Laser cladding – applications and development trends · Laser cladding – applications and development trends J. Tuominen, J. Tuominen, DrDr. Tech. Tech Tampere University of Technology,

[email protected] Laserpinnoituspäivät Kokkola 4.2.2010

Laser cladding – applications and development trends

J. Tuominen, J. Tuominen, DrDr. Tech. TechTampere University of Technology, Department of Materials ScienceTampere University of Technology, Department of Materials Science

TUT Kokkola TUT Kokkola UnitUnit

Korpintie 8 (Korpintie 8 (InnogateInnogate))

67100 67100 KokkolaKokkola

FinlandFinland

[email protected] Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta 8.6.2011


Presentation outline- Surface engineering- Laser cladding

- Methods- Features- Coating and substrate materials- Coating properties

- Laser cladding applications- Power generation- Oil and gas- Moulds and tooling- Mining & construction- Combustion engines- Aerospace

- Development trends in laser cladding- Hybrid techniques (hot-wire, induction assisted laser cladding)- High deposition rate cladding (>10kW) (powder, wire, strip)- On-site repairs and mobile cladding units- Coaxial wire feeding- Monitoring & real time process control



Economic impact of wear and corrosion- Maintenance, repair and material costs as well as losses due to plant shutdowns

- Corrosion of metals cost directly the U.S. economy 276 and indirectly 552 billion USD per year (1998)

- They were 3.1% and 6.0% of the gross national product (GNP)

- In UK, Japan, Australia, Kuwait, Germany, Finland, Sweden, India and China annual direct corrosion costs range from 1 to 5 percent of the GNP

- Approximately one-third of these costs (= avoidable costs) could be reduced by broader application of corrosion-resistant materials

- Wear cost the U.S. economy 20-100 billion USD per year (1980)

Sources: NACE International and FHWA Report ”Corrosion costs and preventive strategies in the United States” (2002)

Department of Trade and Industry - Wear Resistant Surfaces in Engineering (1986)



Surface engineering

, cladding

Surface modification, alloying and coating methods



1917 EinsteinLightAmplification byStimulatedEmission of Radiation

1960 Ruby laser

1964 CO2

Nd:YAG

1965 industrial laser materials processing;Hole drilling and spot welding

1967 CO2

Cutting

1974 CO2

Industrial laser hardening

1976 laser cladding;wire feedingpreplaced powder

1977 industrial laser cladding;preplaced powderCaterpillar Tractor Co.

1979 laser cladding;1-step powder feeding

1981 industrial laser cladding;1-step powder feedingRolls-RoycePratt & Whitney

1984 coaxial powder nozzle for circular beam

1988 Stellite cladding with CO2 laser M. Sc. ThesisLUT, Finland

1999 Nd:YAG –laser cladding2001 HPDL claddingTUT, Finland

1999 Industrial laser cladding in FinlandFortum Service Oy KETEK

1998 HPDL 2.5X more efficient than CO2 in cladding,Induction assisted laser claddingFraunhofer IWS

1992 Hot wire claddingT. U. Clausthal

1969 WC impregnation

* J. Archambeault, L. Dubourg, NRCC, Paper # 1104, ICALEO2005

* *2008 Hot-wire laser cladding: Process, materials and their properties

Dr. Thesis

TUT/KETEK, Finland

Mid 90´s cw Nd:YAG and HPDL > 1 kW

Hybrid cladding techniques

Milestones



Cladding methods

Shielding gas

Laser beamPowder andcarrier gas

Clad layer

Substrate

Shielding gas

Powder andcarrier gas

Clad layer

Substrate

Laser beam

2-step: preplaced powder 1-step: off-axis powder 1-step: coaxial powder

1-step: off-axis hot-wire (tandem) 1-step: coaxial cold-wire 1-step: coaxial hot-wire



