TeroMatec ®

Self shielding, welding cored wire technology for wear protection,

rebuilding & repair

Enduring Performance…

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Castolin Eutectic

Self shielding peripheric arc system ensures :

Fastest weld deposition rates
Higher welding duty cycles
On site capability without shielding gas supplies
Optimised alloy weld properties for longer service life
Maximum cost savings & productivity
TeroMatec®
TEROMATEC® CORED WELDING WIRES
TeroMatec® is a self shielded arc welding process (Open Arc/FCAW) using specially formulated flux cored
wire electrodes. The self shielded peripheric arc conception includes a wide range of custom made alloys
optimised for industrial wearfacing, rebuilding and repair solutions with many advantages :
No shielding gas requirements Solidified slag Wire guide / contact tube
Fastest weld deposition rates Molten slag
Cored wire
Higher welding duty cycles
Particles-elements/compounds
Efficient weld metal recovery
Gas shield
Stock reduction opportunities created by compounds
Arc and Metal transfer
Ease of use by semi skilled operators
Maximum savings & productivity

NO SHIELDING GAS REQUIREMENTS Weld pool

Solidified weld metal

Self shielding peripheric arc

The TeroMatec® process requires no costly investments or complicated manipulation of

heavy gas cylinders, regulators, flowmeters, mixers, hoses etc. TeroMatec®’s autonomous
self shielding peripheric arc is designed for outdoor use where on-site wind or draught
conditions would simply blow away any external protective gas (GMAW) causing porous,
defective welds.

FASTEST WELD DEPOSITION RATES HIGHER WELDING DUTY CYCLES

The deposition rate of TeroMatec® flux cored elec-
trodes is remarkable reaching 4 kg/h with the Ø1.6
mm and almost 10 kg/h with the Ø2.8 mm due to
peripheric arc current density effects. Furthermore,
by increasing the electrode “stick out” (distance
between the contact tube tip and the workpiece)
from 50mm to 75mm, the deposition rate can be
boosted over 12 kg/h due to electrical resistance
heating effects whilst reducing heat input and dilu-
tion with the base metal.
Deposition rate (kg/h)
The welding duty cycle (X) is simply the % rela-
tionship between the effective arc welding time
(t1) and the total time involved (t1 + t2) where t2 is
the non productive time between the arc welding
cycles. Thus TeroMatec® duty cycles easily reach over
90% in automatic mode compared with MMA stick
electrodes which peak around 40%. The higher duty
cycle for TeroMatec® is due to :
no need to keep stopping & changing electrodes
repetitive striking & restriking eliminated
less post weld slag cleaning required
fewer stop-start weld crater defects to grind

400%
extra

Arc On t1
300% X= x 100 %
extra t1 + t2

Arc Off
Time

High efficiency manual electrode

Current (A) TeroMatec® X≈ 80-90%

Manual electrode X≈ 40%

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EFFICIENT WELD METAL RECOVERY ( %)
The weld metal recovery (sometimes called yield or
efficiency) is simply the ratio of the mass of weld de-
posited to the total mass of the original welding elec-
trode. Thus TeroMatec® cored wires have an excellent
weld metal recovery ratio reaching 95% whilst MMA
stick electrodes only reach around 65% due to higher
slag volumes and repetitive stub end losses.
In other words, TeroMatec® ensures that virtually all
the weight of purchased cored wire ends up as a use-
ful weld deposit thus reducing consumable costs.

= 1000g = 1000g

650 g 950 g

MMA
- 65% TeroMatec
- 95%

STOCK REDUCTION OPPORTUNITIES

As a 15kg TeroMatec® spool represents around 22kg of MMA stick electrodes for the same quantity of requi-
red weld deposit, this represents a potential to cut welding consumable stocks by over 30% !
Additionally, when a single spool Ø 1.2 or 1.6 mm TeroMatec® is considered, its all round application welding
capabilities can eliminate the need to stock separate packs of stick electrodes in 2.4mm, 3.2mm, 4.0mm &
5.0mm sizes thus further reducing inventory costs.

EASE OF USE BY SEMI SKILLED OPERATORS

Relatively little training is required for the TeroMatec® process (compared with MMA) which makes it easy to
learn by semi-skilled operators due to the self regulating nature of the arc, variable stick out capability, better
visibility and absence of external shielding gases. Furthermore, powerful flux deoxidisers in the TeroMatec®
cored wire enable direct welding on rusty or oxidised steel surfaces without the meticulous precleaning
needed for the GMAW process, especially when access is limited.

