Our brand is trusted by millions of industrial users in heavy-duty and wear-intensive industries. Over the course of more than 100 years, we have brought innovative products and solutions to our customers challenging ourselves to extend useful life, reduce maintenance costs and increase industrial productivity through welding, brazing and coating technologies. We have transitioned from being a family-owned business into a global company while maintaining our industry expertise, people focus and our deep-rooted belief in sustainability.
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Self-shielded, Flux-cored, Tool Joint Build-Up Wire Application Recommended welding parameters: |
Gas-shielded Tool Joint Build Up Wire Application Recommended welding parameters: |
Casing Friendly Leader of “all purpose” Non Cracking Design wires. Ideal in advanced drilling operations. OTW 16XS Extreme Service is a product ideally suited for drilling in the most demanding ERD and Ultra ERD wells. The unique nature of these wells puts severe stress on the drill string, prompting the industry to respond with High performance Tool Joint Connections (XT™, VX™, TT™). These connections produce higher torque values with lower drag and wall thickness. This requires increased reinforcement through optimized hardbanding solutions, resulting in heightened structural integrity and minimal dilution, while still providing effective overall durability. OTW 16XS was specifically designed for use in Ultra Deepwater applications, where most wells are highly deviated and extremely deep. As these wells require the highest level of strength and prolonged performance, OTW 16XS not only contains superior casing friendly properties, but also demonstrates a unique ability to offer the best wear-resistant materials in both open hole and cased hole environments. |
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Providing the highest casing & open hole wear resistance, OTW 16XS contains a uniquely weighted mix of multicarbides (Cr, Ti, Mo, and W), which is dispersed uniformly throughout a tempered martensitic micro-structure. This creates superior thickness and anti-wear properties, which maximize wear resistance, strength and longevity. OTW 16XS refurbishment and reinstatement. |
Hard but tough all-rounder. Best in class when combined open and case hole wear performance counts. OTW 12Ti actively prolongs against wear in the most extreme drilling conditions, as demonstrated by its performance in highly deviated well & open hole applications. Maximum drill pipe life is achieved through superior wear-resistant properties, coupled with the ultra-smooth, casing friendly features preferred by most oil companies. OTW 12Ti Titanium-Carbide chemical composition creates a martensitic matrix, which infuses ultra-smooth / ultrafine compounds into an abrasion resistant, ultra-hard microstructure, ensuring optimal strength and metallurgicalintegrity. OTW 12Ti hardness scale of 61.5 HRC, combined with our Non-Cracking (NCD) and Flexible Application Designs (FAD), enables high load, open hole performance while simultaneously meeting all casing friendly requirements. End-users yield a higher return on investment and long-term savings through OTW 12Ti‘s life-extending drill pipe technology. |
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OTW 12Ti can be reapplied over itself and most other hardbanding materials, ensuring quick and easy repair in even the most remote locations. OTW 12Ti is a flux-cored wire alloy, designed & manufactured by Castolin Eutectic in our own state-of-the-art facilities, of tool joints. |
Outstanding Casing wear resistance against current industry standard solutions with good tool performance. OTW-13CF has a Crack-Free Design, smooth surface with low friction properties and a microstructure designed to achieve a good balance between casing friendly and tool wear, whilst remaining a cost-effective solution. OTW-13CF has a casing wear resistance that is superior to currently established Non-Cracking wires, whilst retaining a competitive level of all round tool wear resistance. It achieves this with a slag-free deposit that precipitates a dense dispersion of hard, primary niobium and complex CrMo carbide phases finely distributed in a martensitic/residual austenitic matrix. The good resistance to high stress abrasion and erosion even when combined with heavy impact or pressure, are typical conditions that can be expected in an open hole or cased hole environment. OTW-13CF is ideally suited to intermediate to advanced hardbanding applications. |
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OTW-13CF is an exclusive, gas shielded, metal cored alloy wire may be reapplied over itself to refurbish worn drill pipes after drilling operations and also any of the OTW range. The Flexible Application Designed (FAD) feature implies greater fl exibility for the hardbander and signifi cant cost savings in old hardbanding removal and pipe preparation. |
