Castolin solutions%20magazine%202014 2

August - 2014

THE CUSTOMER NEWSLETTER from CASTOLIN EUTECTIC

• Whertec reinforces Castolin Laser Cladding & Boiler Coating expertise

• 60th Anniversary Castolin Germany • Investing in our future

VRM Repair

New Japanese Headquarters

Super Coating

SOLUTIONS - August | 2014

Editorial

A special thank you to the following countries and colleagues who contributed to this edition: Eutectic Canada Inc. | Marcela Cao Castolin France | Vincent Martin Castolin Europe | Michael Pekarek Castolin Europe | Enrique Matey Castolin Germany | Heike BrĂźckner Castolin Poland | Anna Cwiklicka Castolin Russia | Julia Zavaraeva Eutectic Japan | Yuji Ikegawa Eutectic Mexico | Lorena Flores Eutectic USA | Carlos Esteves Monitor Coatings | Amy Kelly VRM Worlwide | Martin Trenk

Whertec Laser Cladding

Eutectic Japan New Headquarters

New headquarters for Poland

VRM repair in Switzerland

Dear Reader This edition of Solutions highlights the significant and continuous investment the Group is making in Castolin Eutectic’s business and the first returns on these investments. The last 6 months have been one of the most investment intensive in the history of the Group and shows the commitment to delivering top quality, technology and service globally.

Investments have been made not just in new buildings, but also in new companies, infrastructure and technologies.

New Building/Infrastructure Investments reflect our ambition and continued growth. Featured in this Solutions are the new Polish offices and production building, the new Japanese offices and CastoLabs plus the New European Central Warehouse.

New Sales related Investments include the updated Booths at important trade shows, such as the ITSC in Barcelona, Petroleum Congress in Mexico plus the Technical Days and new TeroExpo in France. All these developments reflect our modern, technologybased, industry-focused approach to meeting and attracting new customers.

youtube.com/CastolinEutectic

New Technology and Markets via Company Investments. One way to accelerate growth is to bring successful, dynamic companies into the Castolin Eutectic family.

We did this last year with Monitor Coatings in the UK, and this year we see the value of their technology as they win a prestigious contract for the Royal Navy, to coat the carrier deck (an areas of 3 World Cup Football pitches) with a novel thermal sprayed coating.

Congratulations.

Recently Whertec, from the USA, joined our family. They are a specialist in on-site thermal spray coatings in boilers with dedicated coating technology including HVOF, Arc, laser and densification.

Welcome.

We are continuously investing so that we can continue to support our customers and grow successfully, also in new areas, in new industries and with new technologies. We look forward to showing you how the investments in our business can improve your business.

Good reading

Dr Gary Heath Vice President Marketing Castolin Eutectic

linkedin.com/company/castolin-eutectic

YOKOHAMA, Japan

BUSAN, Korea YOKOHAMA, Japan

SINGAPORE, Singapore

The new Eutectic Japan Headquarters cover a 3.200 square meter area in a purpose built, three-story building, located in Yokohama, about 20 km further southwest of the old headquarters in Kawasaki. The offices were officially opened by Siegfried Schabel, Global CEO July 2014. With the new head office situated in the key industrial area of Yokohama, along with the solid five-decade business tradition in Japan, Eutectic Japan will be able to serve MORE customers even BETTER. Eutectic Japan has today 14 sales offices and 6 CastoLab® repair workshops, providing products and services to about 4.300 active customers in Japan.

The company employs 180

3 people, including 90 salesmen.

Since the late 1960’s, the Headquarters together with the main CastoLab® repair workshop have been situated in Kawasaki, just southwest of Tokyo. Reviewing the growing opportunities for the repair and maintenance market in Japan, the company decided in 2013 to expand the capabilities by relocation. The construction of the new building including CastoLab® workshop, warehouse, administration offices, thermal spray booths, equipment maintenance area and training facility was completed in June 2014 on schedule. www.eutectic.co.jp takada@eutectic.co.jp

New maintenance and repair workshop

Warehouse for product stock

>> NEWS CUTS

Asia >> NEWS Eutectic Japan relocates

New Japanese Headquarters and Eutectic Japan team in Yokohama

>> NEWS CUTS

Europe NEWCASTLE, UK

>> NEWS

Vertical Roller Mill GLIWICE, Poland

4 KRIFTEL, Germany

MOSCOW, Russia

ECLEPENS, Switzerland ECLÉPENS, Switzerland At the beginning of May 2014, the Castolin Eutectic mobile Vertical Roller Mill (VRM) refurbishment team successfully completed a VRM job at a cement plant in Switzerland.

