Laser Cladding is a weld build-up process and a complementing coating technology to thermal spray. It is increasingly used instead of PTA (Plasma Transferred Arc) welding and easily outperforms conventional welding methods like TIG (Tungsten Inert Gas) for advanced weld repair applications. Due to its superior focusing ability, lasers allow power densities that are not typically possible with conventional thermal procedures. This enables to process components with minimal thermal loading and distortion. Laser cladding is particularly suitable for applications demanding a high dimensional accuracy. Additional applications include materials that are difficult to weld using conventional methods, such as high temperature-resistant nickel-based alloys in gas turbines or tungsten-carbide-filled wear-protection coatings. Typical components include turbine blades, drilling equipment, and pump components.
Lasermach Laser Cladding Process
In laser cladding, the laser beam is defocused on the workpiece with a selected spot size. The powder coating material is carried by an inert gas through a powder nozzle into the melt pool. The laser optics and powder nozzle are moved across the workpiece surface to deposit single tracks, complete layers or even high-volume build-ups.
- Perfect metallurgically bonded and fully dense coatings
- Minimal heat affected zone and low dilution between the substrate and filler material resulting in functional coatings that perform at reduced thickness, so fewer layers are applied
- Fine, homogeneous microstructure resulting from the rapid solidification rate that promotes wear resistance of carbide coatings
- Edge geometries can be coated and built up with welded deposits
- Near net-shape weld build-up requires little finishing effort
- Extended weldability of sensitive matierals like carbon-rich steels or nickel-based superalloys that are difficult or even impossible to weld using conventional welding processes
- Post-weld heat treatment is often eliminated as the small heat affected zone minimizes component stress
- Excellent process stability and reproducibility because it is numerical controlled welding process
Swing over bed：Φ850mm
Maximun workpiece length：3200mm
Maximun turning length：3100mm
Span of guideway: 435mm
Spindle bore: Φ94mm
Machine overall dimensions：6500×2000×2640mm
The principle is an accelerated application of the coating on the substrate.
This is done by clamping the workpieces on a lathe.
The laser cladding process is a method of applying a fully dense, metallurgically bonded and virtually pure coating which can be used to increase the wear resistance, corrosion resistance or impact performance of metallic components.
In some cases, all three of the properties can be improved. The process utilises a precisely focused high power laser beam to create a weld pool into which a metallic powder is applied.
The powder, which is carried by a stream of inert shielding gas, is blown co-axially through the laser beam. The highly accurate nature of the laser beam allows fully dense cladding with minimal dilution (<5%), yet with a perfect metallurgical bond.
The Metallisation laser cladding system offers control and integration of the entire cladding process. The system offers control of the process gases, cooling system, laser, powder feed and automation interface safely via an intuitive, touch-screen interface.
Continuous caster rolls are used in the steel industry to cast continuous solid forms from liquid steel. The rolls are exposed to thermal fatigue, high temperatures, bending stresses, corrosion oxidation and abrasion.
The standard method of protecting caster rolls is by submerged arc welding with a 400 series stainless steel, which can suffer heat affected zone cracking between weld runs. Laser cladding the caster rolls is a cost effective method of applying a thin layer of a high performance alloy, in this case nickel based super alloys, to improve wear and corrosion resistance.
Laser cladding is a process that falls into the range of hard-facing solutions, which can be used to increase corrosion resistance, wear resistance or impact performance of metallic components, using a method of applying a fully dense, metallurgically bonded and virtually pure coating. Rolls that have been laser clad have been proven to last up to five times longer than the standard submerged arc welded rolls.
The production and processing of steel subjects mill components to combinations of enormous load, high temperature, corrosion, and abrasion. This has the potential to cause many problems throughout the processing line. Modern steel mills have recognized the importance of working with coated rollers. Thermal sprayed components are designed to permit steel to be processed more rapidly and efficiently.
Typical Laser clad components in the steel industry:
- Hot Mill
- Runout table Rolls
- Looper Rolls
- Wrapper Rolls
- Stabilization rods
- Roller bearing seats
- Roller seal rings
- Seal seats
- Rolling Bearing Chocks
- Wear plate surface seats
- Cold Mill
- Bridle Rolls
- Deflector Rolls
- Tensiometer Rolls
- Finishing Lines
- Deflector Rolls
- Flattening Rolls
- Tower Rolls
- Accumulator Rolls
- Pinch Rolls
- Furnace Rolls
- Leveler Rolls
- Downcoiler Rolls
- Pick-up rolls
- Furnace Rolls
- Pickling bath rolls