Outstanding Casing wear resistance against current industry standard solutions with good tool performance. OTW-13CF has a Crack-Free Design, smooth surface with low friction properties and a microstructure designed to achieve a good balance between casing friendly and tool wear, whilst remaining a cost-effective solution. OTW-13CF has a casing wear resistance that is superior to currently established Non-Cracking wires, whilst retaining a competitive level of all round tool wear resistance. It achieves this with a slag-free deposit that precipitates a dense dispersion of hard, primary niobium and complex CrMo carbide phases finely distributed in a martensitic/residual austenitic matrix. The good resistance to high stress abrasion and erosion even when combined with heavy impact or pressure, are typical conditions that can be expected in an open hole or cased hole environment. OTW-13CF is ideally suited to intermediate to advanced hardbanding applications. |
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OTW-13CF is an exclusive, gas shielded, metal cored alloy wire may be reapplied over itself to refurbish worn drill pipes after drilling operations and also any of the OTW range. The Flexible Application Designed (FAD) feature implies greater fl exibility for the hardbander and signifi cant cost savings in old hardbanding removal and pipe preparation. |
Gloves |
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For 150 °C contact heat and 1000 °C radiant heat 5 finger gloves, with simple cuffs, without lining, blue/aluminium, length 355 mm |
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Protective goggles |
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Protective goggle, clear, scratch-proof Highly sophisticated safety spectacle, with black frame, best comfort and fit, with adjustable flexicord retainer, conform to CE EN 166 |
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Unprecedented wearing comfort |
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Formulated for reliable Copper joining applications NON SPARKLING Xuper CuP/CuPAg Xuper PLUS CuP/CuPAg |
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Xuper PREMIUM CuP/CuPAg |
Cu-Zn-Ni-Ag braze welding alloy for steels. Repair and capillary joining of tooling, metallic crafts, tubular frames, keys. Cu-Zn-Ag braze welding alloy for maximum security joints. Ideal for joining of galvanized steel tubes, tubular frames, car bodies, locks, brass plumbing. Features and benefits
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Cu-Zn-Si braze welding alloy. For repair and joining of copper and ferous alloys. MF - MiniFlux®: coated rods for a minimum amount of flux. For precision braze welding operations. Features and benefits
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High-silver content Cadfree® brazing alloy containing nickel and manganese 1703 is a silver alloy containing Ni and Mn and is designed for the brazing of hard metals. It is recommended for joining steel tools and sintered carbides. ApplicationsThe presence of nickel gives excellent wetting for sintered carbides like tungsten carbides for cutting tools. Manganese has good deoxidising powers and nickel increases the strength. |
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Low-melting temperature alloy for capillary brazing of aluminium. Profiles, tubes, air conditioning equipment, heat exchangers. Recommended for good strength joints in shoot and wrought aluminium and some aluminium alloys. Ideal for welding furniture and fittings, window frames, aluminium utensils and applications within the aircraft and radio industries. Castolin 190 can be used in conjunction with the Oxyacetylene and Tungsten inert gas shielded (TIG) processes. |
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An aluminium silicon alloy producing good strength joints and good resistance to corrosion. EutecRod 190 MF has a low melting point which in turn minimises distortion effects, has excellent flow characteristics and provides a good colour match to most aluminium alloy components. Not suitable for parts requiring anodised finishes or aluminium alloys containing more than 1.5% magnesium. |
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Paste flux for braze welding with Brazing Alloy 18. For ferrous and copper alloys, especially galvanized steel. Features and benefits
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Powder flux for all high-silver content brazing alloys. Ideal for small or fine steel parts. Powder brazing flux for capillar brazing with high silver content alloys. At elevated temperature the flux reduces the metal oxides on the base metal and activates the surface. This results in an optimal wetting of the filler metal and increase of the capillar effect in the gap between the two surfaces to be joined. The development of a surface alloy between the filler metal and the base metal ensures the metallic continuity. The surfactant Armosin helps to obtain an even thickness of the brazing flux, which adheres strongly with the base metal during the heating phase. The brazing operation is easier, this increases the productivity specially for large series of parts. |
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The brazing flux 1802 N Atmosin is designed for use with the following heating methods: oxyacetylenic flame, other oxy-fuel flames, air-fuel flames and furnace without gas protection. Industry Examples