Lasers available for cladding and their properties

*External chiller not taken into account

[email protected] ASE-seminar 2011 Tampere 5.5.2011

Fiber Nd:YAG CO2 Disc HPDLWall-plug efficiency* 30% ~3% (lp) ~10% (FAF) 20-28% 35-45%Wavelength 1.07 m 1.06 m 10.6 m 1.03 m 808-1030nmBeam guidance Fiber Fiber Mirror Fiber FiberFootprint 1.2m2 (20kW) 3.2m2 (4kW) 5.7m2 (20kW) 3.9m2 (16kW) 0.3m2 (6kW)Footprint (chiller) 1.2m2 (20kW) 3.1m2 (4kW) 3.0m2 (20kW) 2.0m2 (16kW) 0.4m2 (6kW)Max. power 30kW 6kW 20kW 16kW 15kWMobility Yes No No Yes YesOperating costs Low High Moderate Low Low



Laser cladding: strengths and weaknessesFusion bond (excellent bond strength)Low dilution (few percentages in monolayer coating)100% denseness (real corrosion barrier coatings)Low heat input (small distortion, narrow HAZ)Fine-grained structure (high hardness and strength)Extended solid solubility (not restricted by thermodynamic equilibrium)Low microsegregationNegligible dissolution of externally incorporated carbidesFlexible tailoring of compositions (gradients, multimaterial structures)Easily automatizedReal time process controlHigh capital costs, low wall-plug & process energy efficiencies, hightensile stresses



Coating and substrate materialsHardfacing alloys (Stellites, Tribaloy, Norem, Nanosteel, Self-fluxing alloys, Nistelle, Nucalloy)Superalloys (Inconel, Hastelloy, Monel, CMSX-4, high-Cr NiCr)Tool steels (P20, M4, H13, CPM 10V)Stainless steels (316L, 254SMO, 420, 17-4 PH)Hadfield-steels (12-19%Mn, 1.1-1.4%C, 0-2.5%Cr )Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2)Copper alloys (CuAl, CuNi, CuSn)Metal matrix composites (WC/W2C-NiCrBSi, TiC-Stellite, VC-tool steel, SiC-Al)Solid lubricants (MoS2, WS2, CaF2, graphite) Intermetallics (Cr13Ni5Si2, MoSi2, FeAl, NiTi) Gradient layers (FGM) (metal matrix composites, monolithes)Nanostructured and amorphous alloys, intelligent materialsSubstrates; Fe-, Ni-, Cu-, Al-, Ti-, Mg-alloys



-800-700-600-500-400-300-200-100

0100

0 50 100 150 200Time (h)

E vs

. Ag/

AgC

l (m

V)

LASER PTA WROUGHT HVOF+LASER IHVOF+LASER II HVOF Fe37

-1.0

-0.5

0.0

0.5

1.0

1.E-10 1.E-09 1.E-08 1.E-07 1.E-06 1.E-05 1.E-04 1.E-03 1.E-02 1.E-01

log I [A/cm2]E

vs. A

g/A

gCl (

V)

625 LASER625 PTA625 WROUGHT625 HVOF + LASER625 HVOF316L WROUGHT

Wet corrosion

Inconel 625 on mild steel

0.06 0.1 0.19 0.23 0.3 0.31 0.33 0.34 0.37 0.39 0.39 0.43 0.48 0.5 0.77

7.31

012345678

Titaniu

m wroug

ht

SX-717 l

aser

St 6 la

ser

In-625 H

VOF + las

er

St 21 l

aser

In-625 w

rough

t

Alloy 5

9 las

er

St 6 H

IP

AISI316L

wrou

ght

In-625 l

aser

(19.4 Fe

)

In-62

5 las

er (6.0

Fe)

In-62

5 las

er (9.4

Fe)

In-625 P

TA

St 21 P

TA

In-62

5 HVOF

Mart. S

S

Cor

rosi

on ra

te (µ

m/y

ear)

Laser HVOF Wrought HVOF + Laser PTA HIP

Dilution, micro- and macrosegregation restricted

Corrosion properties equivalent to wrought alloys and better than cast structures



Hot corrosion tests- Low diluted high-Cr NiCr and Inconel 625 laser coatings outperformed wrought Nimonic80A- Inconel 625 laser coating superior to wrought Inconel 625 (grain boundary attack, role of

Mo and its influence on salt acidity)- Inconel 625 laser coating possessed high stability at 650°C- In high-Cr NiCr laser coatings Cr-rich phases were prone to molten salt attack- Low high temperature stability -> amount of Cr-rich phases and their Cr content increased