Martin Trenk, Manager of the Heavy Duty Business Unit explained the VRM wear problem and the Castolin Eutectic approach for a fast and long- lasting repair

1. How many kgs of metal were deposited for the VRM refurbishment?

3. How does the Castolin solution prolong the wear life of the VRM?

For this VRM repair job, about 1.600 kgs were needed to achieve the requested roller profile. The deposition rate always depends on the type of mill, the required welding material and the number of torches we can use at the same time. Castolin has developed different special solutions to get optimal deposition rates for each type of mill.

Plant downtime costs the customer on an hourly basis.

In a cement plant, the loss is always a couple of hundred fthousand euros per hour. Field experience, together with R&D and our advanced welding wire manufacturing plant in Ireland, allows our VRM team to develop special antiwear products and leading-edge welding processes. Castolin makes no compromises in the case of torch arrangement (for instance) inside the mill to achieve the best welding quality possible. This results in longer service life of the welded sections compared to the original casted material.

2. How many days did the Vertical Roller Mill refurbishment operation take?

This job was finished within 5 days including setup and dismantling of the equipment. Especially for this Pfeiffer VRM mill the main advantage for the customer, assisted by the Castolin VRM Service Team, is that he doesn’t need to take out the rollers for re-welding or organise expensive scaffoldings.

www.castolin.com mtrenk@castolin.at

>> NEWS CUTS

60th Anniversary KRIFTEL, Germany In the last week of June 2014, Castolin Germany celebrated its 60th anniversary with live music, new welding equipment demonstrations and bright future plans. After an investment of 400,000 �, the German branch in Kriftel recently became the new Central European Warehouse for Castolin clients in Central, Northern and Eastern Europe. Today Castolin Germany has 134 employees and a 2,600 m2 warehouse surface. In Germany

alone Castolin customer numbers rise at 15,000, including both mediumsized metal- working shops, as well as major industry actors like Opel, BMW or Heidelberg Cement. 350 parcels are sent out from the warehouse daily, with an objective of 100,000 deliveries per year in future. The Castolin Institute in Kriftel completes the portfolio of services in the form of training courses and seminars and shares its expert knowledge in cost savings.

5 Welder repairing one of the King Wilhelm I fire urns.

www.castolin.de daniel.weber@castolin.de

www.castolin.de heike.brueckner@castolin.de Celebration outside MEC Bad-Soden

New CastoLab® MOSCOW, Russia Six years have passed since Castolin opened its Russian CastoLab® , located in a Moscow suburb, 50 km from the main office. With operations steadily growing, the available production space of 750 m2 had lately become too small and it was decided to seek a new location closer to Moscow with potential for further expansion.

Therefore, in May 2014, we have moved into new premises in Korolev (north of Moscow) and now have an overall production space of roughly 1,500 m2 with large offices, a conference room and additional space for a future training center.

With the main machinery, such as cutting machines, CDP® wearplate production and rolling machines successfully installed, engineers and welders have succesfully resumed production.

In the last years, Castolin Russia has also reinforced its on-site service activities.

Various Vertical Roller Mill (VRM) refurbishment operations have been performed at the beginning of 2014. In February, a Loesche LM56.4 and a TRMC1 23.3 coal mill have been repaired in 11 days. In April, a Pfeiffer VRM has been refurbished in Kazakhstan. www.mec-castolin.ru julia.zavaraeva@mec-castolin.ru

Korolev, Russia: Production facilities in CastoLab® Services Workshop

>> NEWS CUTS 6

Investing in Europe

New Castolin Poland building GLIWICE, Poland In September 2014 Castolin Poland is moving to its new headquarters in Gliwice, located in a strategic industrial area called Diamond Business Park, next to the General Motors factory.

