LASER CLADDING

Process characteristics:                    high-end process

Coating characteristics:                     thick coatings

Process temperature:                         hot

Process speed:                                   slow

Processable additive materials:       powder
                                                            (metals/carbides)

Process gases:                                   argon, helium, nitrogen

Laser cladding is an additive manufacturing process where a laser beam is used to locally melt the surface of the base material and an additive material, usually in powder form, is simultaneously added to the resulting melt pool. The melt solidifies as a result of a relative movement of the cladding head to the coating.

Precisely metered and localized heat input into the component surface results in only a minimal degree of mixing and a perfectly metallurgical bond to the base material. The unsurpassed precision accuracy and very good repeatability enable time-consuming and cost-intensive post-processing steps and masking work to be minimized or even eliminated. The mostly metallic materials can also be applied under industrial production conditions with powder utilization rates of up to 95% and more.

Application areas are, for example, the partial coating of punching, bending or cutting tools.

The advancement of laser cladding

Process characteristics:                    high-end process

Coating characteristics:                     thin coatings

Process temperature:                         hot

Process speed:                                   fast

Processable additive materials:       powder
                                                            (metals/carbides)

Process gases:                                   argon, helium, nitrogen

GTV High Speed Laser Cladding combines the advantages of conventional laser cladding with the high surface speeds of thermal spray processes. The new high-speed version of laser cladding is targeted at the economical coating of large surfaces with thin 80 µm to 250 µm protective coatings. With surface rates of over 2.0 m²/h, process times can be increased by a factor of 10 or more. The resulting gas-tight, thin coatings have an excellent metallurgical bond to the base material and can be applied with powder efficiency rates of 80% and more.

The main differences in comparison with conventional laser cladding are the significantly higher surface speeds of up to 300 m/min and more, higher laser power densities at the processing point, and reduced offset of the weld tracks. As a result of the larger overlap areas of the individual tracks, particularly uniform layer thicknesses are produced which require little or no post-processing.

High Speed Laser Cladding is preferably suitable for coating rotationally symmetrical components.

Process characteristics:                    special process

Coating characteristics:                     3D structures 

Process temperature:                         hot

Process speed:                                   slow

Processable additive materials:       powder
                                                            (metals/carbides)

Process gases:                                   argon, helium, nitrogen

Additive manufacturing, also known colloquially as 3D printing, has been experiencing a real boom over the last decade. Often referred to as the "manufacturing technology of the future", this technology is also making its way to us - in the form of GTV 3D laser cladding. The mostly complex three-dimensional shapes are built up layer by layer by melting metallic powders using a laser beam. Compared to other generative manufacturing processes, such as fused deposition modeling (FDM) or selective laser melting (SLM), laser cladding allows large 3D structures in particular to be produced quickly and economically.

It is also possible to build near-net-shape finished parts that require only minimal post-processing, to add additional features to existing part geometries, or to manufacture completely new parts from a special material composite.

Repair and rebuild of worn components (e.g. repair of erosion-damaged turbine blades or turbocharger shafts, center cutting contours of heavily worn Pelton turbine blades).