/Solutions_2-2010_EN by Castolin Eutectic

SOLUTIONS C U S T O M E R I N F O R M AT I O N

Newsletter - Issue 2 - 2010

Frost&Sullivan Double Award Accolade

OEM Solutions for Aluminium brazing

Wear & Fusion Technology with Service and Quality

Content >> Awards

>> Industry & Application

Frost & Sullivan Double Award Accolade Dear Reader,

Castolin Eutectic experts in mining industry Solution for mining equipment : exceptional Impact wear resistance with CDP® wearplates

GAP® IMPA 4501: PTA process with highest deposition rate in the World

OEM solutions for Aluminium brazing

>> Brazing

>> Technology

>> News

Editorial

Moving with our distribution segment !

Impressum Editor >> Dr. Gary Heath

The global economy is still very turbulent, with rapid changes in raw material prices and demands for basic elements such as steel or aluminium. These changes lead to development of new technologies and business opportunities and also to demands for improved performance in the technologies for extraction of these materials and their use subsequent usage. In this issue of Solutions, we look at the important industry of mining and quarrying which are the start points of so many materials that we use everyday, such as our cars, computers, heating systems, etc. It already has the biggest trucks and machines and has massive demands for wear protection in its round the clock operations in Germany, Brazil, Australia, etc. Castolin is bringing lots of innovation to this demanding industry as shown by our innovative new impact wearplates and the world’s largest PTA coating systems, the IMPA 4501. Our recent exhibitions, particularly at the world’s largest quarry show, indicate that there is a growing interest in our innovative products and service approach. The approach has also been recognised by the independent research company Frost & Sullivan, who for the second year running have awarded Service Leadership and Product Awards to the Castolin Eutectic.

E-mail >> gheath@castolin.com Contributors for this edition >> Paolo Temporin, Arnaud van Daele, Dr. Gary Heath, Tony Nogaredes. Graphist >> Gilles Wenger | Pi-Com For more information or contact addresses, please visit our websites www.castolin.com or www.eutectic.com

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2010

Aluminium has been waiting for many years to play a more important industrial role and take over the position of steel in many applications. In replacing copper and stainless steel in heat exchange systems it has really been successful. Driven by a lower weight and lower cost, aluminium is making rapid inroads into the traditional heat exchanger technologies. The problem is joining aluminium and here there are new innovations in brazing technology. Finally, increasingly you will be seeing Castolin not just in the middle of big engineering projects, but also in your local DIY store or brazing distributor as our presence in Distribution continues to grow. Good reading

Gary Heath VP Marketing & Product Management

Frost & Sullivan

This year for the ﬁrst time Castolin Eutectic has received a double accolade award. After 2008 and 2009 awards, this is 3rd consecutive year in which Castolin Eutectic has been rewarded for its Excellence and Technology Leadership. Castolin Eutectic achieved the Double Accolade Award for: «Customer Service Leadership» and «Product Market Growth» in European Repair & Maintenance Welding Consumables. These awards are particularly rewarding as they recognise the success of our increasing focus and growth of the CastoLab® Services. In addition the Product Market Growth recognises the continuous success of the new product leading from our long term R&D projects. Customer Service Leadership Award With end users becoming more aware of their welding requirements and also demanding a higher standard of service, Castolin Eutectic has raced ahead of competitors by providing improved services and paying more attention to critical issues like technical support, training courses and subcontracting facilities. The repair and maintenance welding industry needs an arsenal of diverse alloyed consumables for different repair and maintenance applications for which traditional welding products are not designed. Castolin Eutectic’s proprietary alloys have helped it maintain a very strong historical relationship with the cement, oil & gas, waste and recycling, glass, pulp and paper and other industries. The company’s international team of experts conducts production site surveys to identify “weak links” and show clients the potential cost sav-

ings to be made. Furthermore, Castolin Eutectic regularly organises workshops with its dedicated team of technical experts having full access to its unrivalled applications data base, TeroLink®. Its customers can now also subcontract all the welding operations to the CastoLab® Services teams. In this way, the customers can have their work done professionally by qualiﬁed technicians. Product Market Growth Award Though there has been a low demand for welding equipment and consumables owing to the market recession, the company has not only sustained its market share but also grown it by focusing on customer value addition through the development of speciﬁc application and end user solutions. While several companies have lost market share with declining demand from key end us-

>> Awards

Double Award accolade

ers like automotive, construction and shipbuilding, Castolin Eutectic diversiﬁed and increased market penetration in other industries such as power generation, waste and offshore. An important reason for the increased market share in 2009 is the personalized marketing approach. Castolin Eutectic has direct contact with most of its marketing key end user industries through its dedicated salesman. In addition, technical “Industry teams” are close to maintenance engineers and provide them with technical and application expertise. These well experienced “consulting” teams reach out technology to customers and maintain the company’s brand image in its key targeted industries. If you wish to have more information about the Double Accolade Awards visit our website: www.castolin.com.

