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Protective Coatings for Industrial Fans and Housings
Wear Management Solutions
Typical Industries Served using Eutectic Solutions...
Power Generation
Steel
Mining
Cement
Statement of Liability: Due to variations inherent in specifi c 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 fi tness 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 Eutectic Corporation and its affi liates shall have no liability in respect thereof.
YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS
FANS 9-14 © 2008, Eutectic Corporation, ® Reg. T.M., Printed in the U.S.A.
Eutectic CorporationN94 W14355 Garwin Mace DriveMenomonee Falls, WI 53051 USAP 800-558-8524 • F 262-255-5542www.eutectic.com
CastoLab Services Workshop12300 Carmen AvenueMilwaukee, WI 53225 USAP 800-558-8524 • F 262-255-5542
Whertec Technology Center5409 Highway AvenueJacksonville, FL 32254 USAP 866-207-6503 • F 904-213-8126www.whertec.com
On-Site Services: The Reliability Experts
Whertec is the on-site service division of Castolin Eutectic. The division offers a highly organized inspection, mobilization, welding and thermal spray service covering a wide range of industrial applications. Every job is covered by a pre- and post-project report that can be used to assess future preventative maintenance requirements and evaluate in-service performance of key component parts. Whertec operates with stringent health and safety standards and has established a reputation for effi ciency and reliability.
The combination of Castolin Eutectic’s product and application expertise with a world-class site mobilization team offers customers the best possible solution for on-site projects – test the reliability experts with your demanding repair or material conservation projects.
t i th it i di i i f t li E t ti Th di i i ff h i d i ti bili ti
Stronger, with Castolin Eutectic 2Stronger, with Eutectic
www.eutectic.com
Stronger, with Eutectic
www.eutectic.com
Worn-out bladeWorn-out impeller
Do These Pictures Look Familiar?
• Erosion • Abrasion • Cavitation • Corrosion • Impact • High Temperature
Extreme erosion on blades
XuperWave Weld Quality
Localized abrasion on blade section
Common Enemies of Valuable Fans & Housings
Straight Bead XuperWave Bead
Extend Service Life with CDP® XuperWave® Wear Plate
• Ideal for parts exposed to fi ne particles at high velocity
• Maximum protection against linear erosive wear • Prevents fi ne particle tracking at points most susceptible to wear such as the stress cracks and weld bead overlap
• Reduces wear by up to 30% over conventional weld bead pattern
• Smooth, fl at bead profi le for easy balancing and overall increased fan performance
PLATE
TYPE DESCRIPTION G65*
HARDNESS(HRC)
TOTAL PLATE THICKNESS**
6503 PTA 65% tungsten carbide on a hard nickel
alloy matrix.10 mm3 61-65
7mm (5/16”)
9mm (3/8”)
395N
WEL
DED
NanoAlloy® nano size ultra hardphases.
12 mm3 68-7110mm (3/8”)
13mm (1/2”)
19mm (3/4”)
112
FUSE
D Lightweight plate with hard nickel alloy matrix and tungsten carbide
particles.12 mm3 58-61
6mm (1/4”)
212
FUSE
D Lightweight plate with hard nickel/iron alloy matrix and tungsten carbide
particles.12 mm3 58-60
6mm (1/4”)
4666
WEL
DED Complex carbides and borides.
High-temperature.17 mm3 61-64
8mm (5/16”)
10mm (3/8”)
13mm (1/2”)
19mm (3/4”)
4624
WEL
DED
Chromium carbide. 23 mm3 58-6110mm (3/8”)
13mm (1/2”)
19mm (3/4”)
22X
4X
ALLOY DESCRIPTION
BTCSolutions
Thermal spray protective coatings applied using proprietary processes. Solutions tailored to protect against combinations of abrasion, erosion and corrosion, even at high temperatures.
18X
18X
18X
13X
10X
22
4
1
1
1
1
1
Lower Wear Resistance Compared to AR 400
Higher Wear Resistance Compared to AR 400
EXTE
ND
ED S
ERV
ICE
LIFE
Critical equipment, that’s subjected to extreme conditions, needs the best hardfacing solution!
Workshop Case Study
Plates produced with multiple torch heads, will have an uneven surface, illustrated below. Eutectic XuperWave is made using a single torch which produces fl at, even weld beads across the entire plate. This welding process is cooler which minimizes distortion and dilution and maintains the maximum in wear resistant properties of the alloy. Also, smooth, fl at plate is critical to balance and optimal air fl ow which ensures the best possible wear resistance and overall fan performance.
0
2
4
8
10
12
14
16
18
20
6
Conventional wear plates exhibit uneven welds
StStrStr iaigaighhht Bead XuperWave Be ddad
Conventional wear plates exhibit uneven welds XuperWave welds remain smooth and even
Competitor solution lasted just 12 months (left), while CDP blades (right) are still in service after 2 years.
WEAR PROBLEM: Iron and steel works fans suffer from extreme erosive wear caused by fi ne oxide particles in the steel making process.
PREVIOUS SOLUTION: Fabricate impeller blades of a steel baghouse fan from basic chromium carbide (CrC) plate in 1/4” + 1/4” thickness. The fan lasted 12 months in service.
EUTECTIC SOLUTION: To increase service life, Eutectic recommended fabricating the blades from CDP 4666 XuperWave complex carbide plate in 1/2” total thickness.
RESULTS: Eutectic solution is still in service after 2 years, with minimal wear!
