Powder Spray Fusing

Eutalloy - Eutalloy SF
® ®

Enduring Performance…

Stronger, with
Castolin Eutectic

Stronger, with Castolin Eutectic

www.eutectic.com
 Powder Spray Fusing
Contents
Eutalloy® Process - One step Spray & Fuse .............................................................................................................................................2

Eutalloy® Powders ................................................................................................................................................................................................3

Eutalloy® Equipment ..........................................................................................................................................................................................5

Eutalloy® Accessories .........................................................................................................................................................................................6

Eutalloy® SF Process - One step Spray & Fuse for high yield .........................................................................................................7

Eutalloy® SF Powders ..........................................................................................................................................................................................8

Eutalloy® SF Equipment & Accessories ....................................................................................................................................................9

Simplified overview

Max
Heating Coating Coating
Coating Coating Base mate- coating Coating Deposition Deposition Equipment
of work- surface micro- Bonding rate yield
Energy investment
families material rial thickness structure
piece size porosity
mm
Powder. Steels, Very
cast iron, Medium Small & Homoge- Combustion
Eutalloy Self-fluxing 2 (10)* Negligible good. Medium Medium Low
(aluminium to high precise neous gases
alloys bronze) * Diffusion
Powder. Very
Eutalloy Steels & Medium Homoge- Combustion
Self-fluxing High 2 (6)* Negligible good. High High Low
SF cast iron to large neous gases
alloys Diffusion

Best Second choice

(...)* request special precaution or coating powder

1092

1 Stronger, with Castolin Eutectic

www.castolin.com
Powder Spray Fusing
Eutalloy® Process - One step Spray & Fuse

Basic Principles
of Eutalloy® process

Function
The powder is introduced into the
torch flame and sprayed in a semi-
molten state onto the preheated
part, for fusion. Bonding is achie-
ved by diffusion of the alloys into
the base metal.

Advantages Applications
Eutalloy® provides a wide range The Eutalloy® process is designed
of benefits compared with con- for protective coating of machine
ventional arc welding process and parts and tools subject to a variety
PTA processes: of wear phenomena. Eutalloy®-
No dilution of the base material type oxy acetylene torches are ca-
Metallurgical bonding with no pable of delivering a wide range
Best purity and performance
dilution of Eutalloy® alloy, on of alloys in powder form. The Eu-
of the coating alloy
stainless steel (enlarged x 500). talloy® system has a coating di-
Homogeneous and pore free
A) Deposit mension range from 0.10 mm to
coatings
thicknesses of several millimetres.
B) Diffusion zone Smooth surface for low post The spraying followed by fusion
C) Base metal welding machining and also method can fine-coat to 0.05 mm.
when compared with cold The hardness of a deposit can vary
Bonding of the coating alloy and thermal spraying from 15 to 65 HRC, depending on
base metal is similar to that ob- Higher bond strength the alloy composition. Such depo-
tained in brazing: a liquid phase Better shock resistance sits are perfectly homogeneous
is linked with a solid phase, by and dense.
Thicker coatings capabilities
diffusion. The wetting qualities
of alloys are due to the synergis- Technical data
tic nature of certain constituents. Flame temperature: 3200 °C
These resist oxide formation on Particle velocity: not relevant
the substrate surface during
Deposition rate: 2 to 6 kg/h
spraying, and promote bonding
Coating material: Self-fluxing
with the base metal. An oxide-
Ni, Co or Fe base in powder form
free surface is essential. Melting
ranges, depending on the type Coating thickness: 0.05 to 10 mm
of alloy, vary between 850°C and Coating density: 100%
1100°C. Spraying distances vary Noise level: 70 - 80 dB(A)
between 6 and 20 mm.
1092

