisation and reducing atmospheres
and to corrosion by organic and mineral
acids.
EuTroLoy
16012.04
Alloy
Co-Cr-W-Ni-Fe Slide valve seats, extruder screws
(Gr. 12 Type)
for plastic masses, feed screws for
sawdust and hydropulpers in the
paper industry, tools in the timber
industry, segments of nose rings and
clinker cooling plates, tools for the
paper, plastics and timber processing
Hot-working tools, forming dies, cutting blades, pump and turbine components, components for large steam
valves, etc.
40
~46 HRC
High abrasion resistance under pressure
and impact stress (cavitation). Heat and
corrosion-resistant. Low coefficient of
sliding metal friction, insensitive to
adhesive wear.
www.castolin.com
3
POWDERS
32 WIRES FOR THERMAL SPRAYING
32.10 EUTRONIC ARC – ALLOY WIRES FOR ARC SPRAYING
Designations
Product
Type
EuTronic
Arc 502
Alloy
Cement cooler plates, boiler water
Fe-Cr-Ti-Si-Mn wall protection, pulp production
digesters, steam turbine casings,
cracking installations, high temperature cyclone, fume extractors etc.
Hardness ~860 HV0.3
Self bonding alloy with enhanced surface
wear resistance properties to combat
erosion, thermal shock up to 650°C
EuTronic
Arc 509
Alloy
Fe-Cr-Al-Mo
Corrosion and erosion resistant protective coatings in boiler equipment
up to 900°C
Hardness ~260 HV0.3
wear resistance properties to combat corrosion, erosion up to 900°C and oxidation
EuTronic
Arc 532
Alloy
Fe-Cr-Mn-C
Alternative to 13%Cr-steel. Hard
chrome replacement on hydraulic
pistons. Wear resistant layers for rollers in paper machines, bearing- and
sealing seats
Hardness ~640 HV0.3
wear resistance properties to combat
metal-to-metal friction, corrosion and
oxidation
EuTronic
Arc 579
Alloy
Worn general engineering compoFe-Ni-Cr-Si-Mn nents, undersize external or internal
diameters, bearing seats and faces,
housings, shrink or force fit areas, flat
surfaces etc. Hot gas corrosion protective coatings in heat exchangers,
process piping, etc.
Hardness ~230 HV0.3
Self bonding alloy for thick or thin
coatings with good corrosion resistance.
Easy machinabillity, like machining solid
mild steel
EuTronic
Arc 595
Alloy
Fe-Cr-B-Si-Mn
Hardness ~1200 HV0.3
Self bonding alloy for thick or thin
coatings with good corrosion resistance.
Tel:+43 1 869 45 41
Applications
Properties
Abrasion, erosion and adhesion resistant protective coatings in pumps,
boiler tubes, water walls and fans.
41
www.castolin.com
4 COMPOSITE WEAR FACING MATERIALS
41 MECATEC – COLD SURFACING TECHNOLOGY POLYMERS
Tel:+43 1 869 45 41
Designations
Applications
Properties
MeCaTeC
Express 100
Cold, ultra-rapid setting paste.
Emergency rebuilding, protecting and repairing
damage or cracks in machine parts such as:
foundry casting defects, cast iron housings,
machine bearing journals, fuel pipes, containers, engine, gear box casings, worn pump housings, etc.
Formulated for applications needing a fast reaction with an application or handling time of 5
minutes. Curing will even occur at temperatures down to +5°C. Can also be easily machined,
drilled or tapped.
Service temperature up to 90 °C
MeCaTeC
101F
Cold, rapid setting fluid for general repairs.
Protecting and repairing damaged machine
parts such as keyways, machine beds, bearing
housings, engine, gearbox casings, cast iron
machine housings, pump and valve parts, etc.
Repairs of deep cracks or to fill narrow cavities
in steel, cast iron, aluminium, bronze and concrete. Can also be easily machined, drilled or
tapped.
MeCaTeC
101P
Cold, rapid setting paste for general repairs.
rebuilding, protecting and repairing damaged
machine parts such as: keyways, machine beds,
bearing houings, engine, gearbox casings, cast
iron machine housings, pump and valve parts, etc.
All-positional patch repairs of cracks or fissures
in steel, cast iron, aluminium, bronze and concrete. Easy to fit machine, drill, tap or sand.
MeCaTeC
102P
Cold, rapid setting paste for anti-corrosion and
anti-abrasion coatings.
Rebuilding, protecting and repairing damaged
or new machine parts such as butterfly valve,
gate valves, pump housings, propellors, hydraulic rams, diaphragms, etc.
All-positional protection against wear by a
variety of corrosive liquids, abrasive media,
slurry erosion and cavitation effects. Can be
precision machined, drilled or tapped whilst
exhibiting exceptional resistance to pressure
and deformation.
MeCaTeC
103F
Cold, rapid setting fluid for anti-abrasion
coatings.
Protecting and repairing damaged or new
machine parts such as mixer blades, hoppers,
vessels, chutes, pump impellors, fan blades,
elbows and conduits.
Brushable in thin layers over large areas or
complex forms. Protection against wear by low
pressure abrasion and erosion. Smooth surface
finish and high electrical insulating properties.
Machinable by grinding.
MeCaTeC
104P
Cold, rapid setting paste for food and beverage
industry.
stainless steel parts used in the food industry
such as shafts, chutes, trays, water vessels,
piping, valve parts, pump parts, etc.
For use in potable water systems. All-positional,
rust free, safe repairs of cracks, fissures or dents
in stainless steel. Can also be easily machined,
drilled or tapped.
MeCaTeC
A5
Cold, rapid setting paste for anti-erosion coatings.
All applications needing thick coatings to resist
wear by abrasion and erosion. Rebuilding,
protecting and repairing damaged machine
parts such as sand pumping equipment, slurry
pumps, screw conveyors, pipe elbows, chutes for
clinker, cement and ash handling pipes, etc.
Protection against wear in severe erosion and
abrasion. The tough, composite matrix is reinforced with ultra resilient Kevlar fibres and a
dense dispersion of hard, wear resistant ceramic phases.
42
www.castolin.com
4
COMPOSITE
WEAR FACING MATERIALS
Designations
Applications
Properties
MeCaTeC
A5HT
Same applications as MeCaTeC A5 but for
increased service temperatures
Similar wear resistant properties as MeCaTeC
A5 but using a special heat resistant composite
matrix suitable for service up to 250°C for a
brief exposure.
MeCaTeC
110F
Cold, rapid setting fluid for anti-impact coatings.
Protecting and repairing damaged parts such
as expansion joints, fluid transport systems, fan
blades, pump parts, vibration dampers, rubber
parts, conveyor belts and chutes, hydraulic installations, etc.
Pourable, durable elastomer resistant to tearing.
Useful for damping machine vibrations, reducing
sound waves and harmful noise levels. Good
electrical insulating properties. To be used with
primer compounds MECATEC Bond M or Bond R.
Service temperature up to 80 °C (dry)
MeCaTeC
110P
Cold, rapid setting paste for anti-impact coatings.
or new machine parts such as conveyor belts,
hydraulic installations, fluid transport systems,
anti-slip surfaces, fan blades, pump parts, vibration dampers, rubber components, etc
All-positional repairs. Elastomer resistant to tearing. Useful for damping machine vibrations,
reducing sound waves and harmful noise levels.
Good electrical insulating properties. To be used
with primer compounds MECATEC Bond M or
Bond R.
Service temperature up to 80 °C (dry)
MeCaTeC
Bond M
Primer fluid for optimum substrate bonding
to metal.