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Tungsten carbide - 17% cobalt 55583C is a spherical powder manufactured by agglomerating and sintering a formulation of 83% tungsten carbide with 17% cobalt by weight. It has been developed for spraying with the CastoJet CJK5 system which is a High Pressure HVOF using kerosene as liquid fuel. 55583C powder is also suitable for other HVOF systems or plasma spraying. 55583C sprayed coatings are hard and dense with high bond strengths on a wide variety of metallic substrates. They are tougher with a better fretting and impact resistance than WC-12Co coatings. They resist exceptionally well to low stress abrasion, fretting wear and hard particle erosion for service temperatures up to 500°C. |
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Excellent resistance to friction and corrosion Alloy powder for anti-wear protective coating of steels, stainless steels, nickel-alloy steels and cast iron. Features and benefits
Applications Applications include shaft sleeves, wire drawing dies, jacks, wear rings and seals. - See more at: |
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No deformation or structural change in base metal. Hard but fully machinable deposit Alloy powder for anti-wear protective coatings on all types of metals, except pure copper and magnesium. Applications include shaft sleeves, crankshafts, press pistons, plunger pistons and cylinder liners. Requires separate bond coat of RotoTec 51000 alloy. Features and benefits
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Excellent resistance to abrasion, low coefficient of friction Alloy powder for anti-wear protective coatings on all types of metals, except pure copper and magnesium. Applications include pinch rolls, grippers, excavators and scrapers. Requires separate bond coat of RotoTec 51000 alloy. Features and benefits
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Alloy Fe-Cr-Ti-Si-Mn Self bonding alloy with enhanced surface wear resistance properties to combat erosion, thermal shock up to 650°C Applications Cement cooler plates, boiler water wall protection, pulp production digesters, steam turbine casings, cracking installations, high temperature cyclone, fume extractors etc. |
For manual applications with low welding currents
Micro GAP 50 DC is ideal for welding applications that require precision, high-quality layer quality and low dilution; in particular when fully automatic welding is impractical or inapplicable due to low numbers or the diversity of the tasks. The welding units are available with various features. The operation is carried out via push button selector switches and knobs on the front display. Micro GAP 50 DC is designed for manual and semi-automatic welding tasks in which frequent parameter changes are required. |
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All the settings are displayed on the LCD display in plain text, and up to 100 memory locations are available for storing the welding parameters. The extremely powerful inverter delivers 33 A at a 100% duty cycle, which is also sufficient for micro-plasma welding. |
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Kerozene fuelled high pressure HVOF for cold sprayed coatings of high quality The CJK5 HVOF is a high pressure, high velocity thermal spray process, using liquid fuel (kerosene) and oxygen which are fed into a combustion chamber, where they are ignited and continuously combusted. The resultant hot gas at a pressure close to 1 MPa, emanates through a converging – diverging nozzle and travels through a straight section. The jet velocity at the exit of the barrel (>1000 m/s) exceeds the speed of sound. A powder feed stock is injected into the gas stream, which accelerates the powder up to 800 m/s. The stream of hot gas and powder is directed towards the surface to be coated. The powder partially melts in the stream, and deposits upon the substrate. The resulting coating consists of thin overlapping platelets, has low porosity and high bond strength. The CastoJet® Kerosene 5 - CJK5 - is the latest Castolin Eutectic development of kerosene fuelled high pressure HVOF (High-Velocity Oxy-Fuel) systems. The CJK5 developments have focused on the gun, powder feeder and operator interface. The operator interface is simple to use with a touch screen interface. The powder feeder has mass flow controlled carrier gas and closed loop motor control for reliability and repeatability of powder feed rates. |
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The CJK5 control system is shown with the operator interface mounted onto the gas box for pictorial purposes only. In a typical installation, the gas box would be inside the spray booth. The powder feeder would either be inside or outside the spray booth. The operator interface would be outside the spray booth. The control system for the CJK5 HVOF consists of a PC with a touchscreen screen operator interface and a gas box. The PC provides a means of operator interface and overall system control. For reliability of operation, the actual control of the individual operations of the system are controlled by PLC's in the gas box and powder feeder. The PC and PLC's are all linked by serial bus to minimise wiring and increase reliability. The CastoJet® CJK5 kit comprises:
