Welding and brazing consumables and systems, thermal coatings and wearplates for wear protection
Castolin Eutectic GmbH
Kriftel (DE) · Dublin (IE) · Enghien (BE) · Dubai (AE)New on Amplifa
About Castolin Eutectic
Castolin Eutectic is an internationally active provider of solutions for joining and wear protection: Welding (SMAW, MIG/MAG, TIG, spray welding, PTA-Plasma spray welding), Brazing (brazing, induction brazing, hydrogen torch brazing with OHF electrolysis technology) and thermal spraying (arc spraying, flame spraying, HVOF, Cold Spray and HVAF/Ultrasonic spraying). Additionally, CDP® wearplates and CastoTubes® are manufactured as wear protection plates and tubes, OEM components such as cyclones, fans and housings are produced from them, and repairs are carried out on-site or in 20 Castolin Services workshops. Around 400 Field Application Specialists support customers globally in maintenance and increasing availability. The materials range from cast iron (GJS/GJL, ductile iron) to steel, stainless steel, aluminum, and nickel alloys up to carbides and High Entropy Alloys. The German company is located in Kriftel; alloy manufacturing takes place in the Lloyd's Register certified facility in Dublin.
- Site
- Kriftel
- Processes
- Arc Spray (Twin Wire Arc Spray), HVOF Coating, Flame Spray, Cold Spray, PTA-Plasma Spray Welding, High-Speed Gas-Fuel Spray (HVAF) / XupersoniClad, Brazing, Hydrogen Torch Brazing (OHF Electrolysis Technology)
- Materials
- Cast Iron (GJS/GJL), Ductile Cast Iron, Steel (mild steel), Alloyed Steel, Stainless steel, Aluminum Alloys, Nickel Alloys, Carbide
- Certificates
- Lloyd's Register Certification Cast Iron Welding Consumables (EutecTrode 2-24,, DIN EN 9001 (Quality standard, annual audit according to article), UN Global Compact Membership, Lloyd's Register (PRJ 11088637), DIN EN 9001, UN Global Compact
- Employees
- 400 Field Applicatio
- 01
Alloy/Material Development (R&D)
- 02
Manufacturing of welding wires and electrodes
- 03
Design of wearplates and OEM components
- 04
CNC plasma/oxy/water jet cutting
- 05
Rolling and welding (fans, housings)
- 06
Coating (Arc Spray, HVOF, HVAF, PTA, Cold Spray)
- 07
Assembly/On-site Service and Repair
- 08
Training and maintenance support
Materials & Processes
Cast Iron (GJS/GJL, Ductile Cast Iron)
Lloyd's Register certified welding alloys (EutecTrode 2-24, 2-26D, XHD 2230, EnDOtec DO*23) for hot and cold welding of cast parts.
Steel and alloyed steel
Base material for construction, wearplates and OEM components such as fans and housings.
Stainless steel
Processed with MIG/MAG and TIG welding systems for corrosion-stressed components.
Aluminum alloys
Welding and spraying material, among others, for corrosion protection and lightweight applications.
Nickel alloys
Coating material for XupersoniClad (HVAF) for wear and corrosion protection.
Carbides
Spraying powder for abrasion-resistant HVOF and HVAF coatings.
High Entropy Alloys
Novel multi-element alloys for coatings in vacuum and high temperatures.
Zinc
Corrosion protection and base coating via arc spraying.
Hydrogen Torch Brazing (dyomix® electrolysis)
Fossil fuel is eliminated; brazing and cutting with clean flame derived from water.
XupersoniClad (Ultrasonic Spraying)
Warm HVAF process with high particle velocity for dense, ductile wear protection layers, including blast pretreatment.
PTA Plasma Spray Welding (Castoweld System PTA)
Plasma-based spray welding for wear-resistant layers on critical components.
