August - 2014

THE CUSTOMER NEWSLETTER from CASTOLIN EUTECTIC

New Japanese HeadquartersVRM Repair

Super Coating

• Whertec reinforces Castolin Laser Cladding & Boiler Coating expertise

• 60th Anniversary Castolin Germany

• Investing in our future

Editorial

Dear Reader

This edition of Solutions highlights the significant and continuous investment the Group is making in Castolin Eutectic’s business and the first returns on these investments. The last 6 months have been one of the most investment intensive in the history of the Group and shows the commitment to delivering top quality, technology and service globally.

Investments have been made not just in new buildings, but also in new companies, infrastructure and technologies.

New Building/Infrastructure Investments reflect our ambition and continued growth. Featured in this Solutions are the new Polish offices and production building, the new Japanese offices and CastoLabs plus the New European Central Warehouse.

New Sales related Investments include the updated Booths at important trade shows, such as the ITSC in Barcelona, Petroleum Congress in Mexico plus the Technical Days and new TeroExpo in France. All these developments reflect our modern, technology-based, industry-focused approach to meeting and attracting new customers.

New Technology and Markets via Company Investments. One way to accelerate growth is to bring successful, dynamic companies into the Castolin Eutectic family. We did this last year with Monitor Coatings in the UK, and this year we see the value of their technology as they win a prestigious contract for the Royal Navy, to coat the carrier deck (an areas of 3 World Cup Football pitches) with a novel thermal sprayed coating. Congratulations.

Recently Whertec, from the USA, joined our family. They are a specialist in on-site thermal spray coatings in boilers with dedicated coating technology including HVOF, Arc, laser and densification. Welcome.

We are continuously investing so that we can continue to support our customers and grow successfully, also in new areas, in new industries and with new technologies. We look forward to showing you how the investments in our business can improve your business.

Good reading

Dr Gary HeathVice President Marketing

Castolin Eutectic

SOLUTIONS - August | 2014

youtube.com/CastolinEutectic linkedin.com/company/castolin-eutectic

A special thank you to the following countries

and colleagues who contributed to this edition:

Eutectic Canada Inc. | Marcela Cao

Castolin France | Vincent Martin

Castolin Europe | Michael Pekarek

Castolin Europe | Enrique Matey

Castolin Germany | Heike Brückner

Castolin Poland | Anna Cwiklicka

Castolin Russia | Julia Zavaraeva

Eutectic Japan | Yuji Ikegawa

Eutectic Mexico | Lorena Flores

Eutectic USA | Carlos Esteves

Monitor Coatings | Amy Kelly

VRM Worlwide | Martin Trenk

VRM repair in Switzerland

New headquarters for Poland

Eutectic Japan New Headquarters

Whertec Laser Cladding

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SINGAPORE, Singapore

BUSAN, Korea

Eutectic Japan relocates YOKOHAMA, Japan

The new Eutectic Japan Headquarters cover a 3.200 square meter area in a pur-pose built, three-story build-ing, located in Yokohama, about 20 km further south- west of the old headquar-ters in Kawasaki. The offices were officially opened by Siegfried Schabel, Global CEO July 2014. With the new head office situated in the key industrial area of Yokohama, along with the solid five-decade business tradition in Japan, Eutectic Japan will be able to serve MORE customers even BETTER.

Eutectic Japan has today 14 sales offices and 6 CastoLab® repair work-shops, providing products and services to about 4.300 active customers in Japan. The company employs 180

people, including 90 sales- men.

Since the late 1960’s, the Headquarters together with the main CastoLab® repair workshop have been situat-ed in Kawasaki, just south-west of Tokyo. Reviewing the growing opportunities for the repair and mainte-nance market in Japan, the company decided in 2013 to expand the capabilities by relocation. The construction of the new building includ-ing CastoLab® workshop, warehouse, administra-tion offices, thermal spray booths, equipment mainte-nance area and training facility was completed in June 2014 on schedule.