Na2SO4-V2O5 (50/50 wt.%) at 650°C for 1000h

880 730

0

20

40

60

80

100

120

140

160

SX-707 H

VOF

SX-707 l

aser

SX-717 l

aser

Incon

el 62

5 lase

r

Incon

el 62

5

Incon

el 71

8

Nimon

ic 80

A

42CrM

o4

Mea

n th

ickn

ess

loss

(

m)

Specimen 1 Specimen 2

Wrought



- Low-stress 3-body rubber wheel abrasion

- Crushed dry quartz sand (0.1-0.6 mm)- Abrasive feed rate 20-25 g/min per

specimen- Load 23 N- Surface speed of wheel 1.64 m/s- Testing time 60 min

Abrasion wear studies

NiCrBSi + Recycled WC (70/30 vol.%)

NiCrBSi + SFTC WC/W2C/W (70/30 vol.%)(Ti,Mo)C + Stellite 6 (64/36 vol.%)



- High volume fraction (~75%) sintered and HVOF sprayed cemented carbides outperformed all the laser coatings

- High vol. fraction (~64%) of fine (<2 m) (Ti, Mo)C particles in St 6 matrix best laser coating- Harder the matrix, better the wear resistance (decreased fracture toughness!)- Fused spherical WC/W2C/W and angular WC/W2C outperformed dense-coated WC- Nanosteel and WR6 best monolithic laser coatings- Laser coatings exhibited local differences in wear rates due to overlapping

Abrasion wear studies

151.

2

148.

5

142.

4

141.

5

129.

7

125

106.

3

105.

7

97.5

40.8

37.7

36.7

30 29.6

28.7

27 23.2

23.2

21.4

18.6

17.7

17.6

15.3

14.8

13 13 12.2

12 11.7

10 9.5

3 2 1.1

187.

5

0

2040

60

80100

120

140

160180

200

St 21T-8

00

SX-707

St 6Fe3

7St 1

2

WR 10 St 1

IN-71

8

AISI316L

12C-W

C 70/30

Amperit

522.2

SHS1377

SHS1380

31C-N

S

Nanos

teel

SHS1436

Ni-hard

bulk

16C-W

C 50/50

Amperit

522.2

16C-R

ec W

C 70/30

SHS1389

St21-W

C 50/50

Amperit

522.2

12C-W

C 70/30

WOKA 96

04

12C-W

C 70/30

SFTC WR6

St6-CrC

65/35

St21-W

C 50/50

Amperit

522.3

WR6-VC 70

/30

C42P2-W

C 25/75

Amperit

522.3

16C-C

rC 70

/30

16C-W

C 50/50

Amperit

522.3

2001

+ Duru

m FCT WC 50

/50

SHS1378

Amdry 58

43 (7

5/25)

Amperit

559.0

74 (7

5/25)

WC-6Co-8

Cr (75/2

5)

Volu

me

loss

(mm

3 )

HVOF

Laser

Cast

Sintered

Wrought

Monolithic Fe-based laser coatings



- Block-on-ring type sliding wear tester- Dry conditions at RT- Ring counterparts 42CrMo4 (30 HRC) and

34CrMo4 (60 HRC)- Low-stress conditions (57 N)- Initial Hertzian stresses ~100 MPa- Surface speed 140 m/min- Block temperature monitored during the test- Wear debris collected under the ring

Sliding wear studies

load

wear block

42CrMo4 ring

Clad layer



- Laser coatings outperformed more heavily diluted and softer PTA coatings- Stellite 6 laser coating was better than HIPped Stellite 6- Nanosteel was as good as Tribaloy T-800

Sliding wear studies

0.61

0.67

1.47

1.5

1.9

2.2

3.2

16.7

26.7

47.5

49.8

68.4

7.2

8

3.7

2.9

1.7

2.8

2.5

4.2

2.2

5.9

1

10.4

0 10 20 30 40 50 60 70 80

SHS 1378 laser

SHS 1389 laser

Nanosteel laser

T-800 laser

T-800 PTA

T-400 laser

St 1 laser

St 6 laser

St 6 HIP

St 21 laser

Laser hardened

St 21 PTA

Scar volume (mm3)

42CrMo4 ringWear block

St 6 laser

St 6 HIP



Sliding wear studiesPin-on-disc type sliding wear testerCETR UMT-2Dry or lubricated conditionsTesting temperature -20-+1000°CHumidity 5-95% RHLoad cells 0.5-200N and 0.05-5NRevolve disc speed 0.1-1000rpmASTM G99-95a

31 32 32 34 38 41 51 75

192

400

50

100

150

200

Stellite

6LC vs

. Stel

lite 6LC

Stellite 6L

C vs. M

2+1.4

418

Stellite

21 vs

. Stel

lite 21

Stellite

6LC vs

. Resis

tant

Stellite

21 vs.

