Solutions%201 2011 en 0

1Wear & Fusion Technology with Service and Quality

SOLUTIONSNewsletter - Issue 1 - 2011

CU S TO M E R I N F O R M AT I O N

CastoLab® Services expan-ding its W&R services

New GreenBraz® brazing rods range

SOLUTIONS - Customer Information - Newsletter - Issue 1 - 20112 SOLUTIONS - Customer Information - Newsletter - Issue 1 - 2011

ContentFighting to preserve Earth precious resources

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CastoLab® Services Respond to Growing Demand for Services in the Waste Industry

Solution for refuse recycling : exceptional wear resistance on shred-ders with NanoAlloy®

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Impressum Editor >> Dr. Gary Heath

E-mail >> [email protected]

Contributors for this edition >> Dr. Gary Heath, Dr. Jeff

Luster, John Dalton, Patricia Nigg, Clément Kermarrec,

Tony Nogaredes .

Graphist >> Gilles Wenger | Pi-Com

For more information or contact addresses, please visit

our websites www.castolin.com or www.eutectic.com

News about our Distribution activities

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Green products made in Green Ireland

Breathe a Good Aire

Editorial

Dear Reader,

The theme for this new edition is the environment and Castolin Eutectic con-tinuous tradition of fighting to reduce waste and preserve the Earth pre-cious resources and recognizes its champions. Today we also need to reduce the input of fumes in providing adequate solutions to our customers so we have orientated our R&D resources in eliminating Boric acid and Cadmium from our brazing products in order to optimize their safety properties. We have also drastically reduced our power and waste consumption in our con-sumables production compensating it with the highest technology and have developed a range of fume exhausting systems to create an inoffensive en-vironment for all welders. We are also providing innovative wear protection technology to improve the efficiency of the Waste and Recycling plants, al-lowing recycling more waste with less energy and for an extended time.

Good reading

Gary HeathVP Marketing & Product Management

GreenBraz® : the best for both Environment and Productivity

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3SOLUTIONS - Customer Information - Newsletter - Issue 1 - 2011 Wear & Fusion Technology with Service and Quality

Recycling has been a common prac-tice for most of human history, with recorded advocates as far back as Plato in 400 BC. When resources were scarce, archaeological studies of ancient waste dumps show less household waste (such as ash, bro-ken tools and pottery) - implying more waste was being recycled in the absence of new material.

Industrialisation spurred demand for affordable materials; aside from rags, ferrous scrap metals were coveted as they were cheaper to ac-quire than virgin ore. Railroads both purchased and sold scrap metal in the 19th century, and the growing steel and automobile industries purchased scrap in the early 20th century.

Resource shortages caused by the World Wars and other world-chang-ing occurrences greatly encouraged recycling, urging citizens to donate metals and conserve fibre, as a mat-ter of significant patriotic importance.

The next big investment in recy-cling occurred in the 1970s, due to rising energy costs and today due to the climate changes, all companies have to be more sensitive about the resource consumption. This means that we are bringing the recycling to a new level.

SOLUTIONS - Customer Information - Newsletter - Issue 1 - 2011

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Fighting to preserve Earth precious resources

Castolin Eutectic’s fundamental concept of repairing worn parts is a recycling concept by itself! It avoids companies to throw their old parts away and to buy expensive new ones when they could be repaired and re-used. The fact of throwing those parts away is extremely harmful for the environment because the parts will need to be replaced by new manu-factured ones that will waste ener-gies and resources for the produc-tion as well as creating new garbage to be recycled, but also simply be-

cause resources will have to be used to recycle the worn parts.In order to reward the companies having a real engagement for the environment, the “Conservationist Award” has been created by Castolin Eutectic in 1973 and still remains an important trophy as we can see on the pictures above. Castolin Eutectic is also a member of the International Solid Waste As-sociation, in which our expertise and technical resources are demanded as we work towards solving a new gen-eration of waste disposal problems.

1st conservationist award in 1973

Providing our customers with solu-tions to repair all components and parts is our aim, and of course it in-volves deep research by experts who are constantly developing new pro-cesses and technologies in order to bring solutions to repair all types of metal under all conditions. This is our engagement, focusing our energy to support companies so that they are able to repair all their worn parts, but what about you, do you think about recycling your parts or components before purchasing new ones?