Stronger, with Castolin Eutectic 2

www.eutectic.com
 Powder Spray-Fusing
Eutalloy Powders ®

Designations Product Applications Properties

Type
Eutalloy® 10009 Alloy Resurfacing cams, pushers, stops, guide ~63 HRC
Part N° / Esc Code Ni-Cr-B-Si-Fe wheels, filterpress cake stone remover for Low friction coefficient. Good resis-
100603 10009 0.7 kg sugar mill, decanting screw, steam gate tance to corrosion, erosion and abra-
100604 10009 3.5 kg components. Coating elements subject sion under light load.
to friction.
Eutalloy® 10011 Ni-Cr-B-Si- Coating elements of chains, transport ~65 HRC
100605 10011 0.7kg Fe alloy and screw, wiper segments, brick die frames, 80% tungsten carbides.
tungsten claw excavators, rock drill, brush cutter Excellent resistance to abrasion by
carbide rake, debarking knives fine to coarse sized abrasives
Eutalloy® 10112 Ni-Cr-B-Si- Coating of machine parts used in the ~64 HRC
100608 10112 0.7kg Fe alloy and transport, handling and processing of 60% tungsten carbides.
tungsten minerals: transport screws, clay mixers, Excellent resistance to erosion and
103508 10112 12.5kg
carbide dies, segments, wipers, turbine impeller, abrasion by fine to coarse sized abra-
100609 10112 3.5kg fan impeller, pump screw, etc. sives.
Eutalloy® 10185 Alloy Coating of cast iron and steel molds for ~390 HV30
100610 10185 0.7kg Ni-B-Si plastic material and glass. Well suited for metal-to-metal fric-
Recoating shafts, eccentrics, bearings tion.
100611 10185 3.5kg
Soldering tungsten carbide biscuits on Excellent corrosion resistance.
drilling stabilizers, etc. Machinable with cutting tool.
Eutalloy® 10224 Alloy Repairing glass mold edges, gear teeth, ~250 HV30
100613 10224 0.7kg Ni-B-Si exhaust manifolds, pump bodies, brakes Appropriate for new or worn cast
on drawing tools. iron.
103509 10224 12.5kg
Bonding layer before welding with Good resistance to corrosion.
100614 10224 3.5kg electrode on cast iron that is difficult to Machinable with cutting tool.
weld, etc.
Eutalloy® 10611 Co-Ni-Cr-B- Resurfacing chemical transport screws, ~55 HRC
100617 10611 0.7kg Si alloy and fan blades at cement works, augers, and 50% tungsten carbides.
tungsten extrusion screws. Blades and segments Excellent resistance to abrasion
100618 10611WS 12.5kg
carbide of mixers, etc. under pressure and to corrosion.
Eutalloy® 10680 Alloy Repair of gears, cast iron valve seats, ~240 HV30
100621 10680 0.7kg Ni-B-Si molds, keyways, bearing seating. Good resistance to shocks and oxida-
Renewing drawing tools Correction of tion while hot.
100622 10680 3.5kg
machining errors, etc. Machinable with cutting tool.
Eutalloy® 15999 Ni-Cr-B-Si- Coating of molds for ceramics, rasps. ~65 HRC
202799 15999 0.7kg Fe alloy and Distributor blades for fertilizer spreaders, 15% tungsten carbides.
tungsten cyclone blades, hopper for sand sprea- Excellent resistance to erosion and
carbide ding machines, mouths of baggers, etc. abrasion by fine abrasives.

1092

3 Stronger, with Castolin Eutectic

www.castolin.com
Powder Spray-Fusing
Eutalloy Powders ®

Designations Product Applications Properties

Type
Eutalloy® LT PE Self-fluxing, Repair of mould damage on the seams or ~ 240 HV30 (~18 HRC)
8418 nickel base edges. Easy to machine or file. Grain size -106 µm.
alloy Low energy input for the fusion.
103398 4.5kg
Spot repairs.
103404 12.5kg

Eutalloy® LT PE Self-fluxing, Repair or protection of mould compo- ~ 270 HV30 (~22 HRC)
8422 nickel base nents: seams, blow heads, guide rings. Grain size -106 µm.
alloy Low energy input for the fusion.
103399 4.5kg Small to medium repairs.
103405 12.5kg

Eutalloy® LT PE Self-fluxing, Brazing of tungsten carbides on stabiliz- ~26 HRC (~300 HV30)
8426 nickel base ers.Extensive repairs and preventive coat- Grain size -106 µm.
alloy ings on seams, edges and guides. Low energy input for the fusion.
103400 4.5kg
Fast deposition.
103406 12.5kg