M2+1.4

418

Stellite

21 vs.

Resist

ant

Stellite

6LC vs

. Stel

lite 21

RAEX AR50

0 vs.

CuAl

Stellite

6 vs

. CuA

l

Resist

ant vs

. Res

istan

tKok

onai

smas

sahä

viö

(mg)

(mg)

69 mm

6.35 mm



Residual stress studiesX-ray diffraction methodXstress 3000

n

ni

dddE

2sin1



Applications

Stork Gears & Services, the Netherlands Kokkola LCC Oy, Finland SIFCO, Ireland

NedClad, the Netherlands Metallodomi S.A., Greece

Wind turbine gear box wheel

Mangle



Applications

Praxair Surface Technologies, USAWaterwall tube panel

Laser Cladding Services, USADrill bit

Eaton Corp., USAPiston rod for hydraulic cylinderCertified by DNV for offshore applications

Technogenia, FranceDrilling tool

ERLAS, GermanyMould repair



Hybrid techniques

Technology Centre KETEK Ltd., Kokkola

Hot wire cladding equipment

4.4 kW Nd:YAG + MIG/MAG



Hybrid techniques

Stellite 20 on AISI 1045

F. Brückner, Fraunhofer IWS

Stellite 12 on M238 mould steel (646 x 230 x 196 mm3)

Without induction

With inductionFully closed-loop cladding process

J. Tuominen, TUT

Ring shape induction coil


[email protected] Laserpinnoituspäivät Kokkola [email protected] Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta 8.6.2011

Induction assisted laser cladding

COAXpowerline (4kW laser + 14 kW induction = 8 kg/h)

(10kW HPDL + 40 kW induction = 30 kg/h under development)

Variation of the bead width during processing


Laser cladding with high power levels (HPDL)

Fraunhofer IWS, Germany10 kW HPDL fiber coupled15 kW inductionCoax 11Off-axis9.2 kg/h14.5 kg/h (with induction)

[email protected] ASE-seminar 2011 Tampere [email protected] Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta 8.6.2011


Laser cladding with high power levels (disc)

Fraunhofer ILT, GermanyRWTH Aachen, Germany10 kW Yb:YAG disc (300µm fiber)Coaxial ILT 3-jet nozzle for circular beamOff-axis nozzle for square beam4.6 kg/h (5.25 kW)



Laser cladding with high power levels (fiber)

ARL Penn State, USA12 kW fiber laser1D-scanner (20-30Hz) (water-cooled Cu mirror)Off-axis nozzle

Material: Inconel 625 on HY-80Deposition Rate: 11.4 kg/hrTravel Speed: 0.5 m/minLaser Power: 10 kWScan Width: 25 mm



Beam forming/shapingFiber & disc lasers; excellent beam quality -> very high power densitiesIn laser cladding NOT very high power densities required (100-1000W/mm2)Laser beam spot needs to be expanded:

By defocusing with standard welding opticsBy oscillating mirrors (scanners)By homogenizing optics (integrating mirrors, group of lenses)

10

100

1000

10000

0 0.5 1 1.5 2 2.5 3 3.5

Interaction time (s)

Pow

er d

ensi

ty (W

/mm

2 ) Nd:YAGHPDL

CO2FiberCO2

Not optimal for cladding!



