Protective Coatings for Industrial Fans and Housings

Wear Management Solutions

Typical Industries Served using Eutectic Solutions...

Power Generation

Steel

Mining

Cement

Statement of Liability: Due to variations inherent in specifi c applications, the technical information contained herein, including any information as to suggested product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fi tness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Eutectic Corporation and its affi liates shall have no liability in respect thereof.

YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS

FANS 9-14 © 2008, Eutectic Corporation, ® Reg. T.M., Printed in the U.S.A.

Eutectic CorporationN94 W14355 Garwin Mace DriveMenomonee Falls, WI 53051 USAP 800-558-8524 • F 262-255-5542www.eutectic.com

CastoLab Services Workshop12300 Carmen AvenueMilwaukee, WI 53225 USAP 800-558-8524 • F 262-255-5542

Whertec Technology Center5409 Highway AvenueJacksonville, FL 32254 USAP 866-207-6503 • F 904-213-8126www.whertec.com

On-Site Services: The Reliability Experts

Whertec is the on-site service division of Castolin Eutectic. The division offers a highly organized inspection, mobilization, welding and thermal spray service covering a wide range of industrial applications. Every job is covered by a pre- and post-project report that can be used to assess future preventative maintenance requirements and evaluate in-service performance of key component parts. Whertec operates with stringent health and safety standards and has established a reputation for effi ciency and reliability.

The combination of Castolin Eutectic’s product and application expertise with a world-class site mobilization team offers customers the best possible solution for on-site projects – test the reliability experts with your demanding repair or material conservation projects.

t i th it i di i i f t li E t ti Th di i i ff h i d i ti bili ti

Stronger, with Castolin Eutectic 2Stronger, with Eutectic

www.eutectic.com

Stronger, with Eutectic

www.eutectic.com

Worn-out bladeWorn-out impeller

Do These Pictures Look Familiar?

• Erosion • Abrasion • Cavitation • Corrosion • Impact • High Temperature

Extreme erosion on blades

XuperWave Weld Quality

Localized abrasion on blade section

Common Enemies of Valuable Fans & Housings

Straight Bead XuperWave Bead

Extend Service Life with CDP® XuperWave® Wear Plate

• Ideal for parts exposed to fi ne particles at high velocity

• Maximum protection against linear erosive wear • Prevents fi ne particle tracking at points most susceptible to wear such as the stress cracks and weld bead overlap

• Reduces wear by up to 30% over conventional weld bead pattern

• Smooth, fl at bead profi le for easy balancing and overall increased fan performance

PLATE

TYPE DESCRIPTION G65*

HARDNESS(HRC)

TOTAL PLATE THICKNESS**

6503 PTA 65% tungsten carbide on a hard nickel

alloy matrix.10 mm3 61-65

7mm (5/16”)

9mm (3/8”)

395N

WEL

DED

NanoAlloy® nano size ultra hardphases.

12 mm3 68-7110mm (3/8”)

13mm (1/2”)

19mm (3/4”)

112

FUSE

D Lightweight plate with hard nickel alloy matrix and tungsten carbide

particles.12 mm3 58-61

6mm (1/4”)

212

FUSE

D Lightweight plate with hard nickel/iron alloy matrix and tungsten carbide

particles.12 mm3 58-60

6mm (1/4”)

4666

WEL

DED Complex carbides and borides.

High-temperature.17 mm3 61-64

8mm (5/16”)

10mm (3/8”)

13mm (1/2”)

19mm (3/4”)

4624

WEL

DED

Chromium carbide. 23 mm3 58-6110mm (3/8”)

13mm (1/2”)

19mm (3/4”)

22X

4X

ALLOY DESCRIPTION

BTCSolutions

Thermal spray protective coatings applied using proprietary processes. Solutions tailored to protect against combinations of abrasion, erosion and corrosion, even at high temperatures.

18X

18X

18X

13X

10X

22

4

1

1

1

1

1

Lower Wear Resistance Compared to AR 400

Higher Wear Resistance Compared to AR 400

EXTE

ND

ED S

ERV

ICE

LIFE

Critical equipment, that’s subjected to extreme conditions, needs the best hardfacing solution!

Workshop Case Study

Plates produced with multiple torch heads, will have an uneven surface, illustrated below. Eutectic XuperWave is made using a single torch which produces fl at, even weld beads across the entire plate. This welding process is cooler which minimizes distortion and dilution and maintains the maximum in wear resistant properties of the alloy. Also, smooth, fl at plate is critical to balance and optimal air fl ow which ensures the best possible wear resistance and overall fan performance.

0

2

4

8

10

12

14

16

18

20

6

Conventional wear plates exhibit uneven welds

StStrStr iaigaighhht Bead XuperWave Be ddad

Conventional wear plates exhibit uneven welds XuperWave welds remain smooth and even

Competitor solution lasted just 12 months (left), while CDP blades (right) are still in service after 2 years.

WEAR PROBLEM: Iron and steel works fans suffer from extreme erosive wear caused by fi ne oxide particles in the steel making process.

PREVIOUS SOLUTION: Fabricate impeller blades of a steel baghouse fan from basic chromium carbide (CrC) plate in 1/4” + 1/4” thickness. The fan lasted 12 months in service.

EUTECTIC SOLUTION: To increase service life, Eutectic recommended fabricating the blades from CDP 4666 XuperWave complex carbide plate in 1/2” total thickness.

RESULTS: Eutectic solution is still in service after 2 years, with minimal wear!

Fans - Steel and Iron Works

Stronger, with Castolin Eutectic 2Stronger, with Eutectic

www.eutectic.com

Stronger, with Eutectic

www.eutectic.com

Worn-out bladeWorn-out impeller

Do These Pictures Look Familiar?

