Performance Coatings - Laser Cladding
Laser cladding is an additive manufacturing process that utilizes a laser to metallurgically bond performance coatings to a product’s base material. The process uses the laser to create a shallow melt pool of the base material. The coating material is introduced into this melt pool in either powder or wire form. The energy from the laser subsequently melts the binding materials of the coating material resulting in a true metallurgical bond between the coating and the base material.
The coating bond of a laser-clad part is significantly different than the bonding structures of other hard facing technologies as illustrated in Figures 1 and 2. The molten base material is mixed with the molten coating material creating a dilution layer, which is a combination of the two materials. The dilution layer transitions into pure coating material relatively quickly. Once solidified, the coating actually becomes part of the base material through the transition zone. The remainder of the coating is a fully dense, fully fused material.
Figure 1. Laser Clad Sample
Figure 2. Flame Spray and Fuse Sample
Benefits
• Cost effective
• Fully fuses to metal
• Small heat affected zone
• Improved wear performance
• Can be used as a repair process
One of the more notable advantages of laser cladding over other hard facing technologies is its small heat affected zone. The shallow heat affected zone minimizes distortion of the base component along with minimizing changes in base material properties. This allows coatings to be applied to thin cross sections as well as components that have been previously formed or machined.
The coating material is strictly dependent on the desired performance requirements for the end product. The coating illustrated in Figure 1 shows a material that contains a relatively high percentage of tungsten carbide particles used to improve wear resistance. These types of coatings can improve a product’s wear performance by 3-10 times depending on the application. Other coatings include tool steels and high-speed steels of various grades along with chrome, nickel, and titanium.
Laser cladding can also be employed as a repair process for high value parts. Due to the process’ metallurgical bond and fully dense coating, worn parts can be built back up using powder or wire of the same composition as the base material. Once clad, the part can be easily returned to its original dimensional requirements through machining. A testament to the process’ ability to repair parts to an “as new” condition is illustrated in the fact that one of the main applications in the industry for laser cladding has been the repair of critical jet engine components.
Although laser cladding is not a new process, the advances in laser technology and the subsequent reductions in equipment costs have now made this a cost effective option for component manufacturers. The advantages of the laser cladding process over other coating technologies have opened the door for a wide range of new applications. Kondex is excited to be at the leading edge of the introduction of this process into the agricultural, construction, forestry, and commercial lawn and turf markets.
Laser cladding is also referred to as:
- Laser Deposition Welding
- Laser Metal Deposition
- Direct Metal Deposition
- Laser Metal Forming
Applications
Laser cladding benefits parts of all types including:
- Extreme wear surfaces
- Cutting edge retention
- Knife edges, blades and high wear cutting components of all kinds
- Parts in highly abrasive conditions
- Part-to-part sliding wear
Or, add laser cladding to existing parts to create an enhanced version.
Kondex provides unique solutions for each industry including:
- Agriculture Implements
- Commercial Lawn & Turf
- Forestry
- Construction
- Bio Energy Production
We welcome your inquiries into this unique coating technology. Please contact Kondex to discuss your specific applications and possible solutions utilizing laser cladding.