MAXIMUM SAVINGS &

PRODUCTIVITY
Numerous studies by industry show that
labour costs are the biggest single expense in
welding. As skilled labour rates continue to rise
inexorably, cut and control your welding costs
with TeroMatec®.

TeroMatec® systems significantly increase cost savings and productivity over both Mig / Mag
& MMA processes due to the ease of use by semi skilled operators, the incomparable weld
deposition rates giving superior performance and service life.

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TeroMatec®
TEROMATEC® MANUFACTURING FACILITIES
The TeroMatec® range of high performance cored
electrodes are formulated, developed and manufac-
tured in Castolin Eutectic’s own modern plants using
specially designed production equipment and pro-
cedures in accordance with ISO 9001 and EN 29001
quality assurance standards.
Each TeroMatec® batch after wire drawing and ba-
king, is weld tested for consistent chemistry, proper-
ties & operability before precision spiral spooling and
protective packaging for stock.

metal strip

pre-forming roll

flux Self shielding flux ingredients,

arc ionising stabilisers, fine
finishing rolls grain inoculants, powerful deoxidisers,
metallurgical refining
ø 1,2 mm agents, selected alloying elements,
ø 1,6 mm carbide compounds, etc.
ø 2,4 mm
ø 2,8 mm
Steel strip

core wire

SELF SHIELDED PERIPHERIC ARC

Thanks to TeroMatec®’s self shielding and high current density characte-
ristics, it can be welded at lower welding currents than a solid wire whilst
keeping a stable metal transfer across the arc due to ionising elements
in the core. Additionally, the lower heat input and presence of powerful
deoxidising fluxes means that TeroMatec® weld deposits have better bon-
ding, lower dilution, superior microstructure properties and minimal heat
affected zones for maximum service performance.

UNIQUE ANTI-WEAR ALLOYS

Solid Mag wires can only be manufactured in me-
tallurgical alloys which can be cast and easily drawn
down to final diameters. The TeroMatec® cored elec-
trode concept completely overcomes such limitations
and unique metallurgical alloys have been formula-
ted with high density, ultra-hard micro constituants
in Fe matrices. Thus the wide TeroMatec® alloy range
provides cost effective solutions for most wear pro-
blems found in industry.

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WEAR PROTECTIVE COATINGS TO PROLONG SERVICE LIFE
Classic wear types that occur in industry are:
Abrasion Erosion
Impact Friction
Heat & Corrosion Cavitation
At Castolin Eutectic we take the time to study
Abrasion Erosion industry specific types of wear because until the
nature of the wear is fully understood, the correct
solution cannot be identified.
Damage caused by these wear groups costs money,
especially in downtime and lost production, replace-
ment parts, repair and ongoing maintenance.

Impact Friction Castolin Eutectic has proved for more than a centu-
ry that a preventive maintenance welding program
can extend the life of critical machine parts by as
much as 500%. Castolin Eutectic has the «know-
how» to identify the most serious wear problems
and «show how» to avoid them. Castolin Eutectic
can greatly increase your plant efficiency and pro-
Heat & Corrosion Cavitation fits.

PROVEN WEARFACING APPLICATIONS

Wearfacing a worn VRM segmented roller Wearfaced teeth of a sugar cane crusher

Wearfacing repair of damaged roller press Wearfacing using TeroMatec® and Submerged Arc process

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TeroMatec®
THE COMPLETELY MOBILE TEROMATEC® SYSTEM
Weighing only 24kg, the TeroMatec® Wire Feeder 400 is designed to be easily moved by the welder around the
workshop or for on-site applications. The process is much easier to use than traditional MMA stick electrodes
because of the self regulating nature of the arc length which is directly controlled by the variable speed wire
feeder.
CastoMatec 655 power source

TeroMatec® Wire Feeder 400

Welding Wire feeder Power source

torch auxiliary ground welding cable
cable

Power source
ground cable
Technical data & clamp

Nominal motor supply 28 VDC max

Power 98 W
Welding current range 100 - 400 A
Nominal welding current 400 A
Open Circuit Voltage 80 V max
Duty cycle 100%
Wire feed speed 12 m/min
Wire diameters 1.6/2.4/2.8
Weight 24 Kg

Wire feeding system specially developed

for wearfacing thick, heavy components
Designed for cored wire Ø 1.6, 2.4, 2.8mm.
Powerful wire feeding thanks to the gearing Exclusive wire feeding
of two guide rolls system
Easy maintenance (minimal electronics & no gas) The TeroMatec® Wire Feeder
400 ensures smooth push
Easy to transport for working in extreme
feeding speeds for Tero-
conditions
Matec® flux cored electrodes.
Automatic regulation of wire feed speed.
Remote “on-off” control.