>> NEWSAsia

New maintenance and repair workshop

YOKOHAMA, Japan

www.eutectic.co.jp takada@eutectic.co.jp

Warehouse for product stock New Japanese Headquarters and Eutectic Japan team in Yokohama

NEWCASTLE, UK

KRIFTEL, Germany

ECLEPENS, Switzerland

Europe >> NEWS

Vertical Roller Mill

1. How many kgs of metal were deposited for the VRM refur-bishment?

For this VRM repair job, about 1.600 kgs were needed to achieve the requested roller profile. The deposition rate always depends on the type of mill, the required welding material and the number of torches we can use at the same time. Castolin has developed different special solutions to get optimal deposition rates for each type of mill.

2. How many days did the Vertical Roller Mill refurbishment operation take?

This job was finished within 5 days including setup and dis-mantling of the equipment. Especially for this Pfeiffer VRM mill the main advantage for the customer, assisted by the Castolin VRM Service Team, is that he doesn’t need to take out the rollers for re-welding or organise expensive scaffoldings.

3. How does the Castolin solution prolong the wear life of the VRM?

Plant downtime costs the customer on an hourly basis. In a cement plant, the loss is always a couple of hundred fthousand euros per hour. Field experience, together with R&D and our advanced welding wire manufacturing plant in Ireland, allows our VRM team to develop special anti-wear products and leading-edge welding processes. Castolin makes no compromises in the case of torch arrangement (for instance) inside the mill to achieve the best welding quality possible. This results in longer service life of the welded sec-tions compared to the original casted material.

www.castolin.com mtrenk@castolin.at

MOSCOW, Russia

GLIWICE, Poland

At the beginning of May 2014, the Castolin Eutectic mobile Vertical Roller Mill (VRM) refurbishment team successfully completed a VRM job at a cement plant in Switzerland.

Martin Trenk, Manager of the Heavy Duty Business Unit explained the VRM wear problem and the Castolin Eutectic approach for a fast and long- lasting repair

ECLÉPENS, Switzerland

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Welder repairing one of the King Wilhelm I fire urns.

Celebration outside MEC Bad-Soden

60th AnniversaryIn the last week of June 2014, Castolin Germany celebrated its 60th anniver-sary with live music, new welding equipment demon-strations and bright future plans. After an investment of 400,000 �, the German branch in Kriftel recently became the new Central European Warehouse for Castolin clients in Central, Northern and Eastern Europe. Today Castolin Germany has 134 employ-ees and a 2,600 m2 ware-house surface. In Germany

alone Castolin customer numbers rise at 15,000, including both medium-sized metal- working shops, as well as major industry actors like Opel, BMW or Heidelberg Cement. 350 parcels are sent out from the warehouse daily, with an objective of 100,000 deliver-ies per year in future. The Castolin Institute in Kriftel completes the portfolio of services in the form of train-ing courses and seminars and shares its expert knowl-edge in cost savings.

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www.castolin.de daniel.weber@castolin.de

New CastoLab® Six years have passed since Castolin opened its Russian CastoLab® , located in a Moscow suburb, 50 km from the main office. With opera-tions steadily growing, the available production space of 750 m2 had lately become too small and it was decided to seek a new location clos-er to Moscow with poten-tial for further expansion. Therefore, in May 2014, we have moved into new prem-ises in Korolev (north of Moscow) and now have an overall production space of roughly 1,500 m2 with large offices, a conference room and additional space for a future training center.

With the main machinery, such as cutting machines, CDP® wearplate production and rolling machines suc-cessfully installed, engineers and welders have succesfully resumed production.