Beam forming/shaping (scanners)Large and homogeneous beam profiles required in claddingRectangular beam profiles by scannersBased on galvanometrically driven or direct motor driven oscillatingwater-cooled mirror (spring)Sinus, triangular, square waveformsPower can be adjusted along scanning lineUnique custom energy profilesWater cooled mirrors (~30 kW)



Beam forming/shaping (optics)Availability for high power levels?Circular prism integrators (HighYAG)Facetted integration elements (HighYAG)Integrating mirrorsSome requirements: ability to withstand high power levels, long working distance preferred due to back reflection

Homogenized rectangular spotHomogenized circular spot



St. Petersburg State Polytechnical University

Insitute of Laser and Welding Technologies

Russian-German Laser Technology Centre

15 kW Yb fiber laser (IPG Photonics)

Manufactured by NTO IRE-Polus, Fryazino, Moscow Region, Russia

= 1.07 m

Delivery fiber Ø = 200 m

Fiber length 50 m

Riedel PC250 chiller

Laser cladding with high power levels (fiber)



Setup for scanner cladding (powder)

3D motion system for welding head and nozzle + 2D welding tableILV DC-scanner:- Flat mirror, OFHC-Copper, silver coated, Ø = 48 mm

Precitec YW50 welding head, f = 400 mm

Grit-blasting: Al2O3, grain size 800 m

Substrates: S235JR (Fe37B) (100 x 60 x 20 mm3)

Medicoat AG powder feeder

Flat nozzle + cyclone



Geometrical dilution: 3.3%15 kW, 750 mm/min

Ø = 5 mm

f = 295 g/min

Scan width 75%

Frequency 100 Hz (Triangular)

Bead width 19 mm

Max. bead height above substrate 3.1 mm

Total cross-section 37.2 mm2

-> 14.1 kg/h

Powder catchment efficiency 77% Inconel 625

Scanner cladding with 15 kW fiber laser

3.1 mm



15 kW, 750 mm/min

Ø = 5 mm

f = 315 g/min

Scan width 75%

Frequency 100 Hz (Triangular)

Inter-track advance 9 mm

Coating width 37 mm

Max. coating height above substrate 4.2 mm

Total cross-section 123.7 mm2

-> 15.6 kg/h

Powder catchment efficiency 79%

Scanner cladding with 15 kW fiber laser

Inconel 625

15 kW, 1000 mm/min, 273 g/min, inter-track advance 10 mm



Deposition rates

02468

101214161820

0 2 4 6 8 10 12 14 16 18

Laser power (kW)

kg/h

Nd:YAGHPDLCO2FiberDisc

Hot-wire

Hot-wireInduction

Hot-wire

Cold-strip

Induction

Cold-wire linear traverse cladding

Powder scanner cladding



Cladding efficiency (powder)

0.00.51.01.52.02.53.03.5

0 100 200 300 400

Powder feed rate (g/min)

Cla

ddin

g ef

ficie

ncy

x 10

-4

(kg/

kJ)

15kW, 1000mm/min15kW, 750mm/min10kW, 500mm/min6 kW HPDL6 kW CO24 kW Nd:YAG

Powder scanner cladding with 15 kW fiber laser

*Efficiency of laser was not taken into account



6

8

10

1214

16

18

20

0.001 0.002 0.003 0.004 0.005 0.006

S/F (m/g)

Pow

er (k

W)

Process window for powder scanner cladding

>150° (= no inter-run pores) <150°

D>10%D<10%

mc

m

AAAD

Inconel 625 on mild steel

No fusion bond



Corrosion studies for scanner clad coatings

Coating samples corrosion tested were milled on a Makino A55 CNC millingmachine at TUT

Immersion in 1% HCl + 6% FeCl3 solution at 70°C for 72 hours

Test recommended by DNV for off-shore applications (wrought, weld overlays)


0200400600800

100012001400

Titanium 625 laser (69)

625 wrought

625 laser (68)

625 PTA 316L wrought

2xhard-chrome + 316L laser coating on mild steel

2xhard-chrome on mild steel

Mas

s lo

ss (m

g)

Wrought

LaserHard-chrome

PTA

4222

0



Strip laser cladding with high power levels



4.4 kW YAG, YW50 (f = 500 mm), ILV DC-Scanner

4.4 kW, 72 mm/min, strip feed 37 g/min, scan width 40%, frequency 20 Hz, Triangular scan form

316L strip (w = 30 mm, t = 0.5 mm)