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 TeroMatec® Applications

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Technical Data

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For Joining, Buttering and Rebuilding
Repair of chassis and large parts in cast steel, Tensile strength : 670-740 N/mm²
688 Fe grab arms, buckets, machine bases. Elongation (l=d) : 25-35 %
Hardness : 220-260 HV
Bucket blades, grabs, leveller blades, tooth- Tensile strength : 600-670 N/mm²
690 Fe holders on mechanical shovels Elongation (l=d) : 45-55 %
Hardness : 170-210 HV
Foundry defects in cast steel, shrinkage cavities Tensile strength : 560-640 N/mm²
2010 Fe or blowholes in semihard or cast steel. Hardness : 260-310 HV

Repair of foundry defects in nodular or spheroi- Tensile strength ~475 N/mm2

4226 Fe dal graphite grades of cast iron - porosity, blow Hardness ~50 HRC
holes or shrinkage cavities. Annealed ~24 HRC

For anti-wear Coatings high resistant to Impact, metal/metal Friction, and slight Abrasion
Guides and rolls, rebuilding missing sections Tensile strength : 560-640 N/mm²
3110 Fe on large, very worn parts Caterpillar track Hardness : 270-330 HV
vehicle wear plates..
Rolling mill slide rods, shovel buckets, mobile
Tensile strength : 710-790 N/mm²
crane wheels, rails. Elongation (l=d) : 20-30 %
3205 Fe
Hardness : 220-270 HV
Hardness after workhardening : 400HV
Crusher hammers, rolls, cranes, jaws, power Hardness ~300 HV
3206 Fe
shovel or dredge buckets, pump parts. Work hardened ~45 HRC
Mechanical shovel teeth, crusher hammers and Hardness : 230-280 HV
3220 Fe rolls, grab edges.
For intermediate layers and multi-pass anti- Tensile strength : 580-660 N/mm²
wear coatings, joining of large parts of dissimi- Elongation (l=d) : 35-45 %
3302 Fe
lar composition, rail points, crusher bars and Hardness : 180-220 HV
jaws, drive sprockets.
Railway retarder beams and wagon brakes, Tensile strength : 800-1000 N/mm²
outside parts in hydroelectric power stations, Hardness : 290-340 HV
ES 4530 Fe defects in chromium cast steel. For submerged Hardness after welding : 340-420 HV
arc welding.

For anti-wear Coatings resistant to moderate Abrasion combined with Impact and Pressure
Crusher hammers, bars, anvils, casings, me- Hardness ~59 HRC
4327 Fe chanical shovel bucket teeth & lips, dragline
grab teeth, scraper blades.
Ground augers, percussion grabs, dragline Hardness : 52-57 HV
4415 Fe teeth and leading edges, gravel pumps, con-
veyor screws.
Crusher bars and cylinders, feed screws, clay Hardness : 49-54 HV
crushers, conveyor belts, waste disposal crusher
4625 Fe
hammers.

Crusher hammers and bars, impact and casing Hardness : 54-59 HV

4923 Fe screens, bucket teeth and lips, scraper blades.

For anti-wear Coatings resistant to high Abrasion and Erosion

Sinter crushers and fans, hot sieves, screens Hardness : 61-66 HV
3952 Fe
and bells.
Unique NanoAlloy for transport screws, furnace Hardness ~70 HRC
4395N Fe chutes, exhaust fans, cyclones, conveyor, mixers,
w
Ne duct scrapers, screws, screens.
o
Pr Conveyor screws, rolls, crusher pinions and Hardness : 52-57 HV
4601 Fe
grinders, dragline and pump parts.
Press spindle segment heads, mixer segments, Hardness : 65-70 HV
blades and scraper, wear plates, induction fans,
4630 Fe
drag chains.