Same applications as MeCaTeC 110F and 110P.
MeCaTeC Bond M is a primer compound used
for optimising the adhesive bonding properties
of MeCaTeC 110F or 110P to Metallic substrates.
MeCaTeC
Bond R
Primer fluid for optimum substrate bonding
to rubber.
Same applications as MeCaTeC 110F and 110P.
MeCaTeC Bond R is a primer compound used
for optimising the adhesive bonding properties
of MeCaTeC 110F or 110P to Rubber substrates.
MECATEC Bond R is additionally used for bonding
to other non-metallic substrates such as already
cured MeCaTeC 110F or 110P coatings, fibreglass
materials, concrete surfaces, wooden parts.
Express 100
101F/P
102P
103F
104P
A5/A5HT
110F/P
90
120
175
175
120
120/250*
50/80**
Abrasion
Cavitation
Corrosion
Erosion
Friction
Impact
Electric Insulation
Emergencies
General repair
Machining
Food and drink
Max. temperature °C
Tel:+43 1 869 45 41
43
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9 CASTODUR DIAMOND PLATES
91 WELD CLADDED PLATES
Designations
Thicknesses Properties
(The thicknesses are shown as follows - thickness of metal base + thickness of protective layer)
CDP 4624
5+3
6+4
8+5
10 + 5
15 + 5
Weld cladded wear plate for abrasion and erosion resistance. This is a chromium carbide alloy wearplate, ideal for applications, where the right balance between price
and service life is required.
Hardness: 57 - 60 HRC
Carbide content: > 30%
Standard plate dimensions: 1500 x 3000mm
Surface coating: 1220 x 2740mm (3.34m²).
CDP 4666
5+3
6+4
8+5
10 + 5
15 + 5
Weld cladded wear plate for extreme abrasion and erosion resistance. This is the real
high load resistant wearplate with a unique overlay and a complex carbide structure
with high density of hard particles.
CDP 4666
XuperWave
5+3
6+4
8+5
10 + 5
15 + 5
30% increased wear resistance with XuperWave geometry. XuperWave bed and crack
morphology provide nonparallel geometry to wear flow direction. Weld cladded
wear plate for extreme abrasion and erosion resistance.
On request
Designations
Thicknesses Properties
CDP 3952
6+4
8+5
10 + 5
Weld cladded wear plate for hot abrasion and erosion. Especially designed for extra
fine erosive / abrasive medias and critical applications, where every additional day
in service is critical. Maximum service temperature is 700°C.
CDP 4623i
8+5
10 + 5
15 + 5
Weld cladded wear plate especially for the combined wear of abrasion and impact.
Standard support plates in unalloyed S235 type steel. Standard cutting techniques - e.g. plasma arc, water jets or
laser - may be applied. Castolin offers a comprehensive range of solutions for virtually all wear-intensive fields of
heavy industry in the form of CDP plates and CastoTubes.
On request there are also different types of support plates and special thicknesses of metal base and protective
layer.
Tel:+43 1 869 45 41
44
www.castolin.com
9
CASTODUR DIAMOND
PLATES
92 POWDER COATED PLATES
Designations Thicknesses Properties
CDP 496
4+2
Powder coated wear plate to combat erosion. The Ni Cr B Si alloy deposit offers
excellent resistance to wear by metal-to-metal friction, erosion and a wide range of
corrosive conditions.
Hardness: 55 HRC
CDP 112
2+1
4+2
Powder coated wear plate for extreme abrasion and erosion resistance. The deposit
consists of a wear resistant Ni Cr B Si matrix and additions of fine dispersed tungsten carbides.
Matrix hardness: 55 HRC
Carbide hardness: > 1.700 HV0.03
Carbid content: 35%
93 CASTOTUBES
Designations
Properties
CastoTubes
Applied internal coating thicknesses are typically 3.0 - 4.5mm. The TeroMatec 4666 wearfacing
alloy contains multiple hard phases which resist abrasion and erosion up to 500°C. Tubes with
inner diameter from 82 up to 277mm, a maximum length of 3m and different wall thicknesses
are available. CastoTubes are available with slip-on or integral flanges in accordance with DIN
standards.
TECHNICAL NOTE
Applications
All activities where wear by abrasion is a major problem and the operation costs and work stoppages caused by
this type of wear must be reduced.
Engineering
Castolin Eutectic manufactures complete finished solutions ready for immediate installation in accordance with
your engineering specifications and to suit your individual requirements. Even sophisticated designs can be realised with CDP and CastoTubes
Installation
By welding the metal base side which has good weldability with EutecTrode 6666 or 640, EnDOtec DO*02,
CastoMag 45250 or 45554 S.
Tel:+43 1 869 45 41
45
www.castolin.com
9 CASTODUR DIAMOND PLATES
CERTIFICATION:
THE ASSURANCE OF WELDING QUALITY
THESE DAYS INDUSTRY MANAGERS ATTRIBUTE MORE AND MORE IMPORTANCE TO THE QUALITY OF WELDED JOINTS AND RESPECTING PROCEDURES.
BUSINESSES THEREFORE NEED TO PROVIDE PROOF THAT THE PRESCRIBED WELDING PARAMETERS HAVE BEEN FOLLOWED AND CERTIFICATION IS ONE
OF THE SIMPLE WAYS TO DO THIS.
WHO NEEDS CERTIFICATION?
Everyone who:
• Works with Q.A. (ISO 9000)
• Must follow procedures for welding
• Has to apply the European standard EN 729-2 (Welding Quality Requirements/Level 2: Total Quality)
• Wants to confirm the good condition and accuracy of the measurement and display devices integrated in their welding equipment.
• Needs a certificate to attest that their welding equipment is perfectly operational.
THE STRONG POINTS OF THE CASTOLIN SOLUTION
• Castolin uses a mobile load bench to make the measurements, which ensures much more precise
values than by using manual welders.
• Castolin, with its knowledge of welding and technology developments in this domain, avoids risk
causing errors when handling the machines and interpreting the results.
• Castolin services include verification and not just certification. We in fact certify the units to be good or bad,
compared with the established or required standards, so that the client knows exactly where they
stand.
• The Castolin services include, if the measurement devices are not within the tolerances, and if it is
possible, the adjustment of the devices to restablish the prescribed tolerances.
• The Castolin services can also be extended to include, during the same visit, preventive maintenance
of the equipment. This way the client can have a machine that is fully checked and maintained.
• With the readings, Castolin provides a graphic representation of the deviances making it possible to
see accurately and quickly whether the verified instruments are within the margins.
• The contract that Castolin offers, for a modest fee, liberates clients from the administrative constraints
and follow-up of maintenance programs.
