Plasma Transferred Arc Technology

EuTronic GAP
The Castolin Eutectic PTA process

PlasmaTech
The complete range of power sources
for Plasma Transferred Arc welding
For plasma joining, coating and brazing
For manual, semiautomatic or fully robotised
applications
AC/DC version available for the welding of Al, Mg
and their alloys
Completely modular for immediate, tailor made
configuration and cost effective fitting of applications
Wide range of options, accessories and welding
consumables
Why EuTronic GAP
The EuTronic GAP is the Castolin Eutectic Plasma Transferred
Arc (PTA) process ideal for joining and coating operations.
In the GAP process, the plasma is focused while forced
through the heat resistant anode, causing a considerable
increase of the arc density, energy and temperature.
The welding ller alloy, in microatomised powder or cold
wire form, is conveyed into the plasma arc column where a
shielding gas protects the weld pool from the atmosphere.
The plasma arc and the heat input can be far better con-
trolled than a conventional electric arc and the energy is
almost completely spent to melt the ller metal, reducing the
heat input and dilution to the minimum.
Focused plasma arc allows extra control, that results also in lowest
dilution among all the arc welding processes
GAP technology provides a wide range of benets compared
with conventional arc welding processes:
High energy density in an extremely focused arc
High deposition rates for shorter welding times
Homogeneous, pore and spatter free coatings
Lowest dilution, heat input, distortions and Heat Affected
Zone than any other arc welding process
Ideal control of the deposit thickness
Maximum purity and performance of the alloy
Smoother surface for lower machining costs
Exceptional reproducibility
Suitable also for fully automated processes (3001DC and
3002 AC/DC only)
and also when compared with spray and fuse process:
Higher bond strength and impact resistance
Lower overspray and smoother deposits, reducing the
after welding machining costs
Thicker coatings allowed
Lower heat input
Minimum distortions
All these features make the PTA process ideal for those
operations where extra precision, low heat input and
distortions are needed.
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PTA also delivers extreme purity and performance of the
coating alloy, even on the very rst layer.
This feature, together with the high process efciency,
ideal control of the layer thickness, (that can be adjusted
downto 0,5mm. depending also on the system congu-
ration) and the smoothness of the weld beads, allows
consistent cost savings in terms of machining and ller
alloy costs.
PTA process produces extra smooth and spatter free deposits, minimis-
ing machining and filler alloy costs.
The EuTronic GAP family
After 100 years of history and more than 30 years expe-
rience in PTA equipment and application development,
Castolin Eutectic introduces the new generation of PTA
power sources.
This complete family of machines is based on high-power
inverters for stepless generation and control of welding and
pilot arc current.
From small tool and dies manual operations to fully auto-
mated or extra high deposition rate applications, Castolin
Eutectic is able to recommend, design and provide the
tailor made and cost effective solution you are looking for.
Versatile in use
With the power sources of the EuTronicGAP family is
possible to combine multiple processes on a wide range
of base materials, from tool steels to Al and Mg alloys
(AC/DC version only):
Plasma powder welding
Cold wire plasma welding
Manual Plasma-TIG (with Tig or Laser rods)
Plasma powder and cold wire brazing
Plasma joining with or without filler alloy
Cold wire Tig welding
Tig welding
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EuTronic GAP 2001 DC
The EuTronicGAP 2001, is ideal for welding applications re-
quiring precision, high quality of the deposit and low dilution
on individual parts or small series of pieces, where full auto-
mation is not convenient or applicable.
It is available in two different versions, with specific individual
features; each one of them can be requested with ( Powder
type) or without external feeders motor control card:
EuTronic GAP 2001 DC Touchscreen:
Is the Castolin Eu-
tectic Micro Plasma
GAP power source,
suitable also for joi-
ning of thin plates
or precise tool and
die coating and re-
pairs: a big step clo-
ser to laser welding
at a reasonable cost.
Welding parameters
are set and displayed
in simple menus on the colour touchsreen, that allows
also an immediate monitoring of external cooling units
and setting of powder or wire feeder functions. This po-
wer source is suitable for a simple semi-automation of the
process, as the parameters of an individual program can
be stored in the machine and executed from an external
start-stop signal.
EuTronic GAP 2001 DC Basic: melting temperature oxydes can be successfully welded.
With a standard
button and potenti-
ometers front panel,
developed for fully
manual or semiau-
tomated operations
that require fre-
quent adjustments
of the parameters.
All the settings and
messages are displayed in plain text on the wide LCD and
100 memory units are availble for the storing of welding rou-
tines. The exremely powerful inverter delivers 160A at 100%
duty cycle, satisfy also the most demanding applications.
Mainly designed for
automated applicati-
ons, The EuTronicGAP
3001 DC has a wide
selection of options
and additional fea-
tures available to bet-
ter fulll your applica-
tion requirements.
EuTronic GAP 3002 AC/DC
The EuTronicGAP 3002 AC/DC, placed at the top of the range,
is a higly sophisticated machine, that allows also welding
of Al, Mg and their alloys. It shows the same basic features
and control panel of the GAP 3001DC, standard electronic
plasma gas control valve, interfaces to drive external feeding
devices, a powerful PLC, memory for storing up to 100 user
welding routines, user friendly internal software.
In addition the EuTronicGAP 3002 AC/DC includes a wide
choice of welding modes, for ideal settings and results on
any type of base material and in any condition:
DC-: is the most used (standard) welding mode, with
minimum wear of the tungsten electrode and of the plasma
nozzle.
DC+: with this polarity also alloy surfaces covered by high
This polarity causes a faster wear of the tungsten electrode
and of the plasma nozzle.
Compared to direct polarity, DC+ produces wider weld beads
with a lower penetration and dilution.
AC standard: is mainly used for the welding of Al or Mg
(and their alloys): the positive half-waves break the superfi-
cial oxide film, while during the negative half-waves the heat
is mainly transferred to the piece, increasing the penetration
and allowing the tungsten electrode to cool down.
The AC frequency, that increases the cleaning effect and
the AC negative half-wave width can be adjusted to opti-
mise the results.