The relocation aims to bring all departments under the same roof: technical service, quality department, warehouse, training school, conference rooms, as well as the entire administration.

The new, modern 6,300 m2 building is optimally designed and organized for PTA, Flame Spray Equipment (FSA), CastoTubes® and CDP® production plus CastoLab® activities.

The official opening will take place on 2 December 2014, with the participation of Stefan Messer, CEO of Messer Group, and of customer representatives from Opel, Volkswagen, etc.

Castolin Eutectic has been known to the Polish market since 1963 and has grown constantly from a distributorship to a fully owned selling company and most recently an important Global Supply Center.

Today the company employs 66 people and is active in domestic sales of consumables, equipment and services plus becomes an increasingly valuable Supply Center.

Milestones Supply Center Poland 2005 – CastoTubes® production start 2008 – Opening of new Demo and Training Center „CastoSchool” 2010 – FSE production start 2012 – PTA production start 2013 – CDP® production start

www.castolin.pl anna.cwiklicka@castolin.pl

New Castolin France Visitor Centre With over 25,000 customers and our largest salesforce, Castolin France has a tradition of being close to customers. In order to give a broader overview to our customers, a new TeroExpo exhibition in the entrance hall of the Villebon headquarters has been developed.

There are always new solutions to problems and new products to save our customers money.

Effective communication is the key to cost savings, and the new TeroExpo uses all the latest digital tools for communicating our know -how.

Castolin France is looking forward to welcoming you in the TeroExpo space and introducing you to the Castolin world. Completed in 2014, the new exhibition space shows: • 7 stands dedicated to the Castolin product lines • 6 stands devoted to the Industry Programs • Real industrial parts to illustrate real wear and corrosion problems • Examples of repaired and refurbished parts

The interactive multitouch iDesk presents the company, services and industries covered in detail, via all available media (video, image galleries, flyers, powerpoints and even games ....) Come over to meet us.

>> NEWS

BTC technology Steel mill performance In April 2014, the CastoLab® Division of Eutectic Canada preformed an on-site coating contract for a Steel Mill.

The work was performed on a critical section of the Fume Extraction Ducting (essentially a series of water cooled tubes). These exhaust fumes also contain hot, hard, corrosive ash debris which wears through the metal tubes.

Here, the bottom section of the duct had lost 50% of the original tube thickness.

Eutectic’s solution was to provide a protective erosion and corrosion barrier coating for the tubes. Utilizing the Group’s global experience and applications data bank, a proven BTC coating system was recommended and successfully applied by our CastoLab® Services team. The work was performed in-situ under confined space restrictions during shut down.

The custom BTC densified coating and process will provide maximum protection and trouble-free operation for a minimum of 2 years.

The customer will monitor the project results but, based on the increased life expectancy and high replacement costs for new ducting, they are expecting to use this coating system on future applications.

Eutectic Castolin’s protective coatings significantly extend the service life of worn boiler components, making them last longer than uncoated new parts. Eutectic Castolin, a global company dedicated to wear protection, initiated the BTC Solutions program in 2010.

MILWAUKEE, North Amercia

MEXICO CITY, Mexico

MONTREAL Canada

JACKSONVILLE, USA

Mobile App MEXICO CITY, Mexico Need to consult the Eutectic product range on the go?

We invite you to install our new mobile app to learn more about the main Castolin Eutectic welding, coating and brazing solutions available in Mexico and other NAFTA countries. The app can be downloaded for FREE both from the App store and Google Play. www.eutectic.com.mx

www.eutectic.ca mcao@eutectic-na.com

lflores@eutectic.com.mx

>> NEWS CUTS

NAFTA

7

>> COATINGS 8

Naming Monitor Coatings: Ceremony19,500m² by coating the Queen on UK on Navy’s 4 biggest July Ship 2014 in History

An artist's impression of HMS Queen Elizabeth and HMS Prince of Wales.

The largest military ship in the UK´s one from 20 coating to pass all tests history has formally been named by with flying colours.

