The application advantage of laser cladding in shaft repair

With the mechanical more continuous and more automation the production efficiency has been damanderd higher  As a part of machinery used in industrial production, shaft is easy to cause shaft wear due to long-term over-negative operation, poor lubrication, impurities, external impact and other factors, thus affecting production. Choosing a quick and effective repair method to solve problems and reduce maintenance costs can effectively improve enterprise efficiency and ensure the maximum benefit of the enterprise.

Traditional solutions such as repair welding or surfacing machining, welding, etc., Can not fundamentally solve the problem, and dangerous, such as high temperature deformation, cracks, coating fall off; At the same time these traditional methods can not  improvement to the equipment management.

Laser cladding repair technology , the use of high energy laser as a heat source, metal alloy materials (powder, paste, filiform, etc.) as a welding material, synchronized alloy material with laser rapid melting molten pool formation, ACTS on the metal surface and rapid solidification of dense, uniform and controllable metallurgical bonding layer thickness,surface repair for provides a good way.
The advantages of laser cladding in shaft repair as follows:

1) To optimize the surface of the shaft, the laser cladding can form an alloy coating with completely different components and properties that is mutually fused with the matrix on the shaft surface. Because the substrate melting layer is very thin, it has little influence on the composition of the cladding layer. We can prepare the surface coating with heat resistance, corrosion resistance, abrasion resistance, oxidation resistance, fatigue resistance or optical, electrical and magnetic properties according to the specific requirements, thus effectively improving the performance of the shaft surface.

2) metallurgical bonding strength is high, the laser cladding process, cladding material to join by melt completely, make it become the theme of the alloy cladding layer, and matrix alloy also have a thin layer of melt, and theme alloy form metallurgical combination, not easy to fall off, has solved the traditional electroplating, spray, etc in the process of cold working problem of poor bonding strength of coating and the magnesium substrate.

3) Low deformation of heat input, rapid heating and rapid cooling of laser cladding have little impact on the substrate, and the dilution rate is ≤5-8%, thus solving a series of technical problems such as thermal deformation and thermal fatigue damage that are inevitable in traditional welding and tiG welding thermal processing.

Laser repair shaft item application case
 
Laser repair can not only repair the worn shaft, but also cladding the wear resistant layer on the new shaft surface, so as to effectively improve the wear resistance and corrosion resistance of the shaft and increase its service life.

Laser cladding technology can be used not only on the rotary body, but also on the plane and complex surface. Therefore, it is also widely used in the repair and remanufacturing of mill marks, hydraulic supports, blades, scraper grooves, hydraulic cylinders, gears, die casting molds and so on.

Quality creates brand, professional achieves high quality! WG-HG Laser have a professional team, rich experience, warm service and good prestige. Whether you need laser cladding equipment or laser cladding processing business, HG-HG laser share total win.PLS contact us for more detailed information.

Industry application of laser cleaning machine

The laser cleaning technology in the laser cleaning machine refers to the use of high-energy laser beams to irradiate the surface of the workpiece to cause the dirt, rust or coating on the surface to evaporate or peel instantly, which can effectively remove the surface attachments or surface coatings to achieve cleanliness purpose. This technology is often used in industrial manufacturing, and in order to ensure the quality of the product during the production process, it is necessary to remove dirt, grease, dust, rust and other contaminants on the surface of the product. The following is to show you the industry application of laser cleaning machine.

In the process of electroplating, phosphating, spraying, welding, packaging and integrated circuit assembly of industrial products, grease, dust, rust and residual solvents, adhesives and other dirt on the surface must be removed to ensure the quality of the next process . The current cleaning methods widely used in the cleaning industry include mechanical cleaning, chemical cleaning and ultrasonic cleaning, but their application is greatly restricted under the constraints of environmental protection and the requirements of the high-precision market. The laser cleaning machine has obvious advantages in various industries.

1. Mold cleaning

In the production process, tire mold cleaning must be rapid and reliable to save downtime. Traditional cleaning methods include sandblasting, ultrasonic or carbon dioxide cleaning, etc. These methods take a long time to clean and easily damage the mold. Since the laser cleaning method can be connected with optical fiber to guide the light to the dead corner of the mold or the part that is not easy to clean, it is more convenient to use, and the rubber will not vaporize, so it will not generate toxic gas and affect the safety of the working environment.

2. Cleaning of old aircraft paint

After the aircraft has been working for a period of time, the surface of the aircraft needs to be repainted, so it is necessary to find a way to remove the old paint. The traditional mechanical paint removal method can easily damage the metal surface of the aircraft and bring hidden dangers to the aircraft. Using the washing machine will not damage the surface.

3. Cleaning of building exterior walls

The exterior walls of many office buildings have cleaning problems. Under normal circumstances, manpower is used to clean the exterior walls, while the laser cleaning system uses optical fibers to clean the exterior walls of the building, so machine cleaning is better than manual cleaning. It is more efficient.