Strip cladding with scanner



Strip cladding with scanner


35-55° 45-60°

~0.5m

316L

420

Duplex

Inconel 625



On-site repairs and claddingMobile cladding units transported to the componentsCost efficient solution (high value massive components, dissassembly & transportation to nearest cladding job shop causes too long shutdown, is affixed or welded to some complex systems etc.)Applications in oil & gas drilling platforms, paper mills, steel plants, nuclear power plants, shipyards, ships, turbine power stations



On-site repairs and cladding

LaserAge Ltd, Ireland, 2 kW HPDL, 3 linear axes, 1200kg

Stork Gears & Services BV, the Netherlands, HPDL+robot

Hardchrome Engineering, Australia, HPDL+robot

Duroc, Sweden, 4 kW fiber + robot, 2500kg

ARL Penn State, USA, Nd:YAG repair cell for Vertical Launch System



Stork Gears & Services BV, the Netherlands

Fiber-coupled HPDL + robotFast response time: ”Mobile laser cladding system can be on-site within a day!”

Preparations for on-site ship repair




Repair of dove tail surfaces Repair of damaged flange grooves

NedClad, the Netherlands




SLV Mecklenburg-Vorpommern GmbH, Rostock, Germany

EU-project ”DOCKLASER” 2002-2006Transportation with flatbed truckMobile laser equipment for dock-area100 m length fiber, container length 4.6 m, weight ~3 tons




Joining Technologies, CT, USA (2002)

Transportation with trailerMobile laser equipment for mold and die repairTrumpf PowerWeld, laser cladding with wireCNC motion work tablePulsed Nd:YAG






”Transportable Laser Cladding System” by J. Hakala, Y. Guo, D. He (TTE-5107 Design of Robot Systems)

10kW fiber laser + chiller + robotPowder feeder + coaxial nozzleFloor mounted tracks & carrierPositioner + tailstockLaser safety curtain

Cladding can take place inside and outside container



Coaxial wire cladding headsBeam splitted into three parts (HighYAG) and focused to circular spot

For cold-wire cladding

Cladding trials with 3.5 kW YAG power

HighYAG, 3x beam splitting

Fraunhofer IWS, www.flexilas.de, Germany (2008)


Fully omnidirectional



Coaxial wire cladding heads

Arnold, 2x beam splitting

Fraunhofer IWS, www.flexilas.de, Germany (2008)

Fraunhofer IWS, www.spraynergy.de, Germany (2010)

Wire heated by induction

Beam splitted into two parts (Arnold) and focused to circular spotFor cold and hot-wire and powder cladding



Coaxial wire cladding headsFor cold-wire cladding

Brazing trials with 2.3 kW YAG power

Precitec KG, Germany (2009)



Coaxial wire cladding headsFor hot-wire cladding

Hybrid welding trials with 4 kW YAG power

Mitsubishi Heavy Industries, Ltd., Japan (2005)



Axial symmetric direct diode laser 500W

Source: Alahautala, T.; Lassila, E.: A method and a laser device for producing high optical power density. International patent application WO 03/098758 (27 November 2003)an



Coaxial wire cladding head tests

Rofin diode-pumped Nd-YAG 4.4 kW with HighYAG coaxial laserhead at FraunhoferIWS Wire feeding equipment:

DINSE wire feeder DIX WD 300Water cooled wire nozzleCoaxial gas shielding

Wires:Inconel 625 Ø = 1.0 mm (solid)Stellite 21 Ø = 1.2 mm (flux-cored)



Coaxial wire cladding head tests

IN-625, 3.5kW, 1500mm/min, 1.9 kg/h, dilution 14.9%

1.6 mm

IN-625 2 kW 2000mm/min 1 kg/h dilution 4.2%

0.6mm

IN-625 3.5 kW 2000mm/min 2.1 kg/h dilution 25.2%

High process stabilityHigh cladding efficiencyIN-625 1.2-1.7x10-4 kg/kJSt 21 1.5-1.9x10-4 kg/kJNo overheat of nozzleduring long-term claddingoperation


0.8mm

IN-625 on mild steel(100x60x20mm3)

IN-625 on mild steel(D50mm, L500mm)



Process monitoring & real time process control


Time [s]

Melt pool width as function of time

Mel

tpoo

l wid

th [m

m]

Laser power as function of time

Lase

r pow

er [W

]

Time [s]