Jaw crushers, mixer paddles, pump wheels, Hardness : 59-64 HV

4660 Fe mould screws.

Main application Secondary application

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CastoDur Diamond Plates®
Self shielding TeroMatec® flux cored wires also form the basis for our developments of wearfaced parts such as wearplates
(CastoDur Diamond Plate) and weartubes (CastoTube).These composite material parts consist of an easy-to-weld steel plate or
tube cladded with abrasion and erosion resistant alloys using either arc welding or plasma coating or vacuum furnace fusion
systems. They are suitable not only for the protection of extensive surfaces against wear but also for fabricating complex machi-
nery and equipment with longer service life and lower maintenance costs. CDP and CastoTube production plants have invested
in fully automated robotics and state-of-the-art manufacturing technology to guarantee highest quality, exchangeable wearfa-
ced parts which increase industrial productivity and protect the environment by conserving scarce raw material resources.

CastoDur Diamond Plates®

CDP 4666 - The better quality !
CDP 4666 is the High Load wearplate for extreme abra-
sion and erosion resistance. Its complex carbide struc-
ture contains a high density of hard particles. The ex-
tremely hard boron and niobium particles are finely
dispersed in between the chromium carbides, reducing
their spacing and ensuring the best protection from
abrasive and erosive media of finer size.
Type of wearfacing: C, Cr, Nb, B
Hardness: 62-65 HRC
Carbide content: > 50 %
CDP 4624 DXW - The best ratio cost/per-
formance
CDP XuperWave 4624 is the ideal wearplate for ap-
plications where the right balance between price and
service life is required, thus maintaining the Castolin
high standard welding quality and smooth surface.
Type of wearfacing: C, Cr
Hardness: 57-62 HRC
Carbide content: > 30 %

CDP 4666 application CDP 4624 DXW

in a cement plant applications
Base material (mm) Wearfacing (mm)
CDP 4666 DP and 4624 DXW 0503 5 3
CDP 4666 DP and 4624 DXW 0604 6 4
CDP 4666 DP and 4624 DXW 0804 8 4
CDP 4666 DP and 4624 DXW 0805 8 5
CDP 4666 DP and 4624 DXW 1005 10 5
CDP 4666 DP and 4624 DXW 1505 15 5
Other dimensions available on request

CastoTube®
CastoTubes - the latest addition to our expanding range CastoTubes offer many advantages:
of semi-finished, anti-wear solutions for industry. Highly cost effective
Basically it consists of easy-to-weld mild steel tubes Absence of harmful linear weld joints
which have been internally wearface-welded with
Exceptional wear resistance
TeroMatec® 4666 alloy thus maintaining the exceptio-
nal wear resistance of our well known 4666 CastoDur Perfectly round cross section
Diamond Plates. Furthermore, by avoiding expensive Spiral welding minimises distortion
forming operations of flat plates into tubes, seamless Lightweight for handling
small diameter.
Easy-to-join by welding or mechanical means

Base Tube
Article code Internal External Wall Wearfac-
Diameter Diameter TB (mm) ing
(mm) Do (mm) TH (mm)
0150 CT 0735 150 177,8 7,1 3,5
0175 CT 0635 175 193,7 5,6 3,5
0200 CT 0635 200 219,0 6,3 3,5
0250 CT 0835 250 273,0 8,0 3,5
0275 CT 0930 275 298,50 8,80 3,00
Other dimensions available on request
CastoTube Parts 100 mm diameter CastoTube

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CastoLab®
Our mission is to develop applications and solve cus-
tomer problems. Depending on the customer’s wish,
we can transfer this knowledge to him or perform the
work for him in our approved CastoLab workshops.
CastoLabs can develop advanced procedures to allow
transfer of complete solutions to end users. Casto-
Labs offer a complete and comprehensive service for
the maintenance of machine parts and major com-
ponents subject to extensive service wear or needing
repair. Work can either be undertaken in the Casto- Large CastoLab for major repairs
Lab or alternatively on site. Often the parts being re-
paired or protected need to be produced on a regular
basis, and here “specialist prepared parts” can be pro-
duced in unique manufacturing environment, from
10's of parts to 100,000 parts per year

On site Boiler Coating Precision working

Fan built with wear resistant CDP

Rebuilding

Crusher teeth ready for wearfacing Fan Protected with Powder Arc Wire Spraying
Coated Wear Plates

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technology has positioned Castolin Eutectic ������������������������

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TeroMatec®
CASTOLIN EUTECTIC

Training

To increase customer know-

how in wear technology and
Castolin Eutectic Locations repair techniques, we
have developed a full line
The unique Terolink database of of seminars and training
Castolin Eutectic contains more than programs, teaching all
8,000 fully documented approved relevant personnel from
applications from around the globe. welders and engineers to
The case studies include photographs, sales teams and managing
technical data, detailed descriptions directors.
and cost-saving analyses.