In the last years, Castolin Russia has also reinforced its on-site service activities. Various Vertical Roller Mill (VRM) refurbishment opera-tions have been performed at the beginning of 2014. In February, a Loesche LM56.4 and a TRMC1 23.3

coal mill have been repaired in 11 days. In April, a Pfeiffer VRM has been refurbished in Kazakhstan.

www.mec-castolin.ru julia.zavaraeva@mec-castolin.ru

www.castolin.de heike.brueckner@castolin.de

Korolev, Russia: Production facilities in CastoLab® Services Workshop

KRIFTEL, Germany

MOSCOW, Russia

In September 2014 Castolin Poland is moving to its new headquarters in Gliwice, located in a strategic indus- trial area called Diamond Business Park, next to the General Motors factory.

The new, modern 6,300  m2

building is optimally designed and organized for PTA, Flame Spray Equipment (FSA), CastoTubes® and CDP® production plus CastoLab® activities.

The relocation aims to bring all departments under the same roof: technical service, quality department, ware-house, training school, con-ference rooms, as well as the entire administration.

The official opening will take place on 2 December 2014, with the participation of Stefan Messer, CEO of Messer Group, and of cus- tomer representatives from Opel, Volkswagen, etc.

Castolin Eutectic has been known to the Polish market since 1963 and has grown constantly from a distribu-torship to a fully owned selling company and most recently an important Global Supply Center.

Today the company employs 66 people and is active in domestic sales of consum-ables, equipment and servic-es plus becomes an increas-ingly valuable Supply Center.

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Investing in Europe

www.castolin.pl anna.cwiklicka@castolin.pl

New Castolin Poland building

Milestones Supply Center Poland

2005 – CastoTubes® production start

2008 – Opening of new Demo and Training Center „CastoSchool”

2010 – FSE production start2012 – PTA production start2013 – CDP® production start

With over 25,000 customers and our largest salesforce, Castolin France has a tradition of being close to customers. In order to give a broader overview to our customers, a new TeroExpo exhibition in the entrance hall of the Villebon headquarters has been developed.

There are always new solutions to problems and new products to save our customers money. Effective communication is the key to cost savings, and the new TeroExpo uses all the latest digital tools for communicating our know -how.

Castolin France is looking forward to welcoming you in the TeroExpo space and introducing you to the Castolin world. Completed in 2014, the new exhibition space shows:

• 7 stands dedicated to the Castolin product lines

• 6 stands devoted to the Industry Programs

• Real industrial parts to illustrate real wear and corrosion prob-lems

• Examples of repaired and refur-bished parts

New Castolin France Visitor Centre

The interactive multitouch iDesk presents the company, services and industries covered in detail, via all available media (video, image galleries, fly-ers, powerpoints and even games ....) Come over to meet us.

GLIWICE, Poland

In April 2014, the CastoLab® Division of Eutectic Canada preformed an on-site coat-ing contract for a Steel Mill. The work was performed on a critical section of the Fume Extraction Ducting (essen-tially a series of water cooled tubes). These exhaust fumes also contain hot, hard, corro-sive ash debris which wears through the metal tubes. Here, the bottom section of the duct had lost 50% of the original tube thickness.

Eutectic’s solution was to provide a protective erosion and corrosion barrier coating for the tubes. Utilizing the Group’s global experience and applications data bank, a proven BTC coating sys-tem was recommended and successfully applied by our CastoLab® Services team. The work was performed in-situ under confined space restric-tions during shut down.

The custom BTC densified coating and process will pro-vide maximum protection and trouble-free operation for a minimum of 2 years. The customer will monitor the project results but, based on the increased life expec-tancy and high replacement costs for new ducting, they are expecting to use this coating system on future applications.

Eutectic Castolin’s protective coatings significantly extend the service life of worn boiler components, making them last longer than uncoated new parts. Eutectic Castolin, a global company dedicated to wear protection, initiated the BTC Solutions program in 2010.

www.eutectic.ca mcao@eutectic-na.com

BTC technologySteel mill performance

MONTREAL CanadaMILWAUKEE,

North Amercia

MEXICO CITY, Mexico

JACKSONVILLE, USA

Need to consult the Eutectic product range on the go? We invite you to install our new mobile app to learn more about the main Castolin Eutectic welding, coating and brazing solutions available in Mexico and other NAFTA countries. The app can be downloaded for FREE both from the App store and Google Play.