EuTronic GAP 3001 DC

The EuTronicGAP 3001 DC features a standard electronic
plasma gas control valve and all the necessary interfaces to
drive external feeding devices.
A new, powerful PLC controls all the functions while the
user friendly menus enable all the parameters to be entered
and all the error messages to be displayed in plain text on the
front LCD.
Its memory allows storing up to 100 user welding routines.
AC Minus mix: in the AC Minus Mix operation the current
switches between AC and DC in the adjusted DC Frequency.
AC/DC Mix - operation is used to get a higher fusion and pen-
etration compared to the standard AC operation.
AC Plus mix: in the AC Plus Mix operation the current switch-
es between AC and DC in the adjusted DC Frequency.
AC/DC Mix+ operation is used to get a higher cleaning effect,
compared to the standard AC operation.

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 The ideal choice for manual or semiautomatic operation
The new EuTronicGAP 2001 has been specifically designed for all those applications where a full automation is not required, con-
venient or applicable.
The EuTronicGAP 2001 is available in the Basic and Touchscreen version, with specific individual features; each one of them can
be requested with ( Powder type) or without feeders motor control card:

Touchscreen version: the Micro Plasma inverter, a big step closer to laser welding at a reasonable cost, allows internal setting of the
parameters of a single and simple program, that can be executed from an external start-stop signal.

EuTronicGAP 2001 DC Touchscreen: ESC 260233

EuTronicGAP 2001 DC Touchscreen Powder: ESC 260062

Pilot arc current: 0.5 - 10A ( 10A 100% Duty Cycle )

Main arc current: 1 - 160A ( 160A 100% Duty Cycle )
Voltage supply: 3x400V + N 10%
Supply frequency: 50/60 Hz
Max power consumption: 16 KVA
Open-circuit V main inverter: 110V
Open-circuit V pilot inverter: 100V
Supply fuse: 16 A
Degree of protection: IP 23
Plasma gas adjustment: Manual flowmeter, 0.2-2.5 lt/min
Shielding gas adjustment: Manual flowmeter, 2-20 lt/min
Transport gas adjustment: Manual flowmeter, 0.5-4.2 lt/min
Recommended (max) gas inlet pressure: 2.5 bars (2.5 bars)
Dimensions (L x W x H): 815 x 445 x 635 mm
Weight: 70 kg

MAIN OPTIONS: neutral point generator.