The Conservationist of the year Award being presented to Busatis in Austria

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ryCastoLab® Services Respond to Growing

Demand for Services in the Waste Industry

Of the many types of waste treated today, incineration of household waste and biomass are some of the most interesting as they provide us an opportunity to efficiently man-age natural resources. Unfortu-nately, they are also very demand-ing on mechanical equipment to process, transport and burn them since the composition of waste to be burned is always varying. In-creasing conversion from simple incineration to incineration for power generation puts further crit-ical demands on the installations.The global network of CastoLab® Services workshops are continually investing in equipment and people to provide you the main technolo-gies used to extend the lifetime of your machinery and protect criti-cal components. These include the production of wear parts using mass produced welded or powder wear plates, core-wire welding and application of dense powder coat-ings using the ‘”spray and fuse” Eu-talloy RW process.

The examples of applications that have been carried out in the vari-ous stages of the waste incinera-tion process are endless:

Shredding and processing: shred-ders, knives, sieves, hammers, housing, etc

Transport: feed screws, rotary valves, piping, feed claws, fans

Boiler: protection of water pan-els, combustion chamber walls, superheater tubes, pressure cleaning tubes, etc

Ash treatment: transport, de-ashing, cyclones, grates, dryers

Not only does the waste content vary depending on the chemical content and hardness of the items contained, but the design of the in-stallations is also unique.

This is why there is no single solu-tion recommended for each typical application; your CastoLab® Service technician will recommend the op-timum solution for your operating conditions and wear challenges. In most cases, an increase of the ser-vice life of 2 times or more is real-ized.

Ventilator with powder wear plate

Welded shredder with cored-wire

Chute with CDP® wear plate

Boiler tubes coated with spray & fuse

Screw wearfaced in our workshop

Rotary valve with powder wear plate


Solution for refuse recycling : exceptional wear

resistance on shredders with NanoAlloy®

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Cost Savings

Before With Castolin Eutectic

Price per new part 3000 €Cost of Castolin Eutectic Procedure

4000 €

Previous service life 30 days Actual service life 90 daysDowntime cost per day

20’000 €Nr. of parts used annually

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A constant need to improve pro-duction rates in Recycling plants increases the wear conditions in equipments such as grate bars, de-canter or shredders. Up to now, ma-chines were usually operating with their original parts or protected by standard alloys that provided an ac-ceptable solution, especially where only wear from abrasion was pre-sent.Plant managers, under the pres-sure of cost reduction, have to in-crease the service life of their ma-chines to ensure better production rates while keeping the cost at a minimum. In order to provide maxi-mum satisfaction to its customers, Castolin Eutectic has developed a

LPF *

+200 %

In the agricultural sector, in order to increase the number of harvest, it is very useful and common to use the hothouse effect. The plastic screens used on these systems must be changed every year in order to pro-vide a maximum efficiency. The shredder recycling these plastic devices wears out due to the pres-

Application

powerful arsenal of EnDOtec® cored wire alloys for the war on “High Load High Wear” by attacking abra-sion and erosion forces. The first of a series of EnDOtec NanoAlloy® for-mulations, the EnDOtec® DO*390N was developed to provide outstand-

Minimum Annual

Cost Savings 20’000 €

ence of sand, stones, etc. The ham-mers of the shredder which are the critical parts of the shredder were originally coated every 30 days with a Lastek wire (2400) but this main-tenance operation required produc-tion shutdown and a long interven-tion. Castolin Eutectic’s solution is to apply two passes of DO*390N alloy

on the hammers which provides outstanding performance/resist-ance and, as you can see from the cost analysis below, increases dras-tically its lifetime compared to the original solution.

*Life Prolonging Factor

ing abrasion and erosion resistance. This was achieved by using a lower cost ferrous alloy with bulk hardness values reaching 71HRC! Let’s explore a typical application for a rotor in the refuse recycling.

Hammer protected with DO*390N

Red: Lastek after 6 months with 2400 wireYellow: DO*390N after 6 months Green: repair of Lastek after 6 months, the DO*390N has still 50% thickness more than Lastek


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GreenBraz®: the best for both Environment and Productivity

New GreenBraz® line descriptionThe new line is called GreenBraz® and is composed of powder fluxes, paste fluxes, brazing pastes and brazing rods. The new range is avail-able for a multitude of alloys allow-ing brazing specialists to braze for a wide range of applications as de-scribed below:

Brass: Plumbing, heating, air-conditioning, heat exchangers, surfaces contamined by rust, lap joints and pipe fittings, gauges, jigs, connections, cutting and drilling tools, augers, pincers, keys, carbide tips on drilling tools, copper roofing and containers, brass and bronze valves.