Fans - Steel and Iron Works
Stronger, with Castolin Eutectic 2Stronger, with Eutectic
www.eutectic.com
Stronger, with Eutectic
www.eutectic.com
Worn-out bladeWorn-out impeller
Do These Pictures Look Familiar?
• Erosion • Abrasion • Cavitation • Corrosion • Impact • High Temperature
Extreme erosion on blades
XuperWave Weld Quality
Localized abrasion on blade section
Common Enemies of Valuable Fans & Housings
Straight Bead XuperWave Bead
Extend Service Life with CDP® XuperWave® Wear Plate
• Ideal for parts exposed to fi ne particles at high velocity
• Maximum protection against linear erosive wear • Prevents fi ne particle tracking at points most susceptible to wear such as the stress cracks and weld bead overlap
• Reduces wear by up to 30% over conventional weld bead pattern
• Smooth, fl at bead profi le for easy balancing and overall increased fan performance
PLATE
TYPE DESCRIPTION G65*
HARDNESS(HRC)
TOTAL PLATE THICKNESS**
6503 PTA 65% tungsten carbide on a hard nickel
alloy matrix.10 mm3 61-65
7mm (5/16”)
9mm (3/8”)
395NW
ELD
ED
NanoAlloy® nano size ultra hardphases.
12 mm3 68-7110mm (3/8”)
13mm (1/2”)
19mm (3/4”)
112
FUSE
D Lightweight plate with hard nickel alloy matrix and tungsten carbide
particles.12 mm3 58-61
6mm (1/4”)
212
FUSE
D Lightweight plate with hard nickel/iron alloy matrix and tungsten carbide
particles.12 mm3 58-60
6mm (1/4”)
4666
WEL
DED Complex carbides and borides.
High-temperature.17 mm3 61-64
8mm (5/16”)
10mm (3/8”)
13mm (1/2”)
19mm (3/4”)
4624
WEL
DED
Chromium carbide. 23 mm3 58-6110mm (3/8”)
13mm (1/2”)
19mm (3/4”)
22X
4X
ALLOY DESCRIPTION
BTCSolutions
Thermal spray protective coatings applied using proprietary processes. Solutions tailored to protect against combinations of abrasion, erosion and corrosion, even at high temperatures.
18X
18X
18X
13X
10X
22
4
1
1
1
1
1
Lower Wear Resistance Compared to AR 400
Higher Wear Resistance Compared to AR 400
EXTE
ND
ED S
ERV
ICE
LIFE
Critical equipment, that’s subjected to extreme conditions, needs the best hardfacing solution!
Workshop Case Study
Plates produced with multiple torch heads, will have an uneven surface, illustrated below. Eutectic XuperWave is made using a single torch which produces fl at, even weld beads across the entire plate. This welding process is cooler which minimizes distortion and dilution and maintains the maximum in wear resistant properties of the alloy. Also, smooth, fl at plate is critical to balance and optimal air fl ow which ensures the best possible wear resistance and overall fan performance.
0
2
4
8
10
12
14
16
18
20
6
Conventional wear plates exhibit uneven welds
StStrStr iaigaighhht Bead XuperWave Be ddad
Conventional wear plates exhibit uneven welds XuperWave welds remain smooth and even
Competitor solution lasted just 12 months (left), while CDP blades (right) are still in service after 2 years.
WEAR PROBLEM: Iron and steel works fans suffer from extreme erosive wear caused by fi ne oxide particles in the steel making process.
PREVIOUS SOLUTION: Fabricate impeller blades of a steel baghouse fan from basic chromium carbide (CrC) plate in 1/4” + 1/4” thickness. The fan lasted 12 months in service.
EUTECTIC SOLUTION: To increase service life, Eutectic recommended fabricating the blades from CDP 4666 XuperWave complex carbide plate in 1/2” total thickness.
RESULTS: Eutectic solution is still in service after 2 years, with minimal wear!
Fans - Steel and Iron Works
Protective Coatings for Industrial Fans and Housings
Wear Management Solutions
Typical Industries Served using Eutectic Solutions...
Power Generation
Steel
Mining
Cement
Statement of Liability: Due to variations inherent in specifi c 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 fi tness 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 Eutectic Corporation and its affi liates shall have no liability in respect thereof.
YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS
FANS 9-14 © 2008, Eutectic Corporation, ® Reg. T.M., Printed in the U.S.A.
Eutectic CorporationN94 W14355 Garwin Mace DriveMenomonee Falls, WI 53051 USAP 800-558-8524 • F 262-255-5542www.eutectic.com
CastoLab Services Workshop12300 Carmen AvenueMilwaukee, WI 53225 USAP 800-558-8524 • F 262-255-5542
Whertec Technology Center5409 Highway AvenueJacksonville, FL 32254 USAP 866-207-6503 • F 904-213-8126www.whertec.com
On-Site Services: The Reliability Experts
Whertec is the on-site service division of Castolin Eutectic. The division offers a highly organized inspection, mobilization, welding and thermal spray service covering a wide range of industrial applications. Every job is covered by a pre- and post-project report that can be used to assess future preventative maintenance requirements and evaluate in-service performance of key component parts. Whertec operates with stringent health and safety standards and has established a reputation for effi ciency and reliability.
The combination of Castolin Eutectic’s product and application expertise with a world-class site mobilization team offers customers the best possible solution for on-site projects – test the reliability experts with your demanding repair or material conservation projects.
t i th it i di i i f t li E t ti Th di i i ff h i d i ti bili ti