Sites
Kriftel
DELocation of Castolin Eutectic GmbH
Dublin
IEManufacturing Plant (Alloy Production), Lloyd's Register certified
- Materials
- Cast iron welding alloys (EutecTrode, EnDOtec)
- Alloy production for welding wires/electrodes
Enghien
BEXupersoniClad system including mobile on-site container
- Materials
- Nickel alloys, Carbides, High Entropy Alloys
- XupersoniClad HVAF spraying system with Cobot
Dubai
AEMaintenance & Repair Workshop
- planned 500-kW PV solar project on the roof
Parts
Inside the production
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Arc Spray (Twin Wire Arc Spray)Surface | – | – | – | – | Steel, Zinc, Aluminum, Ceramic-free spray materials, EuTronic Arc Wires |
| HVOF CoatingSurface | – | – | – | – | Carbide, Nickel alloys, Metallic alloy powders |
| Flame SpraySurface | – | – | – | – | Spray and Fuse Powders |
| Cold SpraySurface | – | – | – | – | Cold Spray Powders |
| PTA-Plasma Spray WeldingJoining | – | – | – | – | PTA Powders |
| High-Speed Gas-Fuel Spray (HVAF) / XupersoniCladSurface | – | Inner pipe diameter from 80 mm | – | – | Nickel alloys, Carbide, High Entropy Alloys (HEA), Metallic alloys |
| BrazingJoining | – | – | – | – | Brazing alloys, Soft Solders, Pastes |
| Hydrogen Torch Brazing (OHF Electrolysis Technology)Joining | – | – | – | – | various metals |
| TIG WeldingJoining | – | – | – | – | Tig Rod Alloys |
| MIG/MAG WeldingJoining | – | – | – | – | Gas Shielded Cored Wire Alloys, MIG/MAG Solid Wires, aluminum alloys, stainless, mild steel, alloy steel, cored wires |
| Manual Metal Arc Welding (MMA)Joining | – | – | – | – | Manual Metal Arc Alloys, Cast Iron (EutecTrode 2-24, 2-26D, XHD 2230), EnDOtec DO*23 |
| Cast Iron Welding (Hot and Cold Welding)Joining | – | – | – | – | GJS (nodular iron), GJL (grey flake iron), malleable cast iron, steel |
| Spray Welding/WearfacingJoining | – | – | – | – | Open Arc Cored Wire Alloys, Hardbanding Wires, TeroMatec 4666 |
| Plasma CuttingMachining | – | – | – | – | Metal |
| Oxy-Fuel CuttingMachining | – | – | – | – | Metal |
| Water Jet CuttingMachining | – | – | – | – | CDP® wearplates, Sheet metal |
| Rolling and Welding complex shapes (Fan & Housing manufacturing)Joining | – | – | – | – | CDP® wearplates, Sheet steel |
| Manufacturing of wearplates (CDP®, CastoTube®, Powder Wear Plates, Welded Wear Plates)Forming | – | – | – | – | TeroMatec 4666, mild steel tubes, CDP® 4666 XuperWave, CDP® 112 |
| Repair Service (on-site and in 20 workshops)Assembly | – | – | – | – | cast iron, steel, Kiln tires, rail tracks, roller press, hammers |
| Induction Heating/BrazingJoining | – | – | – | – | Brazing alloys |
| OEM component manufacturing (finished/semi-finished parts)Assembly | – | – | – | – | CDP® wearplates, steel |
| Grit Blasting (Abrasive pretreatment)Surface | – | – | – | – | metal |
| Welding wire/electrode manufacturingJoining | – | – | – | – | EutecTrode 2-24, EutecTrode 2-26D, EutecTrode XHD 2230, EnDOtec DO*23, EnDOtec SAFE-HARD 600 |
11 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Arc Spray System | Castolin Eutectic EuTronic Arc Spray EAS1-i | – | Push-Pull spraying up to 20 m; extension necks 500/1000/1500 mm, Min. bore 75 mm | 2023 | – |
| Arc Spray Transformer | Castolin Eutectic EAS4-HFH | – | – | – | – |
| TIG/MMA Inverter Welding Machine | Castolin Eutectic CastotIG 1611 Advance | – | – | 2021 | – |
| MIG/MAG Pulsed Welding Machine | Castolin Eutectic XuperMIG 3000 PULSE | – | – | 2021 | – |
| MIG/MAG Welding Machine | Castolin Eutectic XuperMIG EnDOtec-Edition | – | – | 2021 | – |
| Hydrogen Torch (Electrolysis) | Castolin Eutectic OHF 4.0/6.0/9.0/12.0 | – | 4–12 kW/h, 0–3200 l/h Gas, Flame temp. >2700°C | 2021 | – |
| Hydrogen Braze Machine (Electrolysis) | Castolin Eutectic OHM 2.4 | – | – | – | – |
| PTA Plasma Spray Welding System | Castolin Eutectic Castoweld System PTA | – | – | 2025 | – |
| CNC Plasma/Oxy/Water Jet Cutting System | – | – | – | – | – |
| HVAF Supersonic Spray System with Cobot | Castolin Eutectic XupersoniClad | – | Inner tubes from 80 mm diameter | 2023 | Enghien, Belgium |
| Castolin Services Workshop (20 locations) | Castolin Eutectic | 20 | – | – | worldwide |
Additional services
Quality & Certification
The cast iron welding alloys and the Dublin plant are inspected annually by Lloyd's Register and are listed in the “Supplementary List of Welding Consumables”
| Evidence | Dublin |
|---|---|
| Lloyd's Register (PRJ 11088637) | |
| DIN EN 9001 | |
| UN Global Compact |
History
- 2020-05
Lloyd's Register re-certifies cast iron welding alloys and the Dublin plant
- 2021-02
Launch of the OHF cutting/brazing machine series (Water electrolysis, dyomix technology, developed since 2009)
- 2021-02
Launch of upgrades CastoTIG 1611 Advance, XuperMIG 3000 PULSE, XuperMIG EnDOtec-Edition
- 2021-09
Joining UN Global Compact
- 2021-12
R&D on Machine Learning and IoT for maintenance processes (R&D Manager Spyros Kamnis)
- 2023-06
Introduction of XupersoniClad (HVAF ultrasonic spraying) in Europe, plant upgrade in Belgium
- 2023-07
Launch of EuTronic Arc Spray EAS1-i (available on market since September 2023)
- 2025-04
Novelty: CastoWeld System PTA (Plasma coating)
- 2025-07
Submission of UN Global Compact CoP report 2025