Integrated Systems / Putting a reliable, performing Package together for OEMs and Workshops Castolin Eutectic has designed, manufactured and commissioned many Turnkey Integrated Systems on a global basis. We have serviced several industries and applications with tailored made system solutions that are fully engineered, cost efficient, fl exible and have state of the art safe operating features. Typical designs include control equipment, sound-proof cabins, robots, turn tables, extraction, etc. These components are fully integrated for operation in automatic mode. As well as providing full monitoring with operational status and alarms, the systems also allow manual intervention for further development and optimisation of parameters. Applications
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For anti-wear and anti-corrosion cold arc sprayed coatings The EAS4 HF was developed to improve running costs, coating deposition and ease of maintenance. The Gun design has been upgraded with screw in tips for |
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EuTronic Arc is the highest productivity thermal spraying process. EuTronic Arc is an Arc Spray Process using a pair of wires which are melted by an electric arc. This molten material is atomised by compressed gas and propelled towards the workpiece to form a coating. EuTronic Arc is a cold spray process having the advantage of not requiring the use of oxygen, kerosene or a combustible gas which means more economic coatings. Low running costs, high spray rates and efficiency make it a good tool
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Cold Wire Feeder Electronic Drive: efficient four roll drive with 30mm wire feeder rolls, fit in wire feeder for 16 Kg wire coils. Special designed pressure arms care for a smooth and reproducible pressure of the wire onto the feeder rolls within the drive. Electronically motor controller for the four roll wire feeder. Functions: forward/backward movement, wire inching, wire feedback, pulse functions, control signals for fault indication. Buttons for: wire inching, forward/backward movement, speed and pulse adjustment. |
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Protecting the torch against overheating Under normal conditions a cooler is connected with the power source and the torch. The coolant is pumped by the cooler through the welding machine, taken at the front of the power source by the torch and led back again. The coolant is sucked from the cooling liquid tank into the cooling circuit by a pump. In the return the hot liquid is pumped through a cooling radiator and finally collected into the cooling liquid tank. |
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Cooling with integrated chiller Weight 50 kg |
Holds gas cylinders, powder feeder, power source and cooling. Wide range of additional trays and accessories for better configuration and ease of use of the trolley. |
Universal Coating System Castolin Eutectic´s GAP UniCoating V2.0 integrates all components necessary for the overlay welding of round parts. Well suited to the Glass Mould industry for baffle and bottom plates. Also very efficient at welding various forge dies and moulds as well as engine valves. With the 200 kg table the machine is capable of handling the smallest parts as well as moderately large ones. The GAP UniCoating V2.0 incorporates a complete Plasma power source. This unit uses the latest technology in plasma welding. With fully programmable gas controls, pilot arc settings, powder delivery and welding current the GAP UniCoating can deliver a completely repeatable, precisely engineered weld overlay. Welding parts can be coated in one welding cycle in one layer or multilayer |
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Modular System to cold spray or to hot spray Castolin Eutectic's modular CDS 8000 torch performs more flame spraying processes, with more alloy powder types than any other comparable system. The CastoDyn SF Lance kit increases this already-wide range of applications by allowing the CDS 8000 to perform spraying with simultaneous fusion. Its robust, water-cooled design permits sustained high-intensity spraying, and is ideal for both automated and manual applications. The kit's two Standard Spray Modules (SSM 50 and SSM 51) offer different flame powers, so workpieces of any mass or thickness can be coated. |
Modular delivery system to spray-fuse Eutalloy® powders SuperJet Eutalloy S® is an oxy-acetylene thermal spray torch which delivers very precise anti-wear protective coatings. Alloy powders are sprayed onto the part to be coated and are fused simultaneously. Bonding with the base metal by diffusion ensures that it does not reach its melting point. The dense coating is not affected by dilution and retains all its designed properties. Modular design |
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Safety First Advantages
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The oxy-acetylene fusion torch to preheat and fuse Eutalloy® RW coatings The advantage of local heating using the CastoFuse torch is obvious compared with an oven. Local preheating Designed for easy operation |
The unique rapid shut-off lever allows the torch to be relit without touching any other control. All components are easily accessible for maintenance.