Tel:+43 1 869 45 41
46
www.castolin.com
9
VARIOUS WELDING
ACCESSORIES
TECHNICAL DATA REFERENCES
Stronger, with
Castolin Eutectic
WEAR & FUSION TECHNOLOGY
Tel:+43 1 869 45 41
47
www.castolin.com
EUROPEAN STANDARDS FOR STEEL
EXAMPLES OF DESIGNATIONS
SYMBOLIC
NUMERIC
DESIGNATION
DESIGNATION
NF A 35-501
SYMBOLIC
NUMERIC
DESIGNATION
DESIGNATION
NF A 35-501
S 275 J2G3
S 355 JO
S 355 K2G3
E 295
E 355
E 360
1.0144
1.0553
1.0595
1.0050
1.0060
1.0070
E28-4
E36-3
E36-4
A50-2
A60-2
A70-2
C45E
C50E
C55E
C60E
1.1191
1.1206
1.1203
1.1221
XC 48
XC 50
XC 55
XC 60
S420ML
S460M
S460ML
1.8836
1.8827
1.8838
E420FP
E460R
E460FP
A510AP
A510AP
A510FP1
P460N
P460NH
P460NL1
1.8905
1.8935
1.8915
A555AP
A550AP
A550FP1
A37CP
A42CP
A48CP
A52CP
16MO3
13CRMO4-5
10CRMO9-10
1.5415
1.7335
1.7380
15D3
15CD4-05
10CD9-10
S500MC
S550MC
S700MC
1.0984
1.0986
1.8974
E490D
E560D
E690D
S355J2WP
S355JOW
S355K2G1W
1.8946
1.8959
1.8966
E36WA4
E36WB3
E36WB4
GENERAL PURPOSE CONSTRUCTION STEEL PER EN 10027
S 185
S 235 JRG1
S 235 JRG2
S 235 JO
S 235 J2G3
S 275 JR
S 275 JO
1.0035
1.0036
1.0038
1.0114
1.0116
1.0044
1.0143
A33
E24-2
E24-2 NE
E24-3
E24-4
E28-2
E28-3
UNALLOYED STEEL FOR QUENCHING AND TEMPERING PER EN 10083-1
C22E
C25E
C30E
C35E
C40E
1.1151
1.1153
1.1178
1.1181
1.1186
XC 16
XC 25
XC 32
XC 38
XC 42
FINE-GRAINED WELDABLE CONSTRUCTION STEEL PER EN 10113-3
S355M
S355ML
S420ML
1.8823
1.8834
1.8834
E355R
E355FP
E420R
FINE-GRAINED STEEL FOR PRESSURE VESSELS PER EN 10028-3
P355N
P355NH
P355NL1
1.0562
1.0565
1.0566
STEEL FOR BOILERS PER EN 10028-2
P235GH
P265GH
P295GH
P355GH
1.0345
1.0425
1.0481
1.0473
HIGH YIELD STRENGTH STEEL FOR COLD FORMING PER EN 10149-2
S315MC
S355MC
S420MC
1.0972
1.0976
1.0980
E315D
E355D
E420D
STEEL RESISTANT TO ATMOSPHERIC CORROSION PER EN 10155
S235JOW
S235J2W
S355JOWP
Tel:+43 1 869 45 41
1.8958
1.8961
1.8945
E24W3
E24W4
E36WA3
48
www.castolin.com
10
TECHNICAL DATA
REFERENCES
EN 10027-1
EN 10027-2
NF A
AISI
STAINLESS STEELS PER EN 10027-1 AND EN 10027-2
X12CRMNNIN 17.7.5
1.4372
Z 12 CMN 17.07 AZ
201
X12CRMNNIN 18.9.5
1.4310
Z 11 CN 18.8
301
X9CRNI 18.8
1.4305
Z 8 CNF 18.09
303
X9CRNI 18.9
1.4303
Z 5 CN 18.11 FF
305
X4CRNI 18.12
1.4567
Z 3 CNU 18.10
XM 5/18.9 LW
X3CRNICU 18.9.4
1.4301
Z 7 CN 18.09
304
X4CRNI 18.10
1.4307
Z 3 CN 19.11
304 L
X2CRNI 18.9
1.4306
Z 3 CN 18.10
304 L
X2CRNI 19.11
1.4311
Z 3 CN 18.10 AZ
304 LN
X2CRNIN 18.10
1.4335
Z 8 CN 25.20
310 S
X10CRNI 25.21
1.4381
Z 1 CNS 17.15
18.15
X1CRNISI 18.15.4
1.4401
Z 7 CND 17.11.02
316
X4CRNIMO 17.12.2
1.4438
Z 7 CND 17.12.02
316
X4CRNIMO 17.13.3
1.4404
Z 3 CND 17.12.02
316 L
X2CRNIMO 17.12.2
1.4432
Z 3 CND 17.13.03
316 L
X2CRNIMO 17.12.3
1.4429
Z 3 CND 17.11 AZ
316 LN
X2CRNIMON 17.11.2
1.4571
Z 6 CNDT 17.12
316 TI
X2CRNIMON 17.13.3
1.4580
Z 6 CNDNB 17.12
316 CB
X6CRNIMOTI 17.12.2
1.4438
Z 3 CND 19.15.04
317 L
X6CRNIMONB 17.12.2
1.4541
Z 6 CNT 18.10
321
X2CRNIMO 18.15.04
1.4550
Z 6 CNNB 18.10
347
X6CRNITI 18.10
1.4439
Z 3 CND 18.14.05 AZ
317 L4
X6CRNINB 18.10
1.4434
Z 3 CND 19.14 AZ
317 LN
X2CRNIMON 17.13.5
1.4468
Z 2 CND 25.22 AZ
310 MOLN
X2CRNIMON 17.12.3
1.4539
Z 2 NCDU 25.20
904 L
X1CRNIMON 25.22.2
1.4537
Z 2 NCDU 25.25.05 AZ
URSB8
Tel:+43 1 869 45 41
49
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PRINCIPAL GRADES OF ALUMINUM
ALUMINIUM
AND ALLOYS
SERIES
ALUMINIUM ALLOYS PER NFA 02.104 AND NFA 02.004
ALUMINUM, PURITY > 99,00%
1000
NFA 02.004
1050 A
1070 A
1080
1100
1199
1200
A5
A7
A8
A45
A9
A4
ALUMINUM COPPER ALLOYS
2000
2011
2014
2017A
2024
2030
2117
2618A
A-U5 PB BI
A-U4SG
A-U4G
A-U4G1
A-U4PB
A-U2 G
A-U2GN
ALUMINUM MANGANESE ALLOYS
3000
3002
3003
3004
3005
3105
A-M1
A-M1G
A-MG 0,5
-
ALUMINUM SILICON ALLOYS
4000
4145
4006
4145
4043
4047
AS1
AS1FE
AS4
AS5
AS12
ALLOYS
5000
5005
5052
5056A
5083
5086
5150
5251
5454
5754
A-G 0,6
A-G5M
A-G4MC
A85-GT
A-G2M
A-G3M
ALLOYS
ALUMINUM-ZINC-MAGNESIUM
6000
6005A
6060
6061
6081
6082
6106
A-GS
A-SGM 0,3
A-SGM 0,7
-
ALLIAGES
ALUMINIUM-ZINC-MAGNÉSIUM
7000
7010
7020
7049A
7050
7075
A-Z5G
A-Z8GU
A-Z5GU
ALUMINUM-MAGNESIUM-SILICON
Tel:+43 1 869 45 41
NFA 02.104
50
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10
TECHNICAL DATA
REFERENCES
MECHANICAL TESTING
THESE SYMBOLS ARE USED:
IMPACT STRENGTH K
TENSILE STRENGTH RM
YIELD STRENGTH AT
0.2% Rp0.2
ELONGATION A5
HARDNESS H
THE IMPACT STRENGTH AND ELONGATION INDICATE THE DUCTILITY.
THESE VALUES ALWAYS CHANGE IN THE SAME SENSE.
(IF K DECREASES, A5 ALSO DECREASES).
K
RM
THE TENSILE STRENGTH , THE YIELD STRENGTH AND THE HARDNESS
INDICATE THE TOUGHNESS. THESE VALUES ALWAYS CHANGE IN THE SAME
SENSE.
(IF RM INCREASES, RP AND H ALSO INCREASE.)