Queen Elizabeth II in a ceremony at Each of the two aircraft lifts can two Coatings Joint Strike Fighters Rosyth, After Scotland, on 4 July test 2014.program, The move a two-year Monitor Ltd. have the hangar to the flight HMS Queen carrier from beenElizabeth awardedaircraft the prestigious contract for providing a non-deck in 60 seconds.

QE Class aircraft project skid, has involved 10,000 people thermal gas wash resistant deck coating for the Queen carriers With can take up to 40 aircraft in the building process 6 different Elizabeth ClassinAircraft CarriersHMS. a flight deck the double the capacity of dockyards. size of three football pitches (19,500m²) and taller than existing Niacarriers gara Elizabeth Falls (56ismeters), HMS Queen Elizabeth and her sister HMS Queen due to begin ship, HMS Prince of Wales, will be is the largest ships ever sea trials in 2017 and flight trials in Navy. The Queen herself 2018. built for and operated by the Royal HMS Queen Elizabeth officially named the ship at Rosyth dockyard on 4 July.

Once completed, the 65,000-tonne

facts and figures

aircraft carriers will become the centrepiece of the UK’s naval miliDisplacement: 65,000 tonnes tary capability in terms of size and Length: The story began in May 2012, of 280m technologies acceptable for technology. unique ship hasin asBeam:large 70m scale application and long when This the UK government, many sociation technical with challenges to over-Carrier the Aircraft term support for the two carrier Draught: 11m come Alliance, during itsengaged development.

One CoatMonitor decks.

Speed: 25+ knots ings Ltda to investigate and deliver of these was very large 19,000m2 The scope of work culminated Propulsion: 2 x Rolls-Royce MT30 gas in a a suitable problem of the deck maincoating carrier that deck.would two day demonstration the proturbines and 4 x diesel generatorof sets withstand the aerothermal enviThe problem was to find a cost efcess application, quality system producing a total of 110 MWe ronment and gas wash exhaust and in-service repair program of fectivefrom coating the complete deck airRange: 8,000-10,000 nautical miles theforLightning II (F-35B) the TMS to both the Aircraft Carthat withstands thermal when craft enginethe andaero Eurofighter Armament: Phalanx automated rier Alliance and the stakeholders. environment and gas washtransition exhaust and conducting a hover close-in systems, day 30mm Theweapons demonstration was very landing. of thevertical F35 engine on JSF and Euwell received by senior naval guns and mini-guns to counter officrofighter when conducting hov-developer Activities included: athe ers threats and civilians from the marine seaborne transition andofvertical landing.required for ment techniques engineering Aircraft: Tailored aircommunity. group of up to large scale preparation and appliMonitor Ltd part of Cas40 aircraft: F35Coatings Lightning II, isMerlin After 2cation years ofof trial Monitor Coatings a Thermal Metal Spray tolin Eutectic since April 2013 and and Chinook helicopters Ltd (part of Castolin Eutectic sincein exSystem (TMS) over an area provides world-class wear protecKeel to masthead: 56m April 2013) have won thethe contract to cess of 19,500m², development Anchors: 3.1m high, each weighing investigate and deliver a unique deck 13 tonnes coating system, that was the only

www.monitorcoatings.com

...a coating that ...a coating that and resists corrosion resists corrosion and the exhaust of the the F35 exhaust engine...of the F35 engine... tion services for Aerospace, Oil & Gas, Steel and many other industries. Monitor Coatings Group has facilities in the UK, Singapore and China. Technology leader for surface engineering in extreme environments, the company has earned its market position due to its cuttingedge technology solutions and highest quality standards, including ISO9001, AS9100 and NADCAP accreditation.

Rebecca Allcock, Monitor Coatings Limited. www.monitorcoatings.com

Castolin Eutectic has acquired WherTec Inc (USA), The Reliability Experts

>> BUSINESS

Laser expertise deepens

9

Laser Cladding

On 11 June 2014, Castolin Eutectic completed the acquisition of Whertec, Inc., a USA-based privately owned company with headquarters in Florida. Whertec operates from a 4,200 square meter factory in Jacksonville, Florida, which is dedicated to advanced coating processes for severe environments. Additionally, Whertec has developed a proven track record performing on-site jobs at power plant locations worldwide.

lar and allows expansion in the vertical and horizontal direction during spraying.