Technical Data
The CastoFuse kit consists of a handgrip with three fusion lances 20, 30 and 40. The kit's three lances offer different flame powers, so workpieces of different mass or thickness can be preheated and heated up to the coating fusion temperature.
Motor-Controller for the powder feeder EP2 The maximum rate of the of the powder quantity depends on: powder feeder (type of wheel, powder density) and torch. With the powder feeder EP2 it is possible to feed up to 7kg/h nickel base powder without tungsten carbide and up to 10 kg/h nickel base powder with tungsten carbide. |
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Motor-Controller for the powder feeder EP2 The maximum rate of the of the powder quantity depends on: powder feeder (type of wheel, powder density) and torch. With the powder feeder EP2 it is possible to feed up to 7kg/h nickel base powder without tungsten carbide and up to 10 kg/h nickel base powder with tungsten carbide. |
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Liquid cooled manual torch Liquid cooled manual torch, available also with 70° and 180° neck |
CastoTubes® are Castolin Eutectic's response to the market request for erosion-resistant pipe sections and elbows. They consist of a mild steel tube which has been internally wearfaced with TeroMatec® 4666 alloy. This provides the exceptional wear resistance of our well-known 4666 CastoDur Diamond Plates®. Furthermore, by avoiding expensive forming operations of flat plates into tubes, seamless small diameter CastoTubes® are available.
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CastoTubes® offer many advantages:
Standard CastoTubes® Range Industries and Applications
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Unique combination of ultra-hard phases providing best service life CDP® 4666 SinusWave is latest addition to our family of highest performance wearplates. Unique weld bead geometry provides additional value, improving even more wear performance and minimizing plate scrap. Sinus pattern completely eliminates linear overlapped beads. This in turn results in identical wear properties in any direction and allows most economical use of entire wearfaced surface. Coating technology preserves all mechanical values of base material allowing further processing by rolling and bending. |
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CDP® 4666 is a composite material made of a structural steel backing and a hard weld surfacing, corresponding to DIN 8555 CDP® 4666 is a composite material made of an easy-to-weld steel plate coated by means of open arc welding with a layer of abrasion and erosion resistant alloy. |
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1. higher carbide density = higher resistance to finer abrasives
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Dispersion Hardening «DH» Wearfacing Alloy Range Main Application: Steel, Cement, Waste & Recycling - Transport screws, furnace chutes, exhaust fans, cyclones, conveyors, mixer blades. |
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Solid-wire, gas-shielded continuous electrode for joining applications on a wide range of mild and low-alloy steels Features and benefits
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Low-alloy steel TIG filler rod for anti-wear protective coating, rebuilding and joining of parts in high-strength steels Features and benefits
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Innovation in maraging steel XHD 6860 - higher performance electrode with a completely new metallurgical formulation with
XHD 6860 protective weld coating solutions are recommended for parts particularly in the following industries: |
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Typical applications include: machine tools and dies for cutting, trimming, shearing, stamping, forming, extrusion, metal working operations etc. |
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This process is a unit for welding, circular exteriors and interiors intended mainly for coating of internal bores from Ø 30 mm Advantages
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Manual electric welding and TIG welding with a single unit connected to 230 V DC Advantages
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Powerful, compact, efficient Advantages
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