Rp02
H
A
IMPACT TESTING (K)
DEFINITION :
The impact strength of a material is measured using an impact testing machine (Charpy or Izod)
allowing an assessment of the property of brittleness.
UF RESILIENCE:
Unified French bar (KCU) Standardized test specimen whose notch is U shaped.
V RESILIENCE:
Bar using the Charpy test (KCV). Standardized test specimen whose notch is V shaped.
Measure
Property
Former
Units
New
Units
Conversion
KCU
Kgf/cm2
J/cm2
1J/cm2= 0,0102 Kgf/cm2
KCV
Kgf/cm2
J/cm2
1J/cm2= 0,0102 Kgf/cm2
TENSILE TESTING
Test method
The test involves subjecting a test specimen to a tensile force until it breaks in order to determine the metal’s
mechanical properties.
Subject to an increasing tensile force, the test specimen stretches uniformly up to a certain characteristic value.
This value where the applied load remains stationary is the elastic limit or yield point for steels .
If the load is removed, the test specimen returns approximately to its original length. If the load continues to
increase, the stretching increases and becomes permanent, followed by breakage – this is the Ulimate Tensile
Strength.
With this test, it is possible to define three mechanical properties:
Rm(Mpa)=
F(N)
S(mm2)
Rpo,2 (Mpa)=
F’(N)
S(mm2)
• Tensile strength (Rm)
The property indicates a material’s resistance to breaking.
• Yield strength (Rp)
This property indicates a material’s capacity to stretch or
deform elastically.
• Elongation A5
This property indicates a material’s capacity to stretch or deform plastically.
It is the value of the elongation in percent, measured after the rupture of a
tensile test specimen.
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MECHANICAL TESTING
Hardness testing (H)
The hardness of a material is assessed by the resistance that it offers to the penetration of a hard body.
Hardness can be related to the material’s tensile strength (Rm).
Brinell test (HB): Indenter is a hard steel ball.
Rockwell test (HR): Indenter is a hard ball (HRB) or diamond cone (HRC)
Vickers hardness test (HV): Indenter is a diamond pyramid with a conical base
Shore hardness test (SK): Indenter is a steel point.
In the following comparison table, the hardness values are only approximate averages. No mathematical data can
make an absolute conversion possible. Therefore be careful to avoid erroneous conversions between these different hardness testing methods.
KG/MM2
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
62
65
67
69
71
74
76,5
79
82
84,5
87
88
89,5
90
92
94,5
97
99
100
102
103
104
105
107
108
110
111
Tel:+43 1 869 45 41
HB
84,6
90,3
95,5
101
107
113
118
124
129
135
141
146
152
158
163
169
174
183
188
194
199
208
215
223
231
237
245
248
252
253
259
267
274
278
282
287
290
293
295
300
304
309
313
HV
173
178
187
192
197
203
210
218
225
233
239
247
249
253
254
260
267
274
279
282
287
290
293
295
300
303
309
312
HRB
53
58
63
66
69
71,5
73,5
75,5
77,5
79,5
81
83
84,5
86
87,5
89,5
91
92
93,5
95,5
96,5
98
99,5
100,5
102
HRC
15,5
17,5
19
21
SHORE
30
31
32
33
34
35
36
37
38
39
24
40
103
104
104,8
105,8
25
26
27
28
29
41
42
43
44
107,3
107,5
30
45
31
108
46
32
108,9
47
33
109,5
48
KG/MM2
113
114
116
117
119
120
123
126
129
130
132
134
136
139
141
143
145
148
150
152
154
156
158
161
164
168
171
173
176
178
180
183
185
187
189
191
193
195
197
200
206
211
222
52
HB
319
321
327
329
335
339
345
354
363
385
390
398
401
409
415
420
426
432
438
444
448
454
457
464
470
481
488
492
499
503
507
514
518
522
526
530
534
538
543
547
560
569
587
HV
318
320
325
327
333
337
343
352
361
404
410
418
424
431
437
443
450
457
463
470
474
482
486
494
502
515
524
529
538
543
548
558
564
570
575
581
587
593
599
606
626
640
671
HRB
HRC
34
110
SHORE
49
35
110,5
50
36
111
111,6
112
114,4
37
38
38,5
41
51
52
53
54
57
42
58
43
115
60
44
45
62
46
63
47
48
65
66
49
68
50
69
70
51
71
72
52
73
74
53
75
54
55
57
76
78
79
81,5
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10
TECHNICAL DATA
REFERENCES
PREHEATING STEELS
PREHEATING IS A FUNCTION OF THE STEEL’S CARBON CONTENT AND THE SECTION THICKNESS.
WE RECOMMEND FOR A CARBON EQUIVALENT:
• UP TO 0.25%: PREHEATING IS UNNECESSARY.
• BETWEEN 0.25 AND 0.40%: PREHEAT TO 100 – 200°C.
• BETWEEN 0.45 AND 0.80%: PREHEAT TO 200 – 350°C.
Never preheat steel with 12 – 14% manganese During welding make sure that the part’s temperature does not
exceed 250°C. For tempered steel, follow the supplier’s recommendations for the preheating temperature which
could be between 200 and 500°C.
TYPE OF STEEL
CURRENT
DESIGNATION
CARBON CONTENT
RECOMMENDED
PREHEAT
TEMPERATURE
XC 18
XC 25
XC 32
XC 38
XC 42
XC 48
XC 80
0,15 – 0,20
0,20 – 0,30
0,30 – 0,35
0,35 – 0,40
0,40 – 0,45
0,45 – 0,50
0,75 – 0,85
< 100°C
100 – 150°C
150 – 250°C
150 – 300°C
150 – 350°C
200 – 400°C
300 – 400°C
15 D 3
20 D 5 - M
0,10 – 0,20
0,20 – 0,30
0,30 – 0,35
150 – 250°C
200 – 320°C
250 – 450°C
30 M 7
40 M 7
45 M 7
Z 120 M 12
< 0,30
< 0,44
< 0,50
1,5
210 – 320°C
260 – 430°C
320 – 480°C
100 C 6
Z 12 C 13
Z 8 C 17
(AISI 430)
Z 10 C 24
(AISI 446)
0,95 – 1,10
< 0,10
< 0,10
200 – 800°C
200 – 400°C
200 – 400°C
< 0,10
200 – 400°C
STEEL WITH CHROMIUM,
MOLYBDENUM
25 CD 4
42 CD 4
30 CD 12
0,20 – 0,30
0,30 – 0,45
0,28 – 0,35
200 – 300°C
250 – 350°C
300 – 400°C
STEEL WITH NICKEL, CHROME
10 CN 6
20 NC 6
35 NC 6
30 NC 11
< 0,12
< 0,20
< 0,40
< 0,35
200 – 300°C
250 – 350 °C
300 – 400°C
400 – 500°C
20 NC D 2
40 NC D 3
35 NC D 16
0,17 – 0,23
0,36 – 0,43
0,30 – 0,37
200 – 300°C
350 – 400°C
400 – 600°C
UNALLOYED STEEL
STEELS ALLOYED WITH
MOLYBDENUM
STEEL WITH MANGANESE
STEEL WITH CHROMIUM
STEEL WITH NICKEL,
CHROMIUM, MOLYBDENUM
STAINLESS STEEL
Z 6 CN 18
– 10
Z 6 CND
18- 12
Z 6 CN 25
-20
NOT RECOMMENDED
GENERALLY
GENERALLY
THE CARBON
PREHEATING IS NOT
CONTENT VARIES
NECESSARY
FROM 0.03 TO
0.08
NOTE :
The preheating temperatures shown in this table have been defined as a function of the carbon content.