Eutalloy® LT PE Self-fluxing, Fast repairs and extensive preventive ~31 HRC

8431 nickel base coatings on mould edges and guides. Grain size -106 µm.
alloy with Low energy input for the fusion.
103401 4.5kg
addition of Cr Good wetting properties and fast.
103407 12.5kg and Mo

Eutalloy® LT PE Self-fluxing, Extensive repairs and preventive coatings ~35 HRC

8435 nickel base on neck rings or blow head. Grain size -106 µm.
alloy with Low energy input for the fusion.
103402 4.5kg
addition of Cr Enhanced fluidity and fast.
103408 12.5kg and Mo

Eutalloy® LT PE Self-fluxing, Enhanced weldability at high hardness ~40 HRC

8440 nickel base level on bottom plates, baffles and guide Grain size -106 µm.
alloy with plates. Low energy input for the fusion.
103403 4.5kg
addition of Cr Fast deposition with enhanced fluidity.
103409 12.5kg and Mo

1092

Stronger, with Castolin Eutectic 4

www.eutectic.com
 Powder Spray-Fusing
Eutalloy Equipment ®

SuperJet-S-Eutalloy®
SuperJet-S- Eutalloy® is an oxy-acety- Advantages
lene thermal spray torch, which Flexible, multi purpose and fast
delivers very precise anti-wear pro-
tective coatings, thanks to its sensiti- Rapid shut-off of acetylene and
ve controls. Alloy powders are sprayed oxygen while maintaining setting
onto the part to be coated and are fused Reliable and precise coatings
simultaneously. Diffusion bonding Usable in all positions on a wide
with the base metal ensures that range of base metals, including
it does not reach its melting point. steels, alloy steels, stainless steels
The dense coating is not affected by and cast-iron
dilution and retains all its designed
properties. For thermal spraying of
Eutalloy® powders.

SuperJet-S- Eutalloy® Kit

Contents of the equipment case:
1 torch with heat shield Accessories such as:
6 tip assemblies for different flame adjustable spanner
sizes to be used according to spark lighter
the size of the part or type of welding goggles
coating required (refer to operating
pressure table, page 6) hose couplings
set of nozzle cleaners *
set of injector cleaners
Also included are Eutalloy® powders special screwdriver *
for a wide range of applications. cleaning rad *
Alloy types: 10680 – 10009 – 10185 set of Teflon washers *
Part N° / Esc Code – 10112 * packed in a plastic box
750731 SuperJet-S- complete kit
Solution R 103 to protect the adjacent
areas from undesirable overspray.
Part N° / Esc Code
290102 SuperJet-S- kit with A1S, B3S and C5S
Other kits with different content are available
on request. Please ask your local Castolin
Eutectic company

KoolTip
Special water cooled tip assemblies called KoolTip® kits are recommended
whenever the SuperJet -S- torch is subject to high duty cycle usage or
prolonged thermal reflections.

C6 water-cooled tip assembly kit contents:

assembly with cooling device Accessories such as:
set of connecting water hoses spark lighter
special heat shield welding goggles
nozzle cleaner *
injector cleaner *
set of Teflon washers *
Part N° / Esc Code
203867 KoolTip C6S kit * packed in a plastic box.
1092

5 Stronger, with Castolin Eutectic

www.castolin.com
Powder Spray-Fusing
Eutalloy Accessories ®

Accessories for SuperJet-S- Eutalloy®

Refill Powder Container

An aluminium refill container may be mounted onto the torch when
powder alloys need to be transferred from bulk packages. Refilling is easily
executed via the lid without removing the container.