4. Cleaning in the electronics industry

The electronics industry will use lasers to remove oxides, and the electronics industry is suitable for lasers to remove oxides. Before the circuit board is soldered, the component pins must be thoroughly deoxidized to ensure the effect of electrical contact, and the pins must not be damaged during the decontamination process. Laser cleaning can meet the requirements of use, and the efficiency is very high, only one stitch of laser irradiation.

5. Deesterification cleaning in precision instrument industry

The precision machinery industry often needs to remove the esters and mineral oils used for lubrication and anti-corrosion on the parts, usually using chemical methods, and chemical cleaning often has residues. Laser deesterification can completely remove esters and mineral oil without damaging the surface of the part. The removal of contaminants is achieved by shock waves. The explosive gasification of the thin oxide layer on the surface of the parts forms a shock wave, which leads to the removal of dirt instead of mechanical interaction. The material is thoroughly deesterified and used for the cleaning of mechanical parts in the aerospace industry. Laser cleaning can also be used to remove oil esters in mechanical parts processing.

6. Pipeline cleaning in nuclear power plant reactor

The laser cleaning system is also used in the cleaning of pipelines in nuclear power plant reactors. It uses optical fibers to introduce high-power laser beams into the reactor to directly remove radioactive dust, and the cleaned materials are easy to clean. And because it is operated remotely, the safety of the staff can be ensured.

Application of laser cladding in the power industry

With the development of economy and society, laser cladding is widely used in the power industry. Renewable resources have been granted new missions such as energy conservation and emission reduction, greenhouse gas emission control and air pollution prevention and control. Wind speed and water power, as pollution-free and pollution-free new energy sources for power generation, have made great contributions to the power industry.

In the power industry, due to the large amount of power equipment and the extremely high utilization rate, it needs to operate continuously for a long time, so the destruction rate of its parts is relatively high. Parts of generator equipment work in different working environments, such as honed in natural gas, high temperature, high pressure, and corrosive substances. If the equipment is used for a long time, the parts will become brittle and damaged. Like the centrifugal impeller, water turbine, shaft tenon, etc. in wind/hydro power plant equipment, in order to increase the service life of expensive production equipment, It is necessary to use surface remanufacturing technology to repair it, especially the blades used for generator sets are usually very expensive. Reinstalling and reusing the repaired blades will greatly reduce the power generation cost of the power plant.
 


Laser cladding technology is an important method of surface modification technology for raw materials. The high-energy density laser is used to quickly melt alloys with different compositions and properties and the surface of the substrate, and produce different compositions and properties on the surface of the substrate. The entire process of rapid condensation of the alloy layer. Under the rapid heating effect, the substrate has little damage when exposed to heat and has no deformation. The molten layer alloy is a self-contained system with compact structure, optimized grains, improved strength and strong ductility, and greatly improved surface properties. Laser cladding technology solves a series of bottlenecks such as thermal deformation and thermal fatigue damage that are inevitable in the entire heat treatment process such as traditional electric welding and argon arc welding
Laser cladding has low dilution rate, compact structure, good fusion of coating and substrate, and reliable application. According to the application of laser cladding at this stage, its key uses are in three levels: one is the surface modification of raw materials, such as steam turbine blades, rollers, etc.; the other is repairing parts, such as wind power main shafts, planet carriers, planetary wheels, etc.; It is rapid prototype manufacturing, that is, the use of metal powder sintering and accumulating step by step to quickly create a model. The use of lasers can also repair damaged three-dimensional complex parts, which fully reflects the flexibility and advanced nature of laser remanufacturing technology.
 

WG-HG Laser 10KW power laser cladding equipment coming!

Work efficiency and Production cost determines development of an enterprise ang income. In order to solve the failure beacause of mechanical equipment parts, due to slowed production rhythm, problems of project delay and so on, WG-HG LASER lanch localization 10KW power laser cladding (repair) equipment, equipment maintenance is fast simple, lower cost, and can be efficiently repair of equipment parts manufacturing.

Laser surface Remanufacture (cladding/repair), which use high-energy laser as a heat source, metal alloy powder as a welding material, through laser synchronization with alloy powder on the metal surface rapidly melting pool formation, and rapid solidification of dense, uniform and controllable metallurgical bonding layer thickness, achieve to strengthen the life extension repair of workpiece surface size effect.


10KW power  laser cladding equipment

Use Domestic laser machine, robot and control system are adopted to form a flexible processing system with multiple additional shafts (According to actual situation such as auxiliary equipment 、autciliary axle and so on )can be customized according to the actual working conditions) to meet the advanced manufacturing process requirements of laser surface remanufacturing (cladding/repair) of metal workpiece surface.
 

