Scan-based Repair Using Laser Cladding

How does scan-based repair using laser cladding work?

Scan-based repair using laser cladding is a modern technology used to recondition complex tools, casting molds, forged parts, and expensive individual components. It can be used to restore component geometry without the need for a CAD model. Thus, damaged components can be repaired using a fully digital process chain.

Integrated scanner

The welding system is equipped with an integrated scanner. This allows the component to be positioned in the system and digitized immediately. The scan data is then processed and the areas to be repaired are identified. The robot’s CAM paths are planned on the derived surfaces from the scan and finally transferred to the system. Welding can then begin immediately without any further changes.

Laser cladding with wire

After preparation, the repair is carried out using wire-based laser cladding. Unlike powder-based laser cladding, wire is easy to handle and allows for a clean welding process. The hot wire option can additionally be used to preheat the wire, thus reducing the heat input into the base material. This enables the welding of difficult-to-process materials.

• Scanning instead of CAD – the integrated scanner eliminates the need for original design data
• Maximum resource efficiency – 100 percent material utilization thanks to wire-based welding
• Protection of the base material – thanks to the hot wire option
• More than just repair – geometries can be adapted or redesigned using additive DED technology

Advantages of scan-based repair using laser cladding

• Reduce costs – targeted repair of worn molds and components instead of purchasing new ones
• Remain flexible – robot guidance enables maximum geometric freedom
• Longer service life – reduced wear thanks to increased surface hardness
• Greater efficiency in use – longer service life thanks to optimized material selection