Mobile App

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>> NEWSNAFTA

www.eutectic.com.mx

lflores@eutectic.com.mx

MEXICO CITY, Mexico

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The largest military ship in the UK´s

history has formally been named by

Queen Elizabeth II in a ceremony at

Rosyth, Scotland, on 4 July 2014. The

HMS Queen Elizabeth aircraft carrier

project has involved 10,000 people

in the building process in 6 different

dockyards.

HMS Queen Elizabeth is due to begin

sea trials in 2017 and flight trials in

2018.

Once completed, the 65,000-tonne

aircraft carriers will become the

centrepiece of the UK’s naval mili-

tary capability in terms of size and

technology. This unique ship has

many technical challenges to over-

come during its development. One

of these was a very large 19,000m2

problem of the main carrier deck.

The problem was to find a cost ef-

fective coating for the complete deck

that withstands the aero thermal

environment and gas wash exhaust

of the F35 engine on JSF and Eu-

rofighter when conducting a hov- er

transition and vertical landing.

After 2 years of trial Monitor Coatings

Ltd (part of Castolin Eutectic since

April 2013) have won the contract to

investigate and deliver a unique deck

coating system, that was the only

one from 20 coating to pass all tests

with flying colours.

Each of the two aircraft lifts can

move two Joint Strike Fighters

from the hangar to the flight deck

in 60 seconds. QE Class aircraft

carriers can take up to 40 aircraft

- double the capacity of existing

carriers

An artist's impression of HMS Queen Elizabeth and HMS Prince of Wales.

...a coating that resists corrosion and the exhaust of the F35 engine...

Naming Ceremony by the Queen on 4 July 2014

HMS Queen Elizabeth facts and figures

Displacement: 65,000 tonnes

Length: 280m

Beam: 70m

Draught: 11m

Speed: 25+ knots

Propulsion: 2 x Rolls-Royce MT30 gas

turbines and 4 x diesel generator sets

producing a total of 110 MWe

Range: 8,000-10,000 nautical miles

Armament: Phalanx automated

close-in weapons systems, 30mm

guns and mini-guns to counter

seaborne threats

Aircraft: Tailored air group of up to

40 aircraft: F35 Lightning II, Merlin

and Chinook helicopters

Keel to masthead: 56m

Anchors: 3.1m high, each weighing

13 tonnes

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www.monitorcoatings.com

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The story began in May 2012, when the UK government, in as-sociation with the Aircraft Carrier Alliance, engaged Monitor Coat-ings Ltd to investigate and deliver a suitable deck coating that would withstand the aerothermal envi-ronment and gas wash exhaust from the Lightning II (F-35B) air-craft engine and Eurofighter when conducting a hover transition and vertical landing.

Activities included: the develop-ment of techniques required for large scale preparation and appli-cation of a Thermal Metal Spray System (TMS) over an area in ex-cess of 19,500m², the development

After a two-year test program, Monitor Coatings Ltd. have

been awarded the prestigious contract for providing a non-

skid, thermal gas wash resistant deck coating for the Queen

Elizabeth Class Aircraft CarriersHMS. With a flight deck the

size of three football pitches (19,500m²) and taller than Nia-

gara Falls (56 meters), HMS Queen Elizabeth and her sister

ship, HMS Prince of Wales, will be is the largest ships ever

built for and operated by the Royal Navy. The Queen herself

officially named the ship at Rosyth dockyard on 4 July.

8

Monitor Coatings: 19,500m² coating on UK Navy’s biggest Ship in History

Rebecca Allcock, Monitor Coatings Limited.

www.monitorcoatings.com

of technologies acceptable for large scale application and long term support for the two carrier decks.