The process parameters

The power range of the 10kw laser cladding equipment is from 10,000W-15000W, the light spot range is from 10-20mm, the efficiency is 0.65㎡/h-1.25㎡/h, and the cladding layer thickness is 0.5-3mm.



Advantage ：

1. High efficiency: High cladding efficiency，which is suitable for repairing and remanufacturing large-area and bulk products.

2. Reduce cost: the equipment purchase and maintenance cost are lower, and the price of core light source is more than 30% lower than similar imported products.

3. Improve the wear resistance and corrosion resistance of the workpiece: the high-performance cladding layer can be selectively prepared on the cheap and easily machined matrix surface, and the composition and performance of the cladding layer are rarely diluted by the composition of the matrix material. The resulting cladding layer has finer grain, denser structure, higher hardness, better wear resistance and corrosion resistance.

4. No damage to the base material: the cooling rate is up to 10^6℃/S, the heat affected area is small, the deformation is small, the dilution rate is ≤5-8%.

5. Energy-saving environmental protection: The process can be programmed and controlled, easy to realize automation, pollution-free to the environment, low noise, comfortable working conditions.

Application Area：

Laser surface remanufacturing (cladding/repair) is widely used in the mechanical equipment industry. Not only to repair and remanufacture the outer surface of shaft, rotor, gear, etc., but also repair the inner hole of oil cylinder, steel bushing, bearing sleeve, gear ring, etc.

Long axis laser cladding
WG-HG laser 10kw high-efficiency laser cladding (repair) equipment, work more efficient, greatly improve the production efficiency of the enterprise, for the production of enterprises.

Quality creates brand, professional achieves high quality! WG-HG Laser have a professional team, rich experience, warm service and good prestige. Whether you need laser cladding（repair） equipment or laser cladding（repair） processing business, PLS contact us for more information.

Environmental the application of laser cleaning in metal welding

Welding technology is a manufacturing technology that combines metal or other thermoplastic materials by heating.Always commonly used material processing method in engineering.Can connect different workpieces stably and effectively. In order to prevent the weld from having pores, cracks, rough appearance, uneven organization and other defects, affecting the welding quality, Before welding.clean the dirt and rust on the surface of the welding joint is the most important.

During the welding process, heat treatment will lead to the oxidation at the interface,make oxide layer. cleaning of the oxide skin, slag skin and spatter,It s usefull and inspection of welding defects after welding, Easy to find detection of surface defects and elimination and repair, to ensure the surface quality of the product.

Now The existing methods of surface treatment after welding are mainly mechanical grinding and chemical cleaning. Mechanical grinding is easy to cause workpiece damage, difficult to deal with the complex surface processing, and noise pollution, high-intensity work. Chemical cleaning is not suitable for local cleaning, easy to cause environmental pollution.

The new laser cleaning technology is to use the high-energy laser beam to illuminate the surface of the workpiece, Make the surface of dirt, rust, particles or coating instantly evaporation or expansion of peeling, to achieve the process of cleaning.

Features of laser cleaning technology
There are some problem from the process of the treatment of stainless steel welding seam, such as cracks, holes, solid impurities, not fusion, not welding penetration, shape defects, etc., the Conventional welding seam process treatment is complex, Not only to achieve, but also need to spend a lot of time, reduce the production efficiency. The application of laser cleaning machine on metal welding surface has the competitive advantage that traditional cleaning method does not have, which is mainly reflected in the following aspects:

1) Comprehensive functions: Laser cleaning not only remove rust, oil, oxide layer and other substances attached to the metal surface, but also remove dust, impurities and so on. It can efficiently treat stainless steel welds, including welding pretreatment, which is efficient and saves time and effort.

2) Local cleaning: The laser beam can not only adjust the size of the spot, but also carry out accurate cleaning on specific parts of the metal surface. Laser intensity can also be adjusted to the various adhesive strength of the adhesive to achieve thorough cleaning.

3) Flexible operation: Laser cleaning has no contact with the material surface, and can effectively clean the complex curved surface of parts and parts that cannot be reached by conventional cleaning.

4) Do not damage the base material: Laser cleaning can achieve selective removal of pollutants, improve cleanliness, and protect the base material.

5) Environmental protection: the impurities cleaned by laser can be directly recycled by means of dust extraction, no noise, waste solution and no secondary pollution.

Application case of weld cleaning (after welding)
Laser cleaning removes lubricant, black and non-ferrous metal impurities on the metal, so that welding and brazing joints of high quality, smooth and no pores, to obtain the best stability and quality of visible welds, suitable for steel and aluminum surface cleaning. As pretreatment before and after welding, it is widely used in automobile industry, precision tool production, shipbuilding and other industries.
 