Part N° / Esc Code

205077 Refill Powder Container

Nozzles
Part N° / Esc Code This nozzle is made out of highly Cu with structural hardening, a special
290129 A0S wear resistant copper alloy which improves service life. It can be screwed
290130 A1S on & off easily. Every standard kit is delivered with this nozzle type.
290131 A2S
290132 B3S
290133 B4S
290134 C5S

Heavy duty Nozzles

Part N° / Esc Code
205117 A2S WC
Reinforced with Tungsten–Carbide
205104 B3S WC
This nozzle can be supplied as an option. Each type can be screwed easily
205116 B4S WC
205105 C5S WC
onto the corresponding standard tips. It is recommended when using
290138 C6S-3 WC powders containing abrasive hard particles such as tungsten-carbides.
This wear-resistant spray nozzle will help you in terms of longer service life
or consistent quality coating.
C6-3 is special nozzle with 3 holes for the powder outlet to coat large sur-
faces.

Compact heavy duty tip

Part N° / Esc Code Tungsten–Carbide brazed on the tube
290078 A0S WC/HT
290079 A1S WC/HT This is the solution for all applications where access is a problem and
290080 A2S WC/HT visibility of the fusion bath is a must. It is recommended for Glass Works
290081 B3S WC/HT
290082 B4S WC/HT
and all big users of powders containing hard particles. It is available as an
290083 C5S WC/HT option.

Compact heavy duty tube

Part N° / Esc Code Tungsten–Carbide brazed on the tube
290084 A0S WC/HT
290085 A1S WC/HT Same as the compact heavy duty tip, however without the gas mixer. It is
290086 A2S WC/HT
available as an option.
290087 B3S WC/HT
290088 B4S WC/HT
290089 C5S WC/HT

1092

Stronger, with Castolin Eutectic 6

www.eutectic.com
 Powder Spray-Fusing
Eutalloy SF Process - One Step Spray & Fuse for high yield
®

Function
The Eutalloy® SF flame spraying
process is designed to deposit a
range of wear resistant powder
coatings with high deposit effi-
ciency. It uses the CastoDyn DS
8000 oxy-acetylene powder spray
system equipped with an SF Lance
to coat onto slowly moving or sta-
tionary even surfaces of massive
steel parts in a one step spray &
fuse operation.
The water cooled SF Lance robust Applications Technical data
design has been engineered to A range of self fluxing Eutalloy® SF Flame temperature: 3200 °C
perform higher powder deposi- powder alloys has been developed Particle velocity: not relevant
tion spraying rates with simul- to meet the precise granulometry
Deposition rate: 2 to 10 kg/h
taneous fusion capabilities. This and morphology tolerances of the
Coating material: Self-fluxing
creates wear resistant requisite SF Lance system thus ensuring
Ni, Co or Fe base in powder form
coatings from 0.8 mm to 3 mm highest possible deposition rates
thickness with strong metallur- combined with efficient yield, re- Coating thickness: 0.8 to 3 mm
gical diffusion bonds to the steel liable deposit quality and ease of Coating density: 100%
substrate. application. This comprehensive Noise level: 70 - 80 dB(A)
range of corrosion resistant nic-
Advantages kel based Eutalloy® SF powder al-
High deposition yield loys is available to meet different
No dilution of the base material hardness and machinability re-
quirements when protecting in-
Best purity and performance
dustrial machine parts in service
of the coating alloy
against wear by friction, abrasion,
Homogeneous and pore free erosion, pressure etc.
coatings
Smooth surface for low Coating with densely packed
post machining hard tungsten carbides in
High bond strength a matrix to form an impenetrable
barrier to abrasive particles.
Good shock resistance
Thick coatings capabilities

Alloy Powder

Powder Injector

Cooling Water

Oxygen

Compressed
Acetylene Air
1092

7 Stronger, with Castolin Eutectic

www.castolin.com
Powder Spray-Fusing
Eutalloy SF Powders ®

Designations Product Applications Properties

Type
Eutalloy® SF 15211 Ni-Cr-B-Si- All round powder for anti-abra- ~60 HRC
Part N° / Esc Code Fe alloy and sion. 60% tungsten carbides
202789 15211 4.5kg tungsten Excellent resistance to erosion and
carbide abrasion by fine to coarse sized
abrasives.

