Gap automated unit robotic coating system

Universal Robotic Coating System

Provides repeatable precision for plasma joining, coating and brazing Turn-key robotic cell to increase productivity Completely modular for immediate, tailor made configuration and cost effective adaptation to application

P L ASM A T EC H

EuTronic GAP

EuTronic GAP

Focused plasma arc allows extra control, which results in the lowest dilution among all the arc welding processes

Universal Robotic Coating System Castolin Eutectic’s Universal Robotic Coating System integrates all components necessary for the overlay welding of round parts. It is well suited to the Glass Mould industry for baffle and bottom plates. It is also very efficient at welding various forge dies and moulds as well as engine valves. With the 150kg table the machine is capable of handling the smallest parts as well as moderately large ones.

The Universal System incorporates the EuTronic GAP 3001 Plasma Transferred Arc welding unit. This unit uses the latest technology in plasma welding. With fully programmable gas controls, pilot arc settings, powder delivery and welding current the EuTronic GAP 3001 can deliver a completely repeatable, precisely engineered weld overlay. The power source is fully integrated with the oscillation and arc length con-

troller to work with the tilting turn table for simple, fast setup of welding parameters. All parameters are programmed using the dedicated controls. There is no programming code to learn, all parameters are set in common welding terms for the optimum in operator friendly set-up and operation.

Features Base frame construction of aluminum profiles Turn table with T-slots, manual tilt adjustment +-45 degree.

Diameter: 400mm, max working weight 150kg Oscillating unit with 300mm stroke, stepper motor controlled Vertical axis with 400mm stroke, AC motor controlled

Control Cabinet Consists of Separate LCD display and buttons for the set up and visualization of the plasma power source Separate LCD display and buttons for the setup and visualization of the axis movements Plasma power source 2 flow meters for shielding gas and powder feed gas Electronic plasma gas control 2

Motor control unit for the powder feeder Motor control unit for the turn table Motor control unit for the oscillator Motor control unit for the vertical axis Plug for the remote control box Transformer for voltage adaptation Stronger, with Castolin Eutectic www.castolin.com www.eutectic.com

Arc voltage control on the vertical axis Welding curtain, pneumatically lifted E-52 machine mount plasma powder torch EP-2 powder feeder Remote control box Water cooled torch with water/ water heat exchanger and water flow sensor

EuTronic GAP Universal Robotic Coating System Technical Data

Why EuTronic GAP ?

The EuTronic GAP is the Castolin Eutectic Plasma Transferred Arc (PTA) process ideal for joining and coating operations. In the GAP process, the plasma is focused while forced through the heat resistant anode, causing a considerable increase of the arc density, energy and temperature. The welding filler alloy, in gas atomized powder or cold wire form, is conveyed into the plasma arc column where a shielding gas protects the weld pool from the atmosphere. The plasma arc and the heat input can be far better controlled than a conventional electric arc and the energy is almost completely spent to melt the filler metal, reducing the heat input and dilution to the minimum.

Gas supply

Ar + AR/H2, @ 30 psi

Water supply

5 l/min

Supply voltage

460V 3 phases 60 Hz

Max. power consumption

20 kva

Welding current (100% duty cycle)

220 amps

Welding current adjustment range

6-280 amps

Open circuit voltage

80 volts

Pilot current at 100% duty

30 amps

Pilot current adjustment range

3-60 amps

Dimensions (LxWxH)

1795x750x2500mm

Weight

350kg

EuTronic GAP Technology benefits when compared with conventional arc welding processes High energy density in an extremely focused arc High deposition rates for shorter welding times Homogeneous, porosity and spatter free coatings Lower dilution, heat input, distortions and Heat affected Zone than any other arc welding process Ideal control of the deposit thickness Maximum purity and performance of the alloy Smoother surface for lower machining costs Exceptional reproducibility Alloy flexibility

EuTronic GAP Technology benefits when compared with the spray and fuse proces Higher bond strength and impact resistance Lower overspray and smoother deposits, reducing the after welding machining costs Thicker coatings allowed Lower heat input Minimum distortions

All these features make the EuTronic GAP process ideal for those operations where extra precision, low heat input and minimum distortions are required.

Optional Torch GAP E 150 P ESC code: 260 434 Torch Type

Powder manual torch

Construction

Horizontal

Max. Current Intensity (100% duty cycle)

150 A

Powder Flow Rate

5-20 g/min

Cooling

Liquid

Weight with Hose Pack

2 kg (3m)

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EuTronic GAP Application Oriented Design Castolin Eurectic develops and manufactures EuTronic GAP welding units and accessories in various models and sizes either as standard units or as special developments.

Our team of technicians is able to design the cost effective and tailor made solution to fit your specific application.

From power source to feeding units, welding torches, even handling devices or robots when required, we take care of all the details.

Let our specialists surprise you, we never talk about products, but only of applications and solutions to your enquiries and necessities.

Castolin Eutectic GAP consumables Castolin Eutectic, since a century, is the market leader and the application specialist in wear & fusion technologies.

We are manufacturers of the widest range of welding, coating and brazing consumables on the market today and can offer you a complete selection of PTA welding alloys, available in different forms, that covers almost every application and any plasma transferred arc welding process: Atomised Ni, Co, Fe or Cu based powders for

wear resistant coatings Atomised Ni based powders additioned

with tungsten carbides for maximum abrasion and erosion resistance Laser wires, laser and Tig rods for manual and

micro plasma welding Solid and flux cored wires for cold wire plasma welding

Ask your local Castolin Eutectic representative for more information.

Your resource for protection, repair and joining solutions Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggested product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fitness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Messer Eutectic Castolin and its affiliates shall have no liability in respect there of.

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