It should be emphasized that the preheating temperatures do not take into account additional elements, the section
thickness, or the location of the weld.
The use of highly alloyed CASTOLIN welding products with superior mechanical properties makes it possible to safely
lower these preheating temperatures, even eliminating them in certain situations.
For example, for a 35NCD15 steel, welding with a conventional electrode requires preheating to 400 - 600°C, whereas
using the 2222 electrode allows preheating to only 250 - 300°C.
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THEORETICAL VOLUME AND WEIGHT OF METAL
(to fill a one-meter chamfer in flat position)
V Joints
Interior Angle
Exterior Angle
90°
60°
90°
a
S
e
s
mm
4
5
6
7
s
cm3/m
e
mm
a
mm
1
1
1
2
2,5
3
3,5
6
8,5
12,5
16
4
4,5
5
5,5
6
6,5
7
7,5
8
9
10
11
12
13
14
15
21
26
31,5
37
42
49,5
57
65
73,5
94
114
138
163
190
224
248
8
9
10
11
12
14
15
16
18
20
25
s
mm
cm3/m
Kg/m
0,05
0,07
0,10
0,13
2
3
4
5
3
7
9
13,5
0,02
0,05
0,07
0,11
0,16
0,20
0,25
0,29
0,33
0,39
0,45
0,51
0,58
0,67
0,89
1,08
1,28
1,49
1,76
1,95
6
7
8
9
10
11
12
15
18
20
22
25
19,5
26,5
34,5
43
53,5
67
79
123
174
206
225
331
0,15
0,21
0,27
0,34
0,42
0,53
0,62
0,97
1,37
1,62
2,00
2,60
Kg/m
BASIS OF CALCULATION: volume to be deposited times density.
average density used for the preceding data: 8kg/dm3.
the values are only approximate; the exact quantities depend on several factors (shape of the bead, gap between
the plates, metal recovery, etc.).
FOR ALUMINUM AND ALUMINUM ALLOYS:
FOR MAGNESIUM AND MAGNESIUM ALLOYS:
FOR ELECTRODES:
Tel:+43 1 869 45 41
Divide the resulting values by 3.
Divide the resulting values by 4.5.
Multiply the resulting values by 1.2.
54
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10
TECHNICAL DATA
REFERENCES
PRINCIPAL METALS
METAL
CHEMICAL SYMBOL
MELTING POINT (°C)
DENSITY (KG/DM3)
IRON
Fe
1535
7,8
COPPER
CU
1083
8,5 – 8,9
ALUMINUM
AL
658
2,7
MAGNESIUM
Mg
650
1,85
LEAD
Pb
327
11,4
ZINC
Zn
420
8,9
TIN
Sn
232
7,3
CADMIUM
Cd
321
8,6
NICKEL
Ni
1452
8,9
CHROMIUM
Cr
1800
7,1
TUNGSTEN
W
3400
19,1
VANADIUM
V
1720
6,0
MOLYBDENUM
Mo
2622
10,2
MANGANESE
Mn
1242
7,3
COBALT
Co
1495
8,9
TITANIUM
Ti
1800
4,5
SILVER
Ag
961
10,5
STEEL
Fe + C
1400-1500
7,8
TYPE 304 L STAINLESS STEEL
Fe+C+Cr+Ni
1450 env.
8,03
TYPE 316 STAINLESS STEEL
Fe+C+Cr+Ni+Mo
1420 env.
7,92
TYPE 310 STAINLESS STEEL
Fe+C+Cr+NI
1450 env.
8,03
CAST IRON
Fe+C
1130-1400
7,2 – 7,8
BRASS
CU+ZN
900 env.
8,5
BRONZE
CU+SN
900 env.
8,5 – 8,9
MONEL
NI+CU
1300-1350
8,5 – 9,0
NICKEL SILVER
CU+ZN+NI
900-1100
8,5 – 9,0
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ASSEMBLY AND REPAIR OF THE PRINCIPAL METALS
NOTE :
THE FOLLOWING TABLES ONLY SHOW SOME POSSIBILITIES AND THE PRODUCTS / PROCESS ARE NOT ARRANGED IN ORDER OF PREFERENCE.
(THE FINAL CHOICE OF THE PROCESS OPTIONS AND ALLOY IN FACT DEPENDS ON FACTORS LIKE STRESS ON THE PARTS, DIMENSIONS, AVAILABLE
FACILITIES, ETC.) THEIR CHOICE DOES NOT PRECLUDE TAKING INTO CONSIDERATION APPLICATION TECHNIQUES AND PROCEDURES TO BE FOLLOWED.
IN SOME CASES, CONTACT WITH CASTOLIN TECHNICAL SERVICES WILL BE NECESSARY.
ASSEMBLY AND REPAIR OF CAST IRON
Grades and Standards
Process options
Most Commonly
Used Alloys
Uses and Types of Parts
GREY CAST IRON
NFA 32101
NFA 32102
Ft 10
Ft 15
Ft 20
Ft 25
Ft 30
Ft 35
Ft 40
Homogeneous welding
CASTOLIN 14 F
Thin or heavy castings
Current cast iron applications.
Soldering
CASTOLIN 157
CASTOLIN 197
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN 1030 XFC
CASTOLIN 16 XFC
CASTOLIN 18 XFC
PEARLITIC MALLEABLE
IRON
A 32703
MP 50.5 – MP 60.3
MP 70.2
FERRITIC MALLEABLE CAST IRON
Silver brazing
Brazing
EUTALLOY process
EUTALLOY 10224
Manual arc process
EUTECTRODE 223
EUTECTRODE 224
EUTECTRODE 2.44 NC
EUTECTRODE XHD 2230
EUTECTRODE 2240
EUTECTRODE XHD 2480
Brazing
CASTOLIN 16 XFC
Manual arc process
EUTECTRODE 223
EUTECTRODE XHD 2230
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN 1030 XFC
CASTOLIN 1702
CASTOLIN 16 XFC
CASTOLIN 18 XFC
EUTECTRODE 223
EUTECTRODE 224
EUTECTRODE XHD 2230
EUTECTRODE 2240
EUTECTRODE XHD 2480
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN1030 XFC
CASTOLIN 1702
CASTOLIN 16 XFC
EUTECTRODE 223
EUTECTRODE 224
CEUTECTRODE XHD 2230
EUTECTRODE 2240
EUTECTRODE XHD 2480
EUTECTRODE XHD 2230
EUTECTRODE 2240
EUTECTRODE XHD 2480
WITH WHITE CORE
NF 32701
MB 40.10
MB 35.7
Silver Brazing
Brazing
Manual arc process
FERRITIC MALLEABLE CAST IRON
WITH BLACK CORE
NF 32702
NN 35.10
NN 32.8
NN38.18
Silver Brazing
UNALLOYED IRON
Manual arc process
Brazing
Manual arc process
WITH SPHEROIDAL GRAPHITE
NFA 32201
FGS 800.2
FGS 700.2
FGS 600.3
FGS 500.7
FGS 400.12
FGS 370.17
Machine casing, frames,
Engine blocks,
Faucets, valves,
Pressing dies
Clutch forks,
Manipulator fingers,
Levers
Joints,
Branches,
Hubs
Parts of all complex shapes,
difficult to forge.
Cam shafts,
Crankshafts,
Disk brakes,
Cylinders,
Jaws, pump body,
Pinions,
Gears.
Alloy cast iron alloys are not list in these tables. Nickel, chromium, molybdenum, and silicon sometimes present in
these types of cast iron give them specific mechanical properties and structures. They are used in the domains of
wear by abrasion, corrosion and heat.