LOMPOC-Pro + EMAqs-camera (high speed process analysis)Measures melt pool size, temperatureMounted coaxially



Summary & Outlook

Beneficial coating properties based on fusion bond and low dilution

Minor heat input, low distortion, narrow HAZ

New type of lasers available: disc up to 16kW, fiber up to 30kW

HPDL´s scaled up to 15kW

High deposition rates (up to 16-17kg/h) with 15kW fiber laser + scanner (powder cladding)

Deposition rates can be enhanced further with additional heatsource

Coaxial wire cladding process shows high stability



References-- BrücknerBrückner, F. et al., ”, F. et al., ”CalculationCalculation of of stressesstresses in in twotwo-- and and threethree--dimensionaldimensional

structuresstructures generatedgenerated byby inductioninduction assistedassisted laser laser claddingcladding””, LIM 2009, LIM 2009-- DiettrichDiettrich, J. et al., ”, J. et al., ”CoaxialCoaxial laser laser brazingbrazing headhead”, LIM ”, LIM 20092009-- HeckertHeckert, S. et al., , S. et al., ”Laser ”Laser processingprocessing headsheads for for claddingcladding and and heatheat treatmenttreatment

applicationsapplications”,”, LAM 2010LAM 2010-- KesslerKessler, B., ”, B., ”ToolsTools for for highhigh powerpower fiberfiber laserslasers and and theirtheir applicationsapplications”, Kokkola ”, Kokkola

Laser Laser CladdingCladding SeminarSeminar 20112011-- MartukanitzMartukanitz, R. et al., , R. et al., ”Deposition ”Deposition technologytechnology: : CurrentCurrent trendstrends and and futurefuture

directiondirection””, LAM 2010, LAM 2010-- NowotnyNowotny, S. et al., ”, S. et al., ”IncreasedIncreased productivityproductivity of laser of laser surfacesurface claddingcladding byby

simultaneouslysimultaneously assistingassisting energyenergy sourcessources””, SMT 2010, SMT 2010-- ””OverlayOverlay WeldingWelding: : TransportableTransportable laser laser claddingcladding systemsystem adaptedadapted for for hazardoushazardous

areasareas”, ”, OffshoreOffshore Magazine 66 (2006) 10Magazine 66 (2006) 10-- TsubotaTsubota, S. et al., , S. et al., ”Laser ”Laser weldingwelding systemsystem for for variousvarious 33--D D weldingwelding –– DevelopmentDevelopment of of

coaxialcoaxial laser laser weldingwelding headhead”, Mitsubishi Heavy ”, Mitsubishi Heavy IndustriesIndustries, Ltd., , Ltd., TechnicalTechnical ReviewReview42 (2005) 42 (2005) 22

-- WitzelWitzel, J. et al., ”, J. et al., ”IncreasingIncreasing the deposition the deposition raterate of of InconelInconel 718 for LMD718 for LMD”, ICALEO ”, ICALEO 20102010



Thank you for your attention!



New type of lasers 10–50 kW available (disc and fiber lasers)Would it be possible to achieve excellent coating quality with considerably higher productivity?To bring some high power (>30kW) technology to FinlandIn cooperation with:

Trilaser 2009-2013 – Laser processing with high power



Fatigue durability of laser clad components•Tampere University of Technology, Technology Centre KETEK Ltd., Luleå TechnicalUniversity and CENTRIA research unit of the Central Ostrobothnia University of AppliedSciences conduct the project related to mechanical fatigue of laser clad components•Project is funded by EU´s Interreg IV A North –program•Project duration is 2 years•Total budget 455 kEUR•Companies benefiting the project include end users of laser coatings (large diesel engines, power transmission components, hydraulic cylinders, pulp and paper handling equipment) and laser cladding job shops, also for those who want their end products to be qualified and proved by official classification societies•Project includes testing under various forms of fatigue (axial, torsional and bending) usingexceptionally large forces and FEM modelling

y = 1933.7x-0.138

R2 = 0.9897

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1.00E+04 1.00E+05 1.00E+06 1.00E+07

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itys

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Documents

Laser cladding – applications and development trends · Laser cladding – applications and development trends J. Tuominen, J. Tuominen, DrDr. Tech. Tech Tampere University of Technology,