• Erosion • Abrasion • Cavitation • Corrosion • Impact • High Temperature

Extreme erosion on blades

XuperWave Weld Quality

Localized abrasion on blade section

Common Enemies of Valuable Fans & Housings

Straight Bead XuperWave Bead

Extend Service Life with CDP® XuperWave® Wear Plate

• Ideal for parts exposed to fi ne particles at high velocity

• Maximum protection against linear erosive wear • Prevents fi ne particle tracking at points most susceptible to wear such as the stress cracks and weld bead overlap

• Reduces wear by up to 30% over conventional weld bead pattern

• Smooth, fl at bead profi le for easy balancing and overall increased fan performance

PLATE

TYPE DESCRIPTION G65*

HARDNESS(HRC)

TOTAL PLATE THICKNESS**

6503 PTA 65% tungsten carbide on a hard nickel

alloy matrix.10 mm3 61-65

7mm (5/16”)

9mm (3/8”)

395NW

ELD

ED

NanoAlloy® nano size ultra hardphases.

12 mm3 68-7110mm (3/8”)

13mm (1/2”)

19mm (3/4”)

112

FUSE

D Lightweight plate with hard nickel alloy matrix and tungsten carbide

particles.12 mm3 58-61

6mm (1/4”)

212

FUSE

D Lightweight plate with hard nickel/iron alloy matrix and tungsten carbide

particles.12 mm3 58-60

6mm (1/4”)

4666

WEL

DED Complex carbides and borides.

High-temperature.17 mm3 61-64

8mm (5/16”)

10mm (3/8”)

13mm (1/2”)

19mm (3/4”)

4624

WEL

DED

Chromium carbide. 23 mm3 58-6110mm (3/8”)

13mm (1/2”)

19mm (3/4”)

22X

4X

ALLOY DESCRIPTION

BTCSolutions

Thermal spray protective coatings applied using proprietary processes. Solutions tailored to protect against combinations of abrasion, erosion and corrosion, even at high temperatures.

18X

18X

18X

13X

10X

22

4

1

1

1

1

1

Lower Wear Resistance Compared to AR 400

Higher Wear Resistance Compared to AR 400

EXTE

ND

ED S

ERV

ICE

LIFE

Critical equipment, that’s subjected to extreme conditions, needs the best hardfacing solution!

Workshop Case Study

Plates produced with multiple torch heads, will have an uneven surface, illustrated below. Eutectic XuperWave is made using a single torch which produces fl at, even weld beads across the entire plate. This welding process is cooler which minimizes distortion and dilution and maintains the maximum in wear resistant properties of the alloy. Also, smooth, fl at plate is critical to balance and optimal air fl ow which ensures the best possible wear resistance and overall fan performance.

0

2

4

8

10

12

14

16

18

20

6

Conventional wear plates exhibit uneven welds

StStrStr iaigaighhht Bead XuperWave Be ddad

Conventional wear plates exhibit uneven welds XuperWave welds remain smooth and even

Competitor solution lasted just 12 months (left), while CDP blades (right) are still in service after 2 years.

WEAR PROBLEM: Iron and steel works fans suffer from extreme erosive wear caused by fi ne oxide particles in the steel making process.

PREVIOUS SOLUTION: Fabricate impeller blades of a steel baghouse fan from basic chromium carbide (CrC) plate in 1/4” + 1/4” thickness. The fan lasted 12 months in service.

EUTECTIC SOLUTION: To increase service life, Eutectic recommended fabricating the blades from CDP 4666 XuperWave complex carbide plate in 1/2” total thickness.

RESULTS: Eutectic solution is still in service after 2 years, with minimal wear!

Fans - Steel and Iron Works

Protective Coatings for Industrial Fans and Housings

Wear Management Solutions

Typical Industries Served using Eutectic Solutions...

Power Generation

Steel

Mining

Cement

Statement of Liability: Due to variations inherent in specifi c applications, the technical information contained herein, including any information as to suggested product applications or results, is presented without representation or warranty, expressed or implied. Without limitation, there are no warranties of merchantability or of fi tness for a particular purpose. Each process and application must be fully evaluated by the user in all respects, including suitability, compliance with applicable law and non-infringement of the rights of others, and Eutectic Corporation and its affi liates shall have no liability in respect thereof.

YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS

FANS 1-15 © 2008, Eutectic Corporation, ® Reg. T.M., Printed in the U.S.A.

Eutectic CorporationN94 W14355 Garwin Mace DriveMenomonee Falls, WI 53051 USAP 800-558-8524 • F 262-255-5542www.eutectic.com

Eutectic Services12300 Carmen AvenueMilwaukee, WI 53225 USAP 800-558-8524 • F 262-255-5542

Whertec Technology Center5409 Highway AvenueJacksonville, FL 32254 USAP 866-207-6503 • F 904-213-8126www.whertec.com

On-Site Services: The Reliability Experts

Whertec is the on-site service division of Castolin Eutectic. The division offers a highly organized inspection, mobilization, welding and thermal spray service covering a wide range of industrial applications. Every job is covered by a pre- and post-project report that can be used to assess future preventative maintenance requirements and evaluate in-service performance of key component parts. Whertec operates with stringent health and safety standards and has established a reputation for effi ciency and reliability.

The combination of Castolin Eutectic’s product and application expertise with a world-class site mobilization team offers customers the best possible solution for on-site projects – test the reliability experts with your demanding repair or material conservation projects.

t i th it i di i i f t li E t ti Th di i i ff h i d i ti bili ti