Laser cleaning can not only clean the small area of the workpiece, but also form the automatic production line of laser cleaning, cleaning and processing large quantities of the workpiece, thus improving the efficiency of laser cleaning.
WG-HG Laser has launched a series of laser cleaning products with different power, efficiency and structure, such as 10-60W backpack laser cleaning machine, low-power (50-200W) handheld laser cleaning machine, medium-power (200-500W) handheld laser cleaning machine, and high-power (500-1600W) laser cleaning machine.

Low and medium power cleaning machine, design with backpack, handheld or clamping design, flexible cleaning, can be used to clean specific parts of the base material, flexible operation.
High power laser cleaning machine adopts clamping design, cleaning efficiency is higher, very suitable for large volume and large area of the production environment of efficient equipment, more intelligent, efficient.
The whole set of laser cleaning equipment adopts customized design, which can be used in a small range or form a laser cleaning flow line for aquatic products, so as to adapt to different places and meet the cleaning needs of different industries and working conditions. The long - term continuous operation of the laser ensures the stability and service life of the equipment.

Quality creates brand, professional achieves high quality! WG-HG Laser have a professional team, rich experience, warm service and good prestige. Whether you need laser cleaning equipment, or laser cleaning processing business, HG-HG laser share  total  win.PLS contact us for more detailed information.

laser surface treatment technology in mechanical gear

The main applications of laser surface treatment technology in mechanical gears include laser surface quenching and laser cladding repair.

I. Laser surface quenching

Gears are widely used in all walks of life. Due to the working characteristics of the gear, the central part of the gear is required to ensure the toughness, while the tooth surface can meet the requirements of hardness, to meet the strength requirements of the use. Under the condition of certain gear manufacturing technology, the hardness and wear resistance of gear surface can be improved rapidly and effectively by laser surface quenching technology.

Laser surface quenching technology, also known as laser phase change hardening, USES a high energy laser as a heat source to make the metal surface hot and cold quickly, instantly complete the quenching process, get high hardness, ultra-fine martensite structure, improve the metal surface hardness and wear resistance, and form compressive stress on the surface, improve the fatigue strength.

Laser surface quenching features:

1 selection quenching, laser quenching can be used to quench the specified area of complex parts, which is very suitable for tooth surface strengthening;

2. Fine grain, extremely fine martensite grain, high dislocation density, and significantly improved surface wear resistance.

3. Small deformation, laser quenching extremely hot and fast cooling, quenching process in a very short time, small heat affected area, quenching stress and deformation, suitable for different shapes and sizes of gears.

4. Energy saving and environmental protection: The laser system with high conversion efficiency is adopted without water/oil and other cooling media.

Gear laser quenching applications

By means of laser quenching, the service life of gear can be extended exponentially, the cycle of gear replacement can be reduced, and the production cost of the enterprise can be effectively saved.

Laser surface cladding

The gear's occlusal surface requirement is high, the work labor intensity is large, so in the tooth surface occlusal area will appear first wear and flake, resulting in the failure of the gear scrap. The scrapping of large mechanical gears is an expensive expense. By laser surface cladding technology, the gear can be repaired and its use can be restored.

Laser surface cladding technology to repair, also called laser material manufacture, USES the high energy laser as a heat source, metal alloy powder as a welding material, through laser synchronization with alloy powder on the metal surface, the formation of dense, uniform and controllable metallurgical bonding layer thickness, so as to achieve and to strengthen the life extension repair of workpiece surface size effect.

Features of laser cladding repair:

1. The thickness of cladding layer is optional, and the original size of the gear can be restored as required;

2. Wear resistance and corrosion resistance, the cladding layer has anti-erosion, anti-wear and anti-corrosion properties;

3. Good metallurgical combination. The cladding layer and the matrix are combined with dense metallurgy, and will not flake off under heavy load and impact service conditions;

4. Low dilution, short laser action time, low cladding layer dilution (5%~8%), saving expensive cladding material;

5. High quality, no thick casting structure, fine solidification structure, compact interface structure, fine grain, no holes, no inclusion cracks and other defects.
 
Application of laser surface cladding for gear

By laser surface cladding repair, the gear can be restored to its original size, so that the failed gear can be used again. Moreover, the wear resistance and corrosion resistance of the gear surface repaired by laser cladding are also improved. Effectively extend the service life of the gear.

Laser surface treatment technology are widely used in machinery industry, not only to strengthen the repair, the gear can also for axial and rolling mill, hydraulic support, such as inner hole for laser surface cladding repairing, for mould, crankshaft, cylinder and so on laser surface quenching strengthening, rust, paint, oxidation layer of conventional laser surface cleaning, etc.

Quality casts the brand, professional achievement is efficient! Wisco Laser has a professional team, rich experience, warm service, good reputation. No matter you need laser cladding, laser quenching, laser cleaning equipment, or laser surface treatment and processing business, you can contact us, WisCO Huazong laser quality, service casting reputation, sharing win-win, for the science and technology closer to life, for the manufacture of higher glory.