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10
TECHNICAL DATA
REFERENCES
ASSEMBLY AND REPAIR OF STEEL
Process options
Most Commonly
Used Alloys
Uses and Types
of Parts
E 24 (A 37)
E 26 (A 42)
Silver Brazing
CASTOLIN 1030 F
CASTOLIN XUPER 1802
CASTOLIN 16 XFC
CASTOLIN 18 XFC
EUTECTRODE 640
EUTECTRODE XHD 646
EUTECTRODE Xuper 680 S
EUTECTRODE 690
EUTECTRODE 3218
EUTECTRODE 4257
EUTECTRODE 6464
EUTECTRODE 66*66 N
EUTECTRODE XHD 6868
CASTOMIG 45250
CASTOMIG 45251
CASTOMIG 45554
CASTOMIG 45513
ENDOTEC DO*02
TeroMatec 3302
CASTOLIN 1030 F
CASTOLIN1030 XFC
CASTOLIN 1702
Construction métallique
Brazing
E 30 (A 47)
E 36 (A 52)
Manual arc process
A 50
A 60
A 70
E 355
E 375
E 420
E 460
MAG process
MIG process
XC 25
XC 38
XC 42
XC48
XC 42 TS
38 CD 4 - 18 CD 4
25 CD 4 - 35 CD 4
42 CD 4 - 30 DC 12
50 CV 4 - 20 NC 6
30 NC 11
18 NCD 6
19 NCD 32
Z 120 M 12
16 NC D 13
Open arc process
Silver Brazing
Brazing
Manual arc process
Manual arc process
Open arc process
MAG process
MIG process
20 NCD 2
50 CV 4
40 NCD 3 – 35 CD 4
42 CD 4 – 55 S 7
45 SCD 6
Brazing
Manual arc process
100 C 6
Z 200 C 12
Z 160 CDV 5
Z 100 CDV 5
45 CDV 6 – 40 NCD 16
35 NCD 16 – Z 35 CDV 5
55 NCDV 7
Manual arc process
Tel:+43 1 869 45 41
TIG process
CASTOLIN 16 XFC
EUTECTRODE XHD 646
EUTECTRODE 690
EUTECTRODE 66*66 N
EUTECTRODE XHD 6865
EUTECTRODE 2222
EUTECTRODE XHD 646
EUTECTRODE 690
EUTECTRODE XHD 6865
EUTECTRODE 2222
TeroMatec 3302
CASTOMIG 45250
CASTOMIG 45251
CASTOMIG 45554
CASTOMIG 45513
CASTOLIN 16 XFC
EUTECTRODE 690
EUTECTRODE XHD 6865
EUTECTRODE 2222
EUTECTRODE XHD 6868
EUTECTRODE 690
EUTECTRODE XHD 6865
EUTECTRODE 2222
EUTECTRODE XHD 6868
CASTOTiG 45507 W
CASTOTiG 45612 W
57
Traveling crane
Storage tanks,
Sheet metal works,
Piping,
Exchangers,
Coolers, silos,
Platforms, mobile structures
for railway material.
Machine frames
Mechanically welded
General mechanics,
Connecting rods, shafts, spindles
Racks, piston rods
Clutch forks,
Coupling jaws,
Lifting shafts,
Coupling hooks,
Crankshafts,
Differential cases,
Drive train components
Public works,
Mines,
Cement works,
Wearing plates,
Quarry materials
Public works machinery,
Oven hoop,
Crusher.
Agricultural machine parts,
Torque shafts,
Gear boxes,
Coupling hooks.
Cold cutting,
forging, stamping tools,
Tools for casting aluminum
and copper alloys under
pressure.
www.castolin.com
ASSEMBLY AND REPAIR OF THE PRINCIPAL METALS
ASSEMBLY AND REPAIR OF STEEL
Process options
Most Commonly
Used Alloys
Uses and Types
of Parts
Z 12 C 13
Z 30 C 13
Z 12 C 13 M
Z 12 CN 13 02 M
Z 6 CN 17 04 M
Silver Brazing
CASTOLIN 1702
CASTOLIN RB 3217
EUTECTRODE 2222
EUTECTRODE XHD 6865
CASTOMIG 45002
CASTOMIG 45554
CASTOMIG 45513
ENDOTEC DO*02
CASTOTiG 45507 W
CASTOTiG 45612 W
CASTOTiG 45513 W
CASTOLIN 157
CASTOLIN 1702
CASTINOX 1610 S
EUTECTRODE 33500
CASTOTiG 45500 W
CASTOTiG 45513 W
CASTOTiG 45612 W
CASTOLIN 157
CASTOLIN 1030 F
CASTOLIN1030 XFC
CASTOLIN 1702
CASTOLIN 1020 F
CASTOLIN 1020 XFC
CASTOLIN 1702
EUTECTRODE 690
CASTOTiG 45507 W
CASTOTiG 45513 W
EUTECTRODE 33300
EUTECTRODE 33226
EUTECTRODE 33273
EUTECTRODE E 310- 17
EUTECTRODE 2222
CASTOMIG 45513
CASTOMIG 45612
CASTOTiG 45513 W
CASTOTiG 45612 W
CASTOLIN 157
CASTOLIN 1020 F
CASTOLIN 1020 XFC
CASTOLIN 1702
CASTINOX 1610 S
EUTECTRODE Xuper
1616
EUTECTRODE 33500
CASTOMIG 45500
CASTOMIG 45612
CASTOTiG 45500 W
CASTOTiG 45612 W
EUTECTRODE 33300
EUTECTRODE 33273
EUTECTRODE 6825
CASTOMIG 45513
CASTOMIG 45612
CASTOMIG 45654
CASTOTiG 45513 W
Pump parts,
Surgical instruments
Hydraulic turbines,
Gates,
Rotors,
Molds for plastics.
Manual arc process
MIG process
TIG process
Z 8 C 15
Z 10 C 17
Soldering
Silver Brazing
Manual arc process
TIG process
Z 2 CN 18.10
Z 6 CN 18.09
Soldering
Silver Brazing
Z 8 CN 20.11
Z 15 CN 24.13
Silver Brazing
Manual arc process
TIG process
Z 12 CN 25.20
Z 12 CNS 25.20
Z 8 CN 25.20 M
Manual arc process
MIG process
TIG process
Z 2 CND 17.13
Z 6 CND 17.12
Z2 CND 19.15
Z 6 CNT 18.10
Z 6 CNNb 18.10
Soldering
Silver Brazing
Manual arc process
MIG process
TIG process
Z 2 CNNb 25.20
Z 5 CNDU 21.08
Manual arc process
MIG process
TIG process
Tel:+43 1 869 45 41
58
Metallic constructions,
Decorative tubes,
Furniture, flatware, hub caps
Boilermaking,
Valves and fittings
Heat exchanger,
Pressure equipment,
Pipe works, storage containers.
Mechanical parts,
Fan blades
Fins, pumps, turbines.
Covering oven tunnels,
Thermal treatment baskets
and grills,
Molded parts.
Boilermaking,
Heat exchanger,
Storage tanks,
Pipe works,
Pressure equipment.
Same usage as the steel
CN 25.20.
Improved resistance to
corrosion in acid environments
with strongly reducing
or oxidizing properties.