Basic version: for all those manual or semiautomatic applications that require higher power output and frequent adjustments of
the welding and process parameters.

EuTronicGAP 2001 DC Basic: ESC 260234

EuTronicGAP 2001 DC Basic Powder: ESC 260063

Pilot arc current: 5 - 20A ( 20A 100% Duty Cycle )

Main arc current: 1 - 160A ( 220A 100% Duty Cycle)
Voltage supply: 3x400V + N 10%
Supply frequency: 50/60 Hz
Max power consumption: 16 KVA
Open-circuit V main inverter: 110V
Open-circuit V pilot inverter: 100V
Supply fuse: 16 A
Degree of protection: IP 23
Plasma gas adjustment: Manual flowmeter, 0.2-2.5 lt/min
Shielding gas adjustment: Manual flowmeter, 2-20 lt/min
Transport gas adjustment: Manual flowmeter, 0.5-4.2 lt/min
Recommended (max) gas inlet pressure: 2.5 bars (2.5 bars)
Dimensions (L x W x H): 815 x 445 x 635 mm
Weight: 65 kg

MAIN OPTIONS: neutral point generator.

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 Born for fully automated applications
The new EuTronicGAP 300X series has been specifically developed for implementation of fully automated applications:
standard plasma gas electronic control valve, powerful PLC, flexible 72 pin Harting plug automation interfaces (available on
request), up to 100 memory cells for storing of welding routines, additional (optional) software package for better control and
display of all the process parameters are the main features of these new state of the art power sources.

EuTronicGAP 3001 DC: powerful and modular can be easily adapted to almost any application, manual, or (semi)automatic.

EuTronicGAP 3001 DC: ESC 260065

Pilot arc current: 3 - 60 A

max 30 A 100% Duty Cycle
Welding current: 6 - 350 A
Max welding arc current: 250 A 100 % Duty Cycle
320 A 60 % Duty Cycle
350 A 50% Duty Cycle
Open-circuit V main-pilot inverter: 80V - 110V
Voltage supply: 3x400V + N 10%
Supply frequency: 50/60 Hz
Supply fuse: 32 A
Degree of protection: IP 23
Plasma gas adjustment: Electronic valve, 0.1-5.0 lt/min,
Shielding gas adjustment: Manual flowmeter, 2-20 lt/min
Transport gas adjustment: Manual flowmeter, 0.5-4.2 lt/min
Recommended (max) gas inlet pressure: 2.5 bars (2.5 bars)
Dimensions (L x W x H): 815 x 445 x 635 mm
Weight: 77 kg

MAIN OPTIONS: neutral point generator, second feeder motor control card, automation interface, GAP Control software + 5m
RS232 fibre optic cable, electronic shielding and transport gas control valves .

EuTronicGAP 3002 AC/DC: at the very top of the range, fits any application, including welding of Al, Mg and their alloys

EuTronicGAP 3002 AC/DC: ESC 260067

Pilot arc current: 3 - 60 A

30 A 100% Duty Cycle
Welding current range: 6 - 380A DC ( 6 - 280A AC)
Max welding arc current: 280A DC ( 280A AC) 100 % Duty Cycle
320A DC ( 280A AC) 60 % Duty Cycle
380A DC ( 280A AC) 35% Duty Cycle
Open-circuit V main-pilot inverter: 80V - 110V
Voltage supply: 3x400V + N 10%
Supply frequency: 50/60 Hz
Supply fuse: 32 A
Degree of protection: IP 23
Plasma gas adjustment: Electronic valve, 0.1-5.0 lt/min
Shielding gas adjustment: Manual flowmeter, 2-20 lt/min
Transport gas adjustment: Manual flowmeter, 0.5-4.2 lt/min
Recommended (max) gas inlet pressure: 2.5 bars (2.5 bars)
Dimensions (L x W x H): 815 x 445 x 635 mm
Weight: 85 Kg

MAIN OPTIONS: neutral point generator, second feeder motor control card, automation interface, GAP Control software + 5m
RS232 fibre optic cable, electronic shielding and transport gas control valves .