Manufacturing Product Portfolio - Widest in the Industry

R&D-Wear Test Laboratory
Together with our sister company, the Messer
Group, we can offer our customers a very powerful
range of products and services. Being «Part of the
Messer World» means:

Investment of over €420 million

More than 6,000 motivated employees
Over 100 factories to meet customer needs
Technical sales support in over 120 countries
2,000 technical sales people in the field with our
customers every day

Metallurgical Laboratory Micrograph of Wear Phenomena

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HISTORY OF CASTOLIN EUTECTIC
1906: Foundation of Castolin in Lausanne, Switzerland by Jean-Pierre
Wasserman. His stroke of genius: to discover a way of welding
cast iron at low temperature; in the following years, this innovation
was further developed for all industrial metals including
aluminium alloys.
1940: Foundation of Eutectic Welding Alloys Corporation in New York
1952: Foundation of Castolin France
1959: Foundation of Eutectic Japan Ltd
1962: Foundation of Eutectic India Ltd.
1960’s: International consolidation under Castolin Eutectic
1970’s: Creation of training centers for Maintenance & Repair technologies
1978: Establishment of World Head Quarters in St-Sulpice, Switzerland
2000: Merger with Messer Cutting & Welding and creation of the
MEC Group - Messer Eutectic Castolin
2005: Part of the Messer World
2006: 100 years of innovation, service and quality.

ADDRESSES OF CASTOLIN EUTECTIC COMPANIES IN EUROPE

Austria, Hungary, South East Europe Netherlands Switzerland
Castolin GmbH Castolin Benelux N.V. Castolin Eutectic Int. SA
Brunner Strasse 69 Rotterdamseweg 406 Swiss Market Centre
1235 Wien 2629 HH Delft
+43-(0)1-869 45 41-0 +31-(0)15-256 9203 Ch. de la Venoge 7
1025 St. Sulpice
Belgium Norway +41-(0)21 694 1111
s.a. Castolin Benelux n.v. Castolin Scandinavia
222-228, Blvd de l’Humanité Teknologiparken, Akersvn. 24 C Russia
1190 Bruxelles 0177 Oslo
+32-(0)2-370 1370 +47-22-11 18 70 Castolin Moscow
Zemlanoy val st. 60/22, of 5D
Czech Republic Poland 109004 Moscow
Castolin pol.s.r.o. Castolin Sp.z.o.o. +795 564 8680
Trojska 18/122 P.O. Box 502, ul. Robotnicza
18200 Praha 8 44-100 Gliwice Turkey
+42-(0)2-83 09 00 77 +48-(0)32-230 6736
Castolin Kaynak Ltd.
France Spain, Portugal Yukari Dudullu Mahallesi
Castolin France S.A. Castolin Iberica S.A. Bostanci Yolu Sehit Sokak 53
22, Av. du Québec BP 325 P. I. de Alcobendas 34775 Istanbul
Z.A. Courtaboeuf 1- Villebon c/ San Rafael, 6
91958 Courtaboeuf Cedex 28108 Alcobendas (Madrid) United Kingdom & Ireland
+33-(0)1-69 82 69 82 +34-914 900 300
Eutectic Company Ltd.
Germany Sweden, Denmark Merse Road
Castolin GmbH Castolin Scandinavia AB North Moons Moat
Gutenbergstrasse 10 Transportgatan 37 Redditch B98 9NZ
65830 Kriftel 42204 Hisings-Backa +44-(0)1527 58 2200
+49-(0)6192-403-0 +46-(0)31-570 470
For all others Countries please contact:
Portugal Lithuania
Castolin Portugal Castolin Sp.z.o.o. filialas Castolin Eutectic Int. S.A.
Rua Maestro Ferrer Trindade, 4B V. Nageviciaus 3-64 Export Market Center
2770-201 Paco de Arcos 08237 Vilnius P.O. Box 360
+351 707 200 855 +370 5 278 8448 CH-1001 Lausanne, Switzerland
+41-(0)21-694 1111
Statement of Liability: Due to variations inherent in specific applications, the technical information contained herein, including any information as to suggest pro-
duct 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 applica-
ble law and non-infringement of the rights of others, and Messer Eutectic Castolin and its affiliates shall have no liability in respect there of.

Your resource for protection, repair and joining solutions

www.castolin.com www.eutectic.com

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Stronger with...
Castolin Eutectic
WEAR & FUSION TECHNOLOGY

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