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10
TECHNICAL DATA
REFERENCES
ASSEMBLY AND REPAIR OF PRINCIPAL COPPER ALLOYS
ASSEMBLY AND REPAIR OF COPPER AND BRONZES
Process options
Most Commonly
Used Alloys
Uses and Types
of Parts
COPPER
Soldering
Silver Brazing
CASTOLIN 157
CASTOLIN 181
CASTOLIN 800
CASTOLIN 1030 F
CASTOLIN1666 XFC
CASTOLIN 1702
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN 1810 F
CASTOLIN XUPER 1802
CASTOLIN 1806
CASTOLIN 18 XFC
CASTOLIN 157
CASTOLIN 181
CASTOLIN 800
CASTOLIN 1030 F
CASTOLIN 1666 XFC
CASTOLIN 1702
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN 1810 F
CASTOLIN XUPER 1802
CASTOLIN 1806
CASTOLIN 18 XFC
CASTOTiG 45706 W
CASTOLIN 157
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN 1666 XFC
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN 1810 F
CASTOLIN XUPER 1802
CASTOTiG 45703 W
CASTOTiG 45706 W
EUTECTRODE 285
CASTOLIN 18 XFC
Electrical and mechanical uses,
Arms of spot welders,
Jewelry making,
Kitchen utensils
CASTOLIN 157
CASTOLIN 1030 F
CASTOLIN 1666 XFC
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN 1810 F
CASTOLIN XUPER 1802
CASTOLIN 157
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN 1030 F
CASTOLIN 1666 XFC
Gears,
Segments.
Cu/A1
Cu/A2 (oxygen
Cu/A3 present)
Cu/b (deoxidized
Cu/c1 without
Cu/c2 oxygen)
BRONZES (Cu+Sn)
UE 9 P
UE 12 P
Brazing
Soldering
Silver Brazing
Brazing
TIG process
Soldering
Silver Brazing
TIG process
UE 16
UE 18
Manual arc process
Brazing
(potentially)
Soldering
Silver brazing
*UE 4 Pb
*UE 7 Z Pb 5
Soldering
Silver Brazing
General uses,
Rubbing parts,.
Valves and fittings,
Bearing bushings,
Mechanical construction,
Low-cut parts
Segments.
Easy to use,
Parts subject to rubbing.
*NB: fragile with arc process
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ASSEMBLY AND REPAIR OF PRINCIPAL COPPER ALLOYS
Process options
Most Commonly
Used Alloys
Uses and Types
of Parts
BRASS
(ZINC IS THE MAIN
Soft Soldering
Silver brazing
CASTOLIN 157
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN1666 XFC
CASTOLIN 1810 F
CASTOLIN XUPER 1802
CASTOLIN 18 XFC
CASTOLIN 45706 W
Sheet metal, sections
Condenser tubes,
Locksmithing,
Decoration, lighting,
Musical instruments.
ADDITIONAL ELEMENT.)
ordinary brass,
(UZ 5 à UZ 15).
UZ 20 à UZ 30
UZ 37 à UZ 40
Brazing
TIG process
(potentially)
Soldering
Silver Brazing
CASTOLIN 157
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN1666 XFC
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN XUPER 1802
CASTOLIN 18 XFC
CASTOLIN 157
CASTOLIN 1030 F
CASTOLIN 1666 XFC
CASTOLIN 1810 F
CASTOLIN XUPER 1802
CASTOLIN 157
CASTOLIN 1030 F
CASTOLIN 1666 XFC
CASTOLIN 1020 F
CASTOLIN XUPER 1802
CASTOLIN 157
Brazing
Soldering
Silver Brazing
*UZ 38 Pb 1E
Soldering
Silver Brazing
*UZ 38 Pb 2
Soldering (brazing difficult,
Mechanical parts,
Parts cut low at high speed.
Joints.
because of lead exudation)
UZ 15 à 3 NS
ALUMINUM
BRONZE (CU + SN)
Soldering (Alutin 51 flux)
CASTOLIN 157
Silver Brazing (Albro flux)
CASTOLIN 181
CASTOLIN 1030 F
CASTOLIN1666 XFC
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN XUPER 1802
CASTOLIN 1810 F
CASTOLIN 157
Soldering (Alutin 51 flux)
Silver Brazing (Albro flux)
UA 9
UA 9M
UA 10 N Fe
UA 10 Fe4
UA 10 N
UA 14 Fe
CUPRONICKEL
AND NICKEL-SILVER
CASTOLIN 1030 F
CASTOLIN1666 XFC
CASTOLIN XUPER 1802
CASTOLIN 1810 F
CASTOMIG 45751
CASTOMIG 45750
CASTOTiG 45706 W
CASTOTiG RB 5248
CASTOLIN 157
CASTOLIN 181
CASTOLIN 1020 F
CASTOLIN 1800
CASTOLIN 1702
CASTOLIN XUPER 1802
CASTOLIN 45751 W
CASTOLIN RB 3229
CASTOMIG 45612
CASTOMIG 45751
EUTECTRODE 2222
MIG process
TIG process
Soldering
Silver brazing
TIG process
MIG process
Manual arc process
High resistance brass,
Marine tubes and parts.
Chemical industry,
Refrigerant tubes,
Steam faucets,
Gears, propellers,
propeller shafts,
Sea water pumps
Drawing dies,
Cylinder pistons
Good resistance to corrosion,
Hydraulic material parts,
Condenser tubes,
Pump bodies,
Silversmithing,
Food industry.
Breweries,
Glassmaking molds.
*NB: Braze welding difficult and fragile on interior angle
Tel:+43 1 869 45 41
60
www.castolin.com
10
TECHNICAL DATA
REFERENCES
ASSEMBLY AND REPAIR OF LIGHT ALLOYS
Process options
Most Commonly
Used Alloys
Uses and Types
of Parts
ALUMINIUM A 5
(1050)
Soldering
CASTOLIN 1827
(décapant Alutin 51)
CASTOLIN 190
CASTOILIN 21 F
EUTECTRODE XHD 2100
CASTOMIG 45803
CASTOLIN 1827
(décapant Alutin 51)
CASTOLIN 190
CASTOLIN 21 F
EUTECTRODE XHD 2100
CASTOLIN 21 F
EUTECTRODE XHD 2100
CASTOMIG 45802
CASTOMIG 45805
CASTOTiG 45802 W
CASTOTiG 45805 W
CASTOLIN 210
EUTECTRODE 2101 S
Materials for chemical
and food industry,
Building coverings,
Household appliances,
Boiler making, decorative pieces,
reflectors
Boiler making, pressed parts,
materials for food and household
appliance industries.
Aluminum alloys
Manganese
AM 1 (3003)
AM 1G (3004)
AM G 05 (3005)
Aluminum alloys
Magnesium
AG 0,6 (5005)
AG 3 M 5 (5754 X)
Manual arc process
MIG process
Soldering
Brazng
Manual arc process
Brazing
Manual arc process
MIG process
TIG process
AS 7B
AS 10B
Tel:+43 1 869 45 41
AS 7 B3
AS 12
Brazing
Manual arc process
61
Buildings, façade panels
and coverings.
Boiler making, automobile,
railway, transport tankers,
household appliance material.
Casing, Mechanical parts,
Valves and fittings.
www.castolin.com
CASTOLIN ONLINE.
www.castolin.com
Visit the Castolin website for the very latest news and information from the market leaders
in wear protection and fusion technology.
n
Products
n
Industry
n
Services
n
TeroLink
n
News
n
Events
n
Downloads
Catalogues
Literature
Wall charts
TeroLink AAP’s
n
New products
n
News letter
TEROLINK - THE APPLICATION DATABANK.