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 Complete Range of Options and Accessories for every application
The power sources of the new EuTronicGAP range, due to the modular design, can be adapted to any application just choosing
the right accessories.

Two EP2 can be driven in parallel (only by power

Manual or foot remote controls are avail- sources with the optional second motor control
able for extra comfort and ease of use card) for applications that require feeding of
different powders in the weld pool: i.e. matrix
RC-H manual remote and carbides.
control: ESC 260231
Powder Feeder EP2: ESC 260229
including 8 metres connecting cable
Carrier gas: Ar, Ar-H2
RC-F foot operated remote control Carrier gas ow rate: 0 - 4 l/min
(pedal): ESC 260232 Powder reservoir: 2 l capacity
including 8 metres connecting cable Degree of protection: IP 23
Weight (without powder): 7.5 kg
Dimensions (L x W x H): 200 x 170 x 470 mm
The oscillator units are available in 3 different ver- Feeding rate stepless controlled via feeding wheel speed
sions: basic OU, Oscillator Unit, an Arc Voltage Con- directly from inverter PLC. Powder feed rate 3-120 g/min,
trol option, AVC, that keeps the distance between
depending on feeding wheel conguration, torch, anode
torch and workpiece constant and a OU with AVC
and powder density.
option (2 axis oscillator).
Electronic OU: ESC 260314
Oscillation width: 60 mm max
Oscillation speed: 0,1 - 60 mm/s
Dwell time: 0 - unlimited
Max load: 5 Kg
Electronic AVC: ESC 260315
Max transverse path: 100 mm
Oscillation speed: 0,1 - 20 mm/s
Fully interfaceable or standalone wire
Max load: 10 Kg feeders.
Electronic OU with AVC: ESC 260316
Cold Wire Feeder KD2: ESC 400560
The system allows oscillation while keeping the distance
Wire feed rate: 0 8 m/min
from the workpiece constant. The max load is 5kg.
Wire feed rolls: 0.8 2.8 mm
Control Box: Degree of protection: IP 23
Supply voltage: 230V AC 50/60Hz Weight: 17.2 kg
Degree of protection: IP 23 Dimensions (L x W x H): 705 x 280 x 420 mm
Weight: 20 kg Speed controlled for continuous or pulsed feeding mode and
Dimensions (LxWxH): 564 x 264 x 440mm wire retraction. Higher wire feed speed option on request

The GAP Control.....

....is the optional easy and user friendly software, that allows display-
ing and setting of all the welding and inverter parameters.
Reports can be generated for quality control issues and, when installed
in fully automated systems, rejects can be authomatically removed
from the production cycle.
The minimum hardware requirements, processor Intel 486 or high-
er, Win98, RS232 interface, allow running it on most computers.
Different password protected levels are set to protect the system and
delicate settings from unauthorised use.
Through the GAP Control it is also possible to modify the functions
assigned to digital and analog inputs-outputs and extend the memory
capacity of the equipment to unlimited as welding routines can be
uploaded from inverter to PC and viceversa.

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 Single or twin circuit cooling units, addi-
tional water-water heat exchanger is
available on request.
Wide range of additional trays
Cooling GAP (*): ESC 260058 and accessories for better con-
figuration and ease of use of the
Weight: 40 kg
trolley.
Dimensions (L x W x H): 900 x 445 x 360mm
Cooling GAP Twin: ESC 260059 Trolley: ESC 260056
Weight: 45 kg Weight: 45 kg
Dimensions (L x W x H): 900 x 445 x 360mm Dimensions (L x W x H): 1.190 x 740 x 1.415 mm
Holds gas bottles, powder feeder, power source and cooler
(*) Use only Castolin Eutectic dedicated cooling liquid

Castolin Eutectic PTA Torches

If power sources are the heart of the system, torches and their accessories (anodes, powder and shielding nozzles) stand for
a PTA installation as the hands for a clock maker: operative precision and construction accuracy are a must.
This is why Castolin Eutectic is constantly developing the torch range, to improve their performance, reliability and results.
If you cannot find here the torch that suits your application please contact our representatives, as additional PTA torches
and accessories can be developed on request!