CuproAluminium: Joining and repairing aluminium bronze parts or heavy alloys containing aluminium, surfaces contamined by oxidation, lap joints and pipe fittings, water tanks, york albro pipes (on ships).

Silver Cadfree: Surfaces con-tamined by rust, lap joints and pipe fittings, surgical instruments and kitchenware.

Boric Acid & Borax freeKeen to follow the current and fu-

ture REACH legislation and to find answers to environmental con-straints applied to our sector, Cas-tolin Eutectic developed a Brazing product range containing no CMR properties (Carcinogen, Mutagen, Reprotoxic). This means no boric acid or borax.

Cadmium freeCadmium is considered eco-toxic and so this is the first reason why Castolin Eutectic developed cadmi-um-free products. Cadmium is used in batteries, plastics, pigments and metal coatings. Cadmium can enter

A newly developed range of brazing products entirely reformulated by our scientists to eliminate Boric Acid, Borax and Cadmium is now sold on the market by Castolin Eutectic.

Some of the products of the GreenBraz® range

What is REACH ?REACH is a new European Com-munity Regula-tion on chemicals and their safe use. The aim of REACH

is to improve the protection of hu-man health and the environment through the better and earlier iden-tification of the intrinsic properties of chemical substances. At the same time, innovative capability and com-petitiveness of the EU chemicals in-dustry should be enhanced.

RoHsThe Directive on the Re-striction of the use of certain Hazardous sub-stances in electrical and

electronic equipment was adopted in February 2003 by the European Un-ion. It is closely linked with the Waste Electrical and Electronic Equipment Directive which sets collection, recy-cling and recovery targets for electri-cal goods and is part of a legislative initiative to solve the problem of huge amounts of toxic waste. Casto-lin Eutectic products are certified to comply with this directive.

into the environment through land-fills, poor waste disposal methods, when burning coal for energy, etc. The particles can travel far before falling to the ground or water and each year many tons of cadmium are discharged into our seas and oceans. Environmental pressures to elimi-nate the use of cadmium in indus-trial goods have been growing and the European Union created several directives to prevent the use of such hazardous substances. Furthermore, cadmium has already been banned from Aerospace, Automotive, Medi-cal and Potable Water applications.


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Green products made in Green Ireland

Breathe a Good AireDuring the last years all over the World, laws concerning workers safety and healthy working en-vironment are becoming key and are strictly controlled by government or dedicated institutions.

The welding, soldering, thermal spraying, grinding and sanding are always creating fumes composed by dusts and gases. It is therefore nec-essary to respect the environment of people working near the area of smoke emission and to use appro-priate fume exhausting equipment.

In order to provide customers and our own welders the best protec-tion, Castolin Eutectic has developed a complete range of torches, tables, arms and also complete systems with 4’200 m³/h capacity.

Not only is the new production plant in Ireland bringing with State-of-the-Art products technology to de-liver advanced powders and wires, but it does so with a reduction of its input on the environment.

A “Green” program for the plant was implemented from the plan-ning stage of the building to reduce energy and water consumption. For example, today the production has been doubled compared to the old plant but the use of water has been reduced by 900%!

Powder particles discharged to Waste

Castolin Eutectic Ireland manufacturing plant


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Our philosophy of delivering com-plete ranges to our distributors is once again perfectly illustrated with the new accessories range that will be available for our dis-tribution segment for the DIY and the Professional market in all Eu-ropean countries where Castolin Eutectic is present with the distri-bution activities.

Hammers, brushes, electrode hold-ers, welding masks, goggles, etc will be launched this summer by the distribution team and once again, at Castolin Eutectic, we do not sell single products, it is a complete marketing concept that is offered to the customers with our complete welding display in-cluding high quality and well posi-tioned products using our modern packaging.

A5 flyer for the W range offer

Special Promotion: Get a tool box for free!

New distribution products: a complete accessories range

Do not wait anymore; Castolin Eutectic is your partner to develop your welding sales!

Special

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Presente

Geschenk

From April 2011 until the end of June 2011, for every Arc or W MMA equipment purchased, customers will receive a Tool Box for free. This operation will be implement-ed in the following countries/area: France, Spain, Portugal, Poland, Czech Republic, Austria and East-ern Countries.

Inside view of the tool box

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Solutions%201 2011 en 0