Whertec cutting-edge technology, service speed and performance.

The Reliability Experts WherTec have developed a solid reputation for solving erosion and corrosion problems on boiler tubes in a vast range of industrial processing equipment. Founded in 1996, the company have deep “hands on” experience of solving large scale problems with its own mobile coating facilities. These can be mobilized within 24-48 hours in the USA to protection customer’s plant.

In situ HVOF spraying: WherTec have 17 HVOF units for on-site HVOF spraying. and “densification”. Densification is a proprietary technology used after spraying to maximise corrosion and erosion performance of its coatings.

In situ Arc Wire spraying: WherTec have 30 arc wire spray systems for reliable onsite spraying. They developed a specialised automation system, which is modu-

Workshop Laser Cladding of boiler tubes: Two 6 KW state-of-the-art High Power Diode Lasers (HPDL) have been installed in the Florida workshop for automated cladding of both single boiler tubes and also boiler tube panels. A specialized fully automated work cell enables WherTec to clad 65 square meters of boiler surface per week. The workshop can coat single tubes and panels up to 16 meters long. The addition of the WherTec lasers to the existing laser cladding units in the Castolin Eutectic Group positions us as not only one of the largest boiler weld overlay companies, but also one of the largest laser cladding companies globally.

www.whertec.com Quality Inspector undertaking rigorous inspection of boiler tubes Fully automated Laser Cladding of boiler tube panels

>> ASIA, EUROPE, NAFTA

10

International Tradeshows Castolin Eutectic regularly participates in industry tradeshows around the world. Come and see us !

Next opportunities to meet CASTOLIN EUTECTIC in person are in September at Waste-to-Energy conference in Vienna, Austria, at RWM 2014 in Birmingham, UK and Cemtech 2014 in Istanbul, Turkey.

Please consult www.castolin.com for a full list.

14

3-5 June 20 e, Germany,

14, Cologn PowerGen 20

Hillhead, UK,

24 June 2014

ico, 4-

apulco, Mex

Oil&Gas, Ac

CIPPE, Beijing

7 June 2014

arch 2014

, China, 19 M

rcelona, ITSC 2014, Ba

3 May 2014

Spain, 21-2

Equipment > New CastoMig and Xuper Arc ranges • Digitally controlled Standard and Pulse Inverters for the best welding results ever !

Two important groups of welding machines have been launched

by Castolin in Europe, incorporating the latest technologies and specifically designed for ease of use and outstanding welding results. The Flagship is the new XuperArc series comprising 3 models at 320, 400 and 500 amps. Featuring an advanced touchscreen control, Castolin builds on the innovative touch screen heritage from PTA machines. These multi tasking machines were exhaustively tested in both standard joining and repair and maintenance applications and are both tough and advanced.

http://www.castolin.com/power-sources mpekarek@castolin.at

Consumables > New Maraging Electrodes • Completely new metallurgical formulation developed Castolin is still driving innovation in metallurgy, and the newly developed electrode XHD 6860 reflects this.

An advanced performance electrode featuring: • improved “as-welded” hardness (40 HRC) • improved “aged” hardness (60 HRC) • increased “tempering resistance” making XHD 6860 the ideal solution for welding aluminium pressure die casting moulds & tooling

XHD 6860 is recommended for repair of parts in the following industries: • Tool & Die manufacturing / maintenance / repair sectors, automotive press / forming dies • light alloy pressure die casting, • plastic injection moulding • cold trimming, stamping, extrusion rams, mandrels, screws, shafts etc Typical applications include: machine tools and dies for cutting, trimming, shearing, stamping, forming, extrusion, metal working operations etc.

Innovation in maraging steel

EutecTrode® XHD 6860 EutecTrode Highest performance for Tool & Die

Enduring Performance…

Stronger with…

Castolin Eutectic

Smooth, regular weld surface requires minimal machining Low temperature ageing treatment eliminates quenching defects & distortion Retain aged hardness up to higher service temperatures Good weldability without preheating for practical engineering applications

WELDING

>> PRODUCTS

11

Stronger, with...

Castolin Eutectic

www.castolin.com