The scope of work culminated in a two day demonstration of the pro-cess application, quality system and in-service repair program of the TMS to both the Aircraft Car-rier Alliance and the stakeholders. The demonstration day was very well received by senior naval offic-ers and civilians from the marine engineering community.

Monitor Coatings Ltd is part of Cas-tolin Eutectic since April 2013 and provides world-class wear protec-

...a coating that resists corrosion and the exhaust of the F35 engine...

tion services for Aerospace, Oil & Gas, Steel and many other indus-tries. Monitor Coatings Group has facilities in the UK, Singapore and China. Technology leader for surface engineering in extreme environ-ments, the company has earned its market position due to its cutting-edge technology solutions and highest quality standards, including ISO9001, AS9100 and NADCAP ac-creditation.

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Laser expertise deepensCastolin Eutectic has acquired WherTec Inc (USA),The Reliability Experts

Quality Inspector undertaking rigorous inspection of boiler tubes

Fully automated Laser Cladding of boiler tube panels

Laser Cladding

On 11 June 2014, Castolin Eutectic com-

pleted the acquisition of Whertec, Inc.,

a USA-based privately owned company

with headquarters in Florida. Whertec

operates from a 4,200 square meter

factory in Jacksonville, Florida, which

is dedicated to advanced coating pro-

cesses for severe environments. Addi-

tionally, Whertec has developed a prov-

en track record performing on-site jobs

at power plant locations worldwide.

Whertec cutting-edge technology, service speed and performance.The Reliability Experts

WherTec have developed a solid repu-

tation for solving erosion and corro-

sion problems on boiler tubes in a vast

range of industrial processing equip-

ment. Founded in 1996, the company

have deep “hands on” experience of

solving large scale problems with its

own mobile coating facilities. These

can be mobilized within 24-48 hours in

the USA to protection customer’s plant.

In situ HVOF spraying: WherTec have

17 HVOF units for on-site HVOF spray-

ing. and “densification”. Densification

is a proprietary technology used after

spraying to maximise corrosion and

erosion performance of its coatings.

In situ Arc Wire spraying: WherTec have

30 arc wire spray systems for reliable on-

site spraying. They developed a special-

ised automation system, which is modu-

lar and allows expansion in the vertical

and horizontal direction during spraying.

Workshop Laser Cladding of boiler

tubes: Two 6 KW state-of-the-art High

Power Diode Lasers (HPDL) have been

installed in the Florida workshop for

automated cladding of both single

boiler tubes and also boiler tube pan-

els. A specialized fully automated work

cell enables WherTec to clad 65 square

meters of boiler surface per week. The

workshop can coat single tubes and

panels up to 16 meters long. The addi-

tion of the WherTec lasers to the exist-

ing laser cladding units in the Castolin

Eutectic Group positions us as not only

one of the largest boiler weld overlay

companies, but also one of the largest

laser cladding companies globally.

www.whertec.com

Quality Inspector undertaking rigorous inspection of boiler tubes

Fully automated Laser Cladding of boiler tube panels

Laser Cladding

On 11 June 2014, Castolin Eutectic com-

pleted the acquisition of Whertec, Inc.,

a USA-based privately owned company

with headquarters in Florida. Whertec

operates from a 4,200 square meter

factory in Jacksonville, Florida, which

is dedicated to advanced coating pro-

cesses for severe environments. Addi-

tionally, Whertec has developed a prov-

en track record performing on-site jobs

at power plant locations worldwide.

Whertec cutting-edge technology, service speed and performance.The Reliability Experts

WherTec have developed a solid repu-

tation for solving erosion and corro-

sion problems on boiler tubes in a vast

range of industrial processing equip-

ment. Founded in 1996, the company

have deep “hands on” experience of

solving large scale problems with its

own mobile coating facilities. These

can be mobilized within 24-48 hours in

the USA to protection customer’s plant.