Eutalloy® SF PE 8213 Ni-Cr-B-Si- For thick coatings. Stabilizer in oil ~55 HRC
202536 PE 8213 12.5kg Fe alloy and and gas drilling industry. 55% tungsten carbides.
tungsten Excellent crack resistance.
202537 PE 8213 4.5kg
carbide Abrasion and corrosion resistance.

Eutalloy® SF PE 8215 Ni-Cr-B-Si- For smooth coatings and parts sub- ~850 HV30
202538 PE 8215 4.5kg Fe alloy and ject to severe abrasion such as agri- 60% tungsten carbides.
tungsten culture parts, centrifugal screws. Excellent abrasion resistance even by
carbide fine particles.

Eutalloy® SF PE 8217 Ni-Cr-B-Si- For parts needing a rough surface ~62 HRC
205951 PE 8217 12.5kg Fe alloy and and subject to severe abrasion 70% tungsten carbides
tungsten such as scraper blades, drill heads, Best edge build-up capability.
carbide scraper parts. Abrasion and corrosion resistance.

1092

Stronger, with Castolin Eutectic 8

www.eutectic.com
 Powder Spray-Fusing
Eutalloy SF Equipment & Accessories
®

CastoDyn SF Lance
The CastoDyn SF Lance kit increases the already wide range of applications by allowing the CDS 8000 to perform spraying
with simultaneous fusion.

Technical data Advantages

Standard Spray Module SSM 50 SSM 51 SSM 52 optional Increased energy output
for highest deposition rate
Deposition rate 4-9 kg/h 2-4 kg/h 1-2 kg/h
Advanced nozzle design delivers
Typical Yield >90 % >90 % >90 % exceptional yield (>90%)
Oxygen flow rate 2000 NI/h 1000 NI/h 500 NI/h Consumable : Eutalloy® SF powders
Acetylene flow rate-Flame 1900 NL/MN 950 NL/MN 475 NL/MN
Oxygen flow rate - Carrier gas 330 NL/MN 240 NL/MN 80 NL/MN
Flame power ~ 28 KW ~ 14 KW ~ 7 KW
Deposit thickness
1-3 mm 0,8-2,5 mm 0,8-2 mm
(one pass)

Schematic showing the assembly of SF Lance on CastoDyn DS 8000

Castolin Eutectic’s modular CDS 8000 torch performs more flame spraying processes, with more alloy powder types than
any other comparable system. Its robust, water-cooled design permits sustained high-intensity spraying, and is ideal for
both automated and manual applications.

1092

9 Stronger, with Castolin Eutectic

www.castolin.com
Powder Spray-Fusing
Eutalloy SF Equipment & Accessories
®

CastoDyn® SF Lance
The kit’s two Standard Spray Modules (SSM 50 and SSM 51) offer different
flame powers, so workplaces of any mass or thickness can be coated.

Part N° / Esc Code

203766 CastoDyn SF Lance kit 500 mm
205527 CastoDyn SF Lance kit 450 mm
203784 CastoDyn SF Lance kit 350 mm
205530 CastoDyn SF Lance kit 250 mm

CastoDyn® DS 8000
The CastoDyn DS 8000 torch is de-
livered in a robust carrying and stor-
age case. This CDS 8000 kit is ready
to be used with an SF lance kit and
contains no Standard Spray Modul
(SSM).

Part N° / Esc Code

203754 CDS 8000 kit without SSM

CastoDyn® Extra-Flat SF Lance

The CastoDyn Extra-Flat SF Lance is the solution where the access is a pro-
blem. A minimum free opening of 60 mm is enough to enable the Extra-
Flat SF Lance to penetrate in the gap and to apply a coating. It is typically
used to apply wear resistant coatings on decanter screws.
The special Extra-Flat kit contains the SSM 51 and a SF Lance with a length
of 380 mm

Part N° / Esc Code

203763 CastoDyn Extra-Flat SF Lance kit

1092

Stronger, with Castolin Eutectic 10

www.eutectic.com
Your resource for protection, repair and joining solutions
Statement of Liability: Due to variations inherent in specific 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 fitness 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 Messer Eutectic Castolin and its affiliates shall have no liability in respect there of.

www.castolin.com www.eutectic.com