Fraunhofer Institute for Production Systems and Design TechnologyWe extend the life of highly stressed components with customized coatings using Laser Cladding
Laser Cladding: Effective Coatings for Wear and Corrosion Protection
Laser Metal Deposition can be used to locally reinforce a wide range of components. These include brakes, bearing seats, valves, knives, pump wheels and turbine blades.
Laser Metal Deposition is a key technology for improving the durability and reliability of many modern systems and machines. It therefore makes an important contribution to corporate sustainability by increasing efficiency and saving materials. By combining a wide range of base and filler materials, this technology is suitable for various applications. LMD coatings are characterized by their precise application and strong bond to the base material. The laser's ability to coat complex structures and tight fits makes the process extremely versatile.
Laser Metal Deposition (LMD) refines the surface of your components by adding a protective layer that gives them exceptional wear and corrosion resistance.
- Wear is inevitable on components that are constantly exposed to mechanical friction and abrasion. The life and functionality of these components can be severely compromised. Wear protection with LMD can solve these problems. Components are coated with a thin layer of a wear-resistant material to increase hardness and abrasion resistance.
- Corrosion occurs on base metals in aggressive chemical environments. The type of corrosion and the coating required to prevent it vary depending on the base material and the environment. Corrosion protection with LMD offers one of the most flexible methods of coating components. We use the appropriate corrosion resistant alloy from a variety of materials to provide a safe shield against harmful environmental influences such as oxidation or chemical reactions.
Another application of laser powder cladding is the production of buffer layers or functionally graded materials (FGM).
The material versatility of the LMD process allows you to combine different materials to protect your components. The bond between the base material and the protective layer can be optimized by inserting buffer layers. For particularly demanding applications, a graded material transition can be created using Directed Energy Deposition (DED). This prevents cracking and chipping. Hard metals such as tungsten carbide can be deposited as a metal matrix composite (MMC) to provide high wear resistance. Corrosion-resistant cobalt-chromium-based alloys such as Stellite or nickel-based alloys such as Inconel can also be used. The focused laser also achieves low heat input, resulting in minimal distortion and precise results. The low degree of mixing prevents the formation of unwanted material phases.
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Complex geometries can be easily achieved with 5-axis machining on a swivel/tilt table. Even complex shapes and structures can be precisely coated. Fraunhofer IPK not only offers the technical implementation of this process, but also supports you in feasibility studies, parameter optimization and distortion optimization by simulation.
In addition, we carry out metallographic investigations and provide you with comprehensive advice. Our expertise makes us the ideal partner for your laser powder cladding challenges. Let us work together to find innovative solutions and successfully implement your applications!
Laser Metal Deposition is of interest to these industries:
- Automotive (brakes, bearings)
- Power generation (turbines, valves)
- Mining and quarrying (drill heads, excavator teeth)
- Aerospace (heat shields)
- Special machinery (propellers, screws, molds)
- Agriculture (knives, grinding tools)