With our extensive experience and a network of world wide
customers, we have developed a market leading database
– TeroLink – with the very latest development in applications
solutions. We also provide training as well as promoting
potential cost savings in the cement industry.
n
Over 6,000 successful applications
n
Technical data
n
Method statements
n
Cost saving and performance enhancing sheets
Tel:+43 1 869 45 41
62
www.castolin.com
10
TECHNICAL DATA
REFERENCES
PERIODIC TABLE OF ELEMENTS.
Tel:+43 1 869 45 41
63
www.castolin.com
INDUSTRY PROGRAMMES
INDUSTRY PROGRAMMES FROM CASTOLIN EUTECTIC
Castolin Eutectic - with their wealth of experience in wear protection – have developed a series of
“Industry Programmes” that look at specific applications of wear throughout major world wides
industries that encounter significant High Load, High Wear issues.
High Load, High Wear
A guide to the various types of wear and their
causes in high load environments, industries
that have high wear issues as well as example
applications with problem, solution and cost
savings to customer.
CemTec
A tour of the various plant equipment and
processes specific to the Cement industry,
common wear problems encountered in these
environments and applications with their
solutions, cost savings and life enhancing data.
Castolin Eutectic is part of a dedicated global
CemTec team focused on providing solutions to
wear protection in the cement industry.
NEW Waste & Recycling
A guide to the different types of recycling
sectors, from Waste to Glass and Tyres to
Sewage, Castolin Eutectic have a programme of
proven wear protection solutions designed to
enhance product life and reduce costs.
Tel:+43 1 869 45 41
64
www.castolin.com
10
TECHNICAL DATA
REFERENCES
INDUSTRY PROGRAMMES
Pulp & Paper
Pulp and paper mills have a unique range of
wear and corrosion problems. For example
severe abrasion is found in the wood yard at
the debarking stage while abrasion and/ or
erosion occurs in the production of chips and
their transport to the digesters.
Tool & Die
Castolin Eutectic works together with Tool
& Die manufacturers and also their major
users (such as automotive companies
and component producers shaping steel,
aluminium, glass, etc.)
The tool and die steels used have to withstand
severe impact and wear during service,
whilst maintaining their exact dimensional
tolerances for many thousands of parts.
Consequently, the steels are usually complex
in their manufacturing and very sensitive.
The ability to repair cracked sections,
renovate worn areas or make slight geometry
modifications by welding, can lead to large
cost savings and flexibility gains.
Other Industry Programmes are available on request.
PRODUCT LITERATURE
This is a selection of our wide range of product marketing literature
More available on request.
Tel:+43 1 869 45 41
65
www.castolin.com
DEVELOPMENT AND PROJECT MANAGEMENT
Choosing Castolin Eutectic as your industrial partner brings clear benefits - higher quality manufactured
products, enhanced durability, increased productivity and significantly improved profits.
PROJECT
MANAGEMENT
Castolin Eutectic’s world-wide experience enables us to:
n
Take a look at your wear issues
n
Review your requirements
n
Provide turnkey solutions to resolve your problems.
Consultancy
Adopting a “Consultancy” approach, we have experience of providing bespoke solutions to meet your every need, whether it is joining solutions or
enhanced wear protection from site surveys through to the development
of products specific to your requirements.
Plant Survey
We offer an in-depth plant survey where appropriate
to identify the best solution to specific problems. This
thorough on-site study is conducted in partnership
with plant engineers to analyse all aspects of the
situation and develop a problem-solving strategy.
Documentation covering the application areas is produced, leading to a method statement
describing step-by-step the procedure for repairs and wear prevention and an estimate
of potential cost savings. This ensures quality control and reproducibility of the process,
thereby detailing ‘best practice’.
Tel:+43 1 869 45 41
66
www.castolin.com
10
TECHNICAL DATA
REFERENCES
SERVICE
CastoLab
Creative solutions through Specialist Workshops
CastoLab is the sub-contract engineering Wear & Fusion and service division of Castolin Eutectic, offering a complete and comprehensive service for the maintenance and repair of machine parts and major
components subject. Work can either be undertaken in the workshop facility or alternatively, an on-site
service is available.
CastoLab utilises the latest Wear and Fusion technologies and materials and is fully equipped with
the most advanced processes for repair maintenance. Highly experienced engineers will undertake a
complete study of your manufacturing equipment from diagnosis of the problem, preparation and
reclamation treatment of the component, final machining, a detailed inspection and test of all treated
parts to make them ready for use.
CastoLab has the facility to offer:
n
TIG
n
MMA & MIG/MAG
n
THERMAL SPRAYING
n
ARC SPRAY
n
PTA
n
BRAZING
n
POLYMERIC COATING
n
FUSE COATING
We also offer small and medium batch production runs of semi finished products in the above processes
Service
Clear benefits from service excellence
Choosing Castolin Eutectic as your industrial partner brings clear benefits - higher quality
manufactured products, enhanced durability, increased productivity and significantly
improved profits.
n
Service equipment
n
Installation and repair of equipment
n
Offer validation & calibration of equipment
n
Dedicated service manager
n
Industrial gas equipment inspection by trained personel
These benefits are delivered across a huge range of industries and are supported by top-quality
customer service and fast response.
Tel:+43 1 869 45 41
67
www.castolin.com
Reliability
Performance
PRODUCTION
Reliability. Performance. Value for Money
These are important values for customers of Castolin Eutectic who
demand the best – and we strive to offer the best; first time – every
time.
Value for Money
At our manufacturing facilities around the world we continue to produce the highest quality products to
suit requirements of customers and their demanding applications. This is reflected by the number and
variety of products available as well as the quality which is in evidence when using our products.
Included in this catalogue are a number of products which we have been selling for years; in some cases
over 20 or 30 years old – for example 1020 XFC, 680S, 244 and Eutalloy 10675. They are quite simply so
good at their application that they are unsurpassed, even to this day.
RESEARCH & DEVELOPMENT
Our vast accumulated research and development data enable us to create state-of-the-art solutions
through our qualified technical support engineers in different countries around the world. With Castolin
Eutectic, you are tapping into a wealth of information shared between hundreds of experts over the five
main continents. This means that we are continually on the cutting edge of new products, with a worldleading reputation as the first to market in product development.
Where we lead, others follow.
Where we lead,
others follow
Tel:+43 1 869 45 41
68
www.castolin.com
10
TECHNICAL DATA
REFERENCES
Training
Knowledge Transfer by Training
Castolin Eutectic offers industry a range of
specialised training courses, which covers all
aspects of the welding processes, e.g. MMA,
Mig, Tig. Brazing, Soldering and Thermal Spray
Coatings. These courses can be tailor-made to
suit your company requirements and conducted
to all levels of operators, from basic skills to advanced levels. Depending on your requirements
for your operators courses can comprise 100%
practical or theoretical, or a mixture of both,
and are aimed at both manual staff and skilled
engineers.
Training courses offered by Castolin Eutectic
TIG
MMA & MIG/MAG
THERMAL SPRAYING
ARC SPRAY
PTA
BRAZING
n
n
n
n
n
n
n
n
TIG
MMA & MIG/MAG
THERMAL SPRAYING
ARC SPRAY
PTA
BRAZING
POLYMERIC COATING
FUSE COATING
POLYMERIC COATING
FUSE COATING
Contact us to book your training course now
Tel:+43 1 869 45 41
69
www.castolin.com
Castolin GmbH
Austrian Market Center, Brunner Strasse 69, A-1235 Vienna
Tel: +43 1 869 45 41 - 0 Fax: +43 1 869 45 41 - 10
Email: [email protected] Web: www.castolin.com
06/2008

1 low heat input welding alloys

Transcription

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