Who are Frost & Sullivan?

The awards were presented to Siegfried Schabel, CFO, in London at a special ceremony at the Emirates Stadium, the home of the Arsenal football team.

F&S, founded in 1961, has 31 global ofﬁces with more than 1700 industry consultants, market research analysts, technology analysts and economists. F&S conducts independent research in the industry and presents excellence awards. The award recognizes efforts towards innovation, quality and cost effectiveness as well as the impact on customer satisfaction.

Wear & Fusion Technology with Service and Quality

Castolin Eutectic experts in

>> Industry

Mining industry

From the extreme cold of Canada to the heat of Chile and Australia, we have a deep knowledge of application solutions for the wear problems in the mining industry: boring tools, crushers, roller presses, sieves, impact liners, excavation teeth, shovel liners, scraps, conveyors. Based upon hundreds of successful applications approved by clients across the globe, we can provide optimized solutions to combat wear in the Mining industry. Our know-how is shared world wide through our international Mining experts team, composed of specialists in mining process applications. The power that pulls our extensive know-how together around the world is our Key Industry Program and our unique Terolink® applications database. The most important is the dedicated analysis of the industry speciﬁc types of wear to allow the correct solution to be identiﬁed. Classic mining wear damages are due to: Impact, Erosion and Abrasion which costs money (especially in downtime and lost production, replacement parts, repair and ongoing maintenance). Use of advanced wear technology and preventive maintenance can extend the life of critical machine parts by as much as 500%.

Innovations Our goals through Development & Innovation are to bring new and INNOVATIVE SOLUTIONS to our customers. In addition to processes and applications, our mining experts have been developing: CDP® Impact wearplate.

Wide mining area in Brazil

Complete structure with the innovative Impact CDP® wearplate

Bucket teeth wearfaced with NanoTechnology®

Wearfacing of large parts on-site with TeroMatec® wires

New GAP® IMPA torch

Highest deposition rate GAP® equipment (see presentation on page 6) and associated powders. TeroMatec® (Open Arc / FCAW) wires and special equipment for onsite work

Castolin Eutectic at HillHead show in UK The World’s biggest working quarry show took place from the 22-24 June 2010 near Buxton in England. Between excavators, dump trucks, loading shovel etc... our innovative wearfacing solutions have attract hundred’s of visitors everyday, coming to ﬁnd solutions to increase their equipment lifetime.

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2010

If you would like to get more information about our solutions, contact your local sales representative or visit our ofﬁcial website: www.castolin.com.

Solution for mining equipment : exceptional

Impact wear resistance with CDP® wearplates welded wearplates that offer a far higher abrasion resistance than hardened plates have started to be used more widely in such industries. Nevertheless, they were not suitable in impact or high pressure applications due to their brittleness. As the largest global wearplate producer and with 20 years of CDP® wearplate experience in heavy industries, we developed our new impact plate CDP® 4623i that completes our offer by providing the best solution against impact even when abrasion is present.

>> Application

The constant need to improve production rates in mines and quarries increases the wear conditions in equipments such as buckets, chutes and crushers. Up to now, machines were usually protected by thick and heavy hardened plates that provided an acceptable solution, especially where only wear from impact was present. Plant managers, under cost improvement pressure, must now increase the service life of their machines to ensure larger production rates while keeping the cost at their minimum. To solve this need,

Application Crushing equipment In mines and quarries, the raw extracted material must be processed by crushers in order to reduce its

size. The crusher hopper can be fed by excavators or any dump truck. The material is then fed into the crushing system where it is ground to the desired size. Several types of crushers exist, even mobile, such

as for instance impact, cone or jaw crusher as the one shown below. In each machine, numerous parts (indicated in red in the ﬁgure) are exposed to high abrasion and impact wear phenomena.

Jaw crusher

Solutions While in the past, hardened steel plates were used to protect the equipment, OEM’s and ﬁnal customers asked us to provide more resisting wearparts. In the crusher shown on the right, 400mm rocks fall onto the sieve entry from a height of 1m.

They then enter the jaw crusher where extremely high pressure forces and abrasion are present on the side plates. Our impact plate CDP4623i was installed and compared to the previous solution, the service life has been improved by a factor of 5.

