Capability
Laser Cladding
What is Laser Cladding?
Laser cladding utilises a high powered energy source to melt an additive stock material and weld it to the substrate, providing the advantageous properties of the additive material to the surface. Because the laser energy is so concentrated, it allows for the cladding material to have a full metallurgical bond, without the disadvantages of typical welding processes by minimising heat affected zone (HAZ), dilution and distortion.
In late 2020 Avweld commissioned our brand new robotic laser cladding system. The high-powered Coherent 10kW direct diode D-series laser unit is the latest and most powerful laser cladding system of its type in Australia. The robotic cell includes capacity for welding 30 tonne jobs, up to 3m diameter and 10m long.
Since then we have commission 2 new laser cladding cells, which utilise smaller fibre-lasers which are suitable for cladding smaller, precision parts, such as internal diameters, small shafts, and edges.
| HVOF | PTA | Laser Cladding | |
|---|---|---|---|
| Heat Source | Gas Flame | Plasma/Electric Arc | Laser Beam |
| Coating Thickness | 0.05–0.5mm | 0.5–5mm | 0.1–10mm |
| Deposition Rates | 1–9 kg/h | 1–5kg/h | up to 30kg/h |
| Dilution | 0% | 5–15% | 1–5% |
| Bond Type | Mechanical | Metallurgical | Metallurgical |
| Bond Strength | < 80MPa | < 800MPa | < 800MPa |
| Heat Input | Low | High | Medium |
| Porosity | >5% | 100% dense | 100% dense |
-
10KW Coherent D-SeriesIdeal for large jobs
-
3KW Fibre LaserPrecise control for accuracy
-
2KW PortableFor use in-situ and bore cladding
| Metallurgical Bond | Metallurgical bond vs. mechanical bond |
| Low Dilution | 1–5% typical (~1/3 dilution of PTA process) |
| Controllable Process | Highly controllable, repeatable and efficient |
| Smooth Clad | Less post machining required |
| Small Heat Zone | Removes need for post weld heat treatment or stress relief |
| High Quench Rates | Finer grain structure = higher corrosion potentials |
| High Deposit Speed | Faster than thermal spray or PTA |
| High Efficiency | Deposit efficiency >80% |
- Shafts, struts, journals
- Cylinders, rods, rams
- Rollers
- Crusher components
- Drilling and ground-engaging tools
- Wheels, tracks
- Buckets, teeth
- Pipes, chutes, ducts
- Screws, augers
- Wind turbine components
- Boiler tubes
- Cutting blades, knives
- Mulcher and chipper components
- Pump components (sleeves, shafts, impellers, wear rings)
- Valves (stems, discs, seats, balls)
- Gearboxes
- Rotary valves and rotary feeders
- Vacuum pumps
Laser Heat Treatment
Using the same equipment required for laser cladding, by removing the feed stock material, we are able to heat treat surfaces with high efficiency and speed.
| Precision Control of Heat | Only heat treat desired surfaces |
| Minimal Post-Processing | Low distortion – limited post-machining |
| Self-Quenched Process | Simple and highly repeatable |
| Improved Access & Flexibility | Line of sight process – easy part changeover via software |
| Improved Process Control | Simple, non-contact process – supports use of optical pyrometer to control the heating |
| Material | Maximum Hardness (Rc) | Max Depth (mm) |
|---|---|---|
| Carbon Steels | ||
| 1080 | 68 | 2 |
| 1075 | 68 | 2 |
| 1045 | 60 | 1.5 |
| 1030 | 50 | 0.75 |
| 1018 | 30 | 0.25 |
| Heat Treatable Alloys | ||
| 4140 | 68 | 2 |
| 4340 | 68 | 2 |
| Heat Treatable Stainless Steel | ||
| 420 | 65 | 1.5 |
| 410 | 50 | 0.5 |
| Cast Irons | ||
| Gray | 65 | 1 |
| Ductile | 55 | 0.75 |
Laser Heat Treatable Materials Carbon & Alloy Steels
(> 0.3% carbon recommended)
- AISI 1030, 1045, 1060, 1075, 1080, 4140, 4340
- Ductile & Grey Cast Iron
- Martensitic Stainless Steels (AISI 410, 420, 440)
Notes:
- Max depth & max hardness for some materials do not coincide
- Actual results are dependent on carbon content and part geometry
- Results are based on direct diode laser system results.