TeroMatec® - Castolin Eutectic

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TeroMatec®TeroMatec® CORED WELDING WIRESTeroMatec® is a self shielded arc welding process (Open Arc/FCAW) using specially formulated flux coredwire electrodes. The self shielded peripheric arc conception includes a wide range of custom made alloysoptimised for industrial wearfacing, rebuilding and repair solutions with many advantages :No shielding gas requirementsFastest weld deposition ratesHigher welding duty cyclesEfficient weld metal recoveryStock reduction opportunitiesEase of use by semi skilled operatorsMaximum savings & productivitySolidified slagMolten slagWire guide / contact tubeCored wireParticles-elements/compoundsGas shieldcreated by compoundsArc and Metal transferNO SHIELDING GAS REQUIREMENTSSolidified weld metalWeld poolSelf shielding peripheric arcThe TeroMatec® process requires no costly investments or complicated manipulation ofheavy gas cylinders, regulators, flowmeters, mixers, hoses etc. TeroMatec®’s autonomousself shielding peripheric arc is designed for outdoor use where on-site wind or draughtconditions would simply blow away any external protective gas (GMAW) causing porous,defective welds.FASTEST WELD DEPOSITION RATESHIGHER WELDING DUTY CYCLESThe deposition rate of TeroMatec® flux cored electrodesis remarkable reaching 4 kg/h with the Ø1.6mm and almost 10 kg/h with the Ø2.8 mm due toperipheric arc current density effects. Furthermore,by increasing the electrode “stick out” (distancebetween the contact tube tip and the workpiece)from 50mm to 75mm, the deposition rate can beboosted over 12 kg/h due to electrical resistanceheating effects whilst reducing heat input and dilutionwith the base metal.The welding duty cycle (X) is simply the % relationshipbetween the effective arc welding time(t1) and the total time involved (t1 + t2) where t2 isthe non productive time between the arc weldingcycles. Thus TeroMatec® duty cycles easily reachover 90% in automatic mode compared with MMAstick electrodes which peak around 40%. The higherduty cycle for TeroMatec® is due to :no need to keep stopping & changing electrodesrepetitive striking & restriking eliminatedless post weld slag cleaning requiredfewer stop-start weld crater defects to grindDeposition rate (kg/h)400%extra300%extraArc Ont1X = x 100 %t1 + t2Arc OffTimeHigh efficiency manual electrodeCurrent (A)TeroMatec® X≈ 80-90%Manual electrode X≈ 40%2Stronger with Castolin Eutecticwww.castolin.com
EFFICIENT WELD METAL RECOVERY ( %)The weld metal recovery (sometimes called yield orefficiency) is simply the ratio of the mass of weld depositedto the total mass of the original welding electrode.Thus TeroMatec® cored wires have an excellentweld metal recovery ratio reaching 90% to 95%whilst MMA stick electrodes only reach around 65%due to higher slag volumes and repetitive stub endlosses.In other words, TeroMatec® ensures that virtually allthe weight of purchased cored wire ends up as a usefulweld deposit thus reducing consumable costs.= 1000g= 1000g650 g950 gMMA- 65%TeroMatec- 95%STOCK REDUCTION OPPORTUNITIESAs a 15kg TeroMatec® spool represents around 22kg of MMA stick electrodes for the same quantity of requiredweld 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 weldingcapabilities 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 OPERATORSRelatively little training is required for the TeroMatec® process (compared with MMA) which makes it easy tolearn by semi-skilled operators due to the self regulating nature of the arc, variable stick out capability, bettervisibility 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 precleaningneeded for the GMAW process, especially when access is limited.MAXIMUM SAVINGS &PRODUCTIVITYNumerous studies by industry show thatlabour costs are the biggest single expense inwelding. As skilled labour rates continue to riseinexorably, cut and control your welding costswith 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 welddeposition rates giving superior performance and service life.Stronger with Castolin Eutecticwww.castolin.com3
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TeroMatec® - Castolin Eutectic

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