Cost Savings Before Price per new part Previous service life Nr. of parts used annually

With Castolin Eutectic 518 €

Cost of Castolin Eutectic Procedure

4 months Actual service life 3

Nr. of parts used annually

756 € More than 14�months < 0.8

LPF *

+250

Minimum Annual Cost Savings 910 €

*Life Prolonging Factor

Wear & Fusion Technology with Service and Quality

GAP® IMPA 4501: >> Technology

PTA process with highest deposition rate PTA is a hybrid of welding and coating with near laser quality but with welding’s practicality and cost. As one of the pioneers in PTA, with more than 45 years experience, we have recently developed the world’s most powerful heavy duty unit, the GAP® 4501 DC IMPA. This new system is ideal for all heavy duty applications requiring very high deposition rate for the best ratio productivity/coating quality. The previous unit GAP® IMPA has been used for several years by Castolin’s experts for different industries such as: open cast mining, Oil&Gas extraction, civil engineering, etc. In order to extract the best potential of the torch in terms of coating quality and efﬁciency, Castolin Eutectic decided to design and bring to the market a complete solution with the equipment as well as a dedicated powder range (EutroLoy®) to reliably reproduce excellent coatings quality. The torch has been optimized using sophisticated ﬂuids dynamic programs. If you would like to get more information about those new products, contact your local sales representative.

Huge mining application with IMPA

in the World

Processes

IMPA Torch

* Depending on powder chemistry

Standard PTA

Standard welding Deposition rate (kgs/hr)

Description

GAP® 4501 DC IMPA

Supply voltage

3x400V or special US version 34kVA 450A 300A 6-450A IP21S 815x445x785mm 90 Kg

Max power consumption Welding current (35%ED) Welding current (100%ED) Adjustment range Protection index Dimensions L x W x H (mm) Weight

Automation interface with analogous and digital in- and outputs. Powerful PLC 72 pin harting plug automated interfaces DC power source with HF-ignition Plasma welding 100 memory cells for parameter storage

Powder gas ﬂow diagram of the torch

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2010

Powder coating using powder feeder EP3 Optional GAP control software package for enhanced control and display of parameters Special chiller cooling

OEM solutions for

With more than 100 years of experience in brazing technologies it’s natural that we are taking a lead in the trend to Al brazing. The use of aluminium has been increasing for more than 20 years. More and more product designers and manufactures are interested in developing even more products using varies types of aluminium. For the last 3 decades the most common brazing alloy used for joining aluminium parts was the AlSi12. This alloy has a eutectic composition and allows aluminium to be joined at about 580°C (recommended brazing temperature is 593°C). 580°C has been sufﬁcient in the last few decades, but in recent years, the use of high strength aluminium alloys has been increasing. Those alloys usually employ other metals such as Mg, Si, Zn or Cu and have higher strengths and improved characteristics for individual applications. However they also have much lower melting temperatures than standard aluminium alloys with many 6000 and 7000 series alloys now melting at a little above 600°C, and standard brazing processes with AlSi12 are becoming very difﬁcult if not even impossible

to carry out. In addition, there are several aluminium alloys that rapidly lose there strength and hardness as they are heated. They can not be joined with AlSi12 alloys and maintain their original characteristics which limits their use in several industries. As most brazing alloys in the market have too high temperatures, Casto-

lin has designed a complete product range in order to satisfy all its customers’ requirement in terms of aluminium as well as aluminium-copper joining. From alloys and wires, through ﬂuxes and pastes, we have deep expertise of all brazing technologies in order to solve all industrial joining challenges.

Al alloy cycle frame

Al-Al brazed joint

Manual copper-Al joining

Al-Al joining with pastes

Al-Al brazing on radiator

Al-Cu brazed joint in heat exchanger

>> Products

Aluminium brazing

Wide brazing product range for OEM manufacturer

Wear & Fusion Technology with Service and Quality

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Strong actions and the will of the Castolin Eutectic Group to meet the speciﬁc needs of our partners and end users are constantly driving our activities.

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In recent months, you may have seen the new colours of our dedicated range to professional craftsmen and individuals. Indeed, Castolin now displays its true desire to best serve its customers through various existing distribution networks (professional and DIY) : new design, enhanced team, innovative marketing campaigns...

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New Italian catalogue

What’s new ? Exhibitions allow our local teams to show their expertise in these specific markets. We have recently participated to the “ExpoComfort” fair in Milan. The Italian team has once again surprised by its vitality and creativity, reflected in a fantastic stand, and a new brochure presenting all products (traditional and new ones). We also participated to the Do It Yourself fair in Paris. It was the first “outing” of our new blister packaging for the Do It Yourself segment. New packaging to meet a demand for more clarity on product labels but also the internationalization of many customers demands that packaging is translated in several languages. Each blister now adopts

the new graphic and product information (product features but also security and procedures) in nearly 10 languages. Our aim is to increase our international presence, so that each professional, each craftsman and even

ExpoComfort show at Milan

SOLUTIONS - Customer Information - Newsletter - Issue 2 - 2010

New blister packaging for the Do It Yourself

individuals can now buy and use Castolin products. This is a strong indication of a dynamic group looking at innovative channels to share with as many people as possible the recognized quality of Castolin’s products.