GAP E12N GAP E15

Construction: horizontal Construction: horizontal
Max current at 100%: 100A Max current at 100%: 150A
Powder ow rate: N.A. Powder ow rate: N.A.
Weight with hose pack: 1.9 kg (4m) Weight with hose pack: ca. 2.5 kg (4m)
Description: liquid cooled manual torch, available also with 70 Description: liquid cooled manual torch, available also with 70
and 180 neck. Hose pack: 4-6-8 metres; longer hose packs on and 180 neck. Hose pack: 4-6-8 metres; longer hose packs on
request. Cold wire holder available. request. Cold wire holder available.

GAP E80 E54 S-M-D-DL

Construction: horizontal Construction: horizontal
Max current at 100%: 80A Max current at 100%: 200A
Powder ow rate **: 5-20 g/min Powder ow rate **: 10 - 40 g/min
Weight with hose pack: 2.0 kg (3m) Description: powder machine torch for inner coatings of parts
with diameter > 80mm, available in four different lengths (mo-
Description: 3m hose pack, liquid cooled
dels): 330(S), 550(M), 920(D) and 1770(DL)mm. with various hose
powder manual torch.
pack lengths.
Built on request, please ask for delivery time.
GAP E52
Construction: vertical
Max current at 100%: 200
GAP E42
Construction: vertical
Powder ow rate **: 3 - 80 g/min
Max current at 100%: 200A
Weight with hose pack: 4.8 kg (4m)
Powder ow rate **: 3 - 140 g/min
Description: liquid cooled powder machine torch
Weight with hose pack: 3.7 kg (4m)
for general applications. Cold wire holder available.
Hose pack: 4-6-8 metres; longer hose packs on request. Description: liquid cooled powder machine torch
Wide range of anodes and powder nozzles. for high duty applications. Cold wire holder available.
** Max feeding rate depending also on powder density, powder feeder settings and type of anode

A complete range of
anodes, powder and gas
nozzles has been designed
and is constantly improved
to allow ideal access, feed-
ing and fusing of powder,
even on the most difficult
parts.

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 Application Oriented Design
Castolin Eurectic develops and manufactures GAP weld-
ing units and accessories in various models and sizes
either as standard units or as special developments.
Our team of technicians is able to design the cost
effective and tailor made solution to fit your specific
application.
From power source to feeding units, welding torches,
even handling devices or robots when required, we take
care of all the details.
Let our specialists surprise you, we never talk about
products, but only of applications and solutions to your
enquiries and necessities.

Castolin Eutectic GAP consumables

Castolin Eutectic, since a century, is the market leader and the application special-
ist in wear & fusion technologies.
We are manufacturers of the widest range of welding, coating and brazing con-
sumables on the market today and can offer you a complete selection of PTA weld-
ing alloys, available in different forms, that covers almost every application and
any plasma transferred arc welding process:

Atomised Ni, Co, Fe or Cu based powders for wear resistant coatings

Atomised Ni based powders additioned with tungsten carbides for
maximum abrasion and erosion resistance
Laser wires, laser and Tig rods for manual and micro plasma welding
Solid and flux cored wires for cold wire plasma welding

Ask your local Castolin Eutectic representative for more information.

YOUR RESOURCE FOR PROTECTION, REPAIR AND JOINING SOLUTIONS

Switzerland
Castolin Eutectic Intl. S.A.
Case postale 360
CH-1001 Lausanne
Tl. +41.21. 694.11.11
Fax +41.21. 694.11.70
U.S.A.
Eutectic Corporation
N94 W14355 Garwin Mace Drive
Menomenee Falls WI 53051
Tel. +1 (262) 255.55.20
Fax. +1 (262) 255.55.42
Australia Germany
Eutectic Australia Pty. Ltd. Castolin GmbH
Unit 21, 317-321 Woodpark Road Gutenbergstrae 10
Smithfield NSW 2164 Sydney D-65830 Kriftel
Tel. +61.2. 87.86.37.05 Tel. +49.6192. 40.30
Fax +61.2. 97.25.33.76 Fax +49.6192. 40.33.14

We reserve the right to improve or modify these information or technical specifications without previous notice. by Castolin Eutectic 11-2006

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