In situ HVOF spraying: WherTec have

17 HVOF units for on-site HVOF spray-

ing. and “densification”. Densification

is a proprietary technology used after

spraying to maximise corrosion and

erosion performance of its coatings.

In situ Arc Wire spraying: WherTec have

30 arc wire spray systems for reliable on-

site spraying. They developed a special-

ised automation system, which is modu-

lar and allows expansion in the vertical

and horizontal direction during spraying.

Workshop Laser Cladding of boiler

tubes: Two 6 KW state-of-the-art High

Power Diode Lasers (HPDL) have been

installed in the Florida workshop for

automated cladding of both single

boiler tubes and also boiler tube pan-

els. A specialized fully automated work

cell enables WherTec to clad 65 square

meters of boiler surface per week. The

workshop can coat single tubes and

panels up to 16 meters long. The addi-

tion of the WherTec lasers to the exist-

ing laser cladding units in the Castolin

Eutectic Group positions us as not only

one of the largest boiler weld overlay

companies, but also one of the largest

laser cladding companies globally.

www.whertec.com>>

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Laser expertise deepensCastolin Eutectic has acquired WherTec Inc (USA),The Reliability Experts

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, EU

ROPE

, NA

FTA

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Castolin Eutectic regularly participates in industry tradeshows around the world. Come and see us !Next opportunities to meet CASTOLIN EUTECTIC in person are in September at Waste-to-Energy conference

in Vienna, Austria, at RWM 2014 in Birmingham, UK and Cemtech 2014 in Istanbul, Turkey.

Please consult www.castolin.com for a full list.

PowerGen 2014, Cologne, Germany, 3-5 June 2014

Oil&Gas, Acapulco, Mexico, 4-7 June 2014

ITSC 2014, Barcelona, Spain, 21-23 May 2014

Hillhead, UK, 24 June 2014

CIPPE, Beijing, China, 19 March 2014

International Tradeshows

• Digitally controlled Standard and Pulse Inverters for the best welding results ever !

Consumables > New Maraging Electrodes >>

PRO

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• Completely new metallurgical formulation developed

Castolin is still driving innovation

in metallurgy, and the newly de-

veloped electrode XHD  6860 re-

flects this.

An advanced performance elec-

trode featuring:

• improved “as-welded” hardness

(40 HRC)

• improved “aged” hardness

(60 HRC)

• increased “tempering resistance”

making XHD 6860 the ideal solu-

tion for welding aluminium pres-

sure die casting moulds & tooling

XHD 6860 is recommended for repair

of parts in the following industries:

• Tool & Die manufacturing /

maintenance / repair sectors,

automotive press / forming dies

• light alloy pressure die casting,

• plastic injection moulding

• cold trimming, stamping, ex-

trusion rams, mandrels, screws,

shafts etc

Typical applications include: ma-

chine tools and dies for cutting,

trimming, shearing, stamping,

forming, extrusion, metal working

operations etc.

Highest performance for Tool & Die

Innovation in maraging steel

EutecTrode® XHD 6860

Smooth, regular weld surfacerequires minimal machining

Low temperature ageing treatment eliminates quenching defects & dis-tortion

Retain aged hardness up to higher service temperatures

Good weldability without preheating for practical engineering applications

Stronger with… Castolin Eutectic

WELDIN

G

EutecTrode

Enduring Performance…

http://www.castolin.com/power-sources mpekarek@castolin.at

Two important groups of welding machines have been launched

by Castolin in Europe, incorporating the latest technologies and

specifically designed for ease of use and outstanding welding

results. The Flagship is the new XuperArc series comprising 3

models at 320, 400 and 500 amps. Featuring an advanced

touchscreen control, Castolin builds on the innovative touch

screen heritage from PTA machines. These multi tasking ma-

chines were exhaustively tested in both standard joining and

repair and maintenance applications and are both tough and

advanced.

Equipment > New CastoMig and Xuper Arc ranges

Stronger, with... Castolin Eutectic

www.castolin.com