Laser Cladding

and Hardening
Background with
Diode Lasers
Markus Ruetering

Sales Manager Asia

© Laserline GmbH
Laser Cladding Background

Outline
Diode Laser for Cladding
Cladding Process Basics
Process Principle
Main Cladding Technologies
Layer Properties of different Hardfacing Techniques
Process Efficiency: Features Comparison (CO2 – Diode Laser)
Laser Cladding and Coating – Usage Examples
Laser Equipment for Cladding
Cladding Examples
Repair Welding Examples
Cladding Systems
Cladding and Repair Welding References

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Cladding Process Basics
Process Principle

Process:
Powder and assist gas is fed into
the laser beam coaxially or off-axis
Laser beam
Laser beam melts powder onto
base material
Powder Melt pool
nozzle

Clad layer

Bonding zone
Substrate Heat affected zone

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Diode Laser for Cladding
Cladding with Laserline
Advantages:
Much thinner bonding zone than with
conventional techniques like (PTA)
Lower dilution and thinner layers
Less powder necessary
Better adhesion than conventional techniques
Small heat affected zone
Stable and reliable, very important due to
duration of cladding processes
Top hat beam profile, allowing for tailoring of
the deposition process
Laser head isolated from process, in controlled
environment
Easy integration of the laser in robotic systems
Full 3-D capability
Efficient, the laser will save energy and money
Beam quality tailored to process needs
High BPP needed for fine repair work
Low BPP for “paving”

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Main Cladding Technologies
Layer Properties of different Hardfacing Techniques

Photo: The Standard Alloy

Steel Industries Photo: AREF Photo: GTV

thermal spraying conventional welding laser cladding

Layer thickness [mm] 0.05 – 0.15 1–3 0.15 – 1.5
Layer width [mm] Large area 4–6 1 – 15
Heat affected zone [mm] 0.2 – 0.5 2–4 0.4 – 2
Layer quality porous dense dense
Micro structure fine coarse fine
Adhesion mechanical metallurgical metallurgical
Distortion low high medium

www.laserline.de Data: Fraunhofer IPT © Laserline GmbH 5

Main Cladding Technologies
Process Efficiency:
Features Comparison (CO2 – Diode laser)

CO2 Diode
1 mm radiation has better absorption in Power [kW] 5 3
material than 10 mm radiation
Less laser power needed to achieve Speed [mm/s] 15 15
same cladding results Width of clad [mm] 5 5
High heat input leads to distortion of
Speed of clad [mm²/s] 75 75
parts and coarser grain structure of
the deposited layer Amount of clad [kg/h] 2,16 2,2

Data: IREPA, Strasbourg, France

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Main Cladding Technologies
Laser Cladding and Coating – Usage Examples

Automotive industry Agriculture

Valves and valve seats Saws blades
Repair or change of shape of forming Harrow disks
and cutting tools Scraper and counter blades
Oil industry Aerospace and Energy Generation
Drilling tools Turbine blade repair
Oil string wear protection Vane repair
Mining Bladed disk repair
Hydraulic cylinders Ship industry
Hand tools Repair of gear components
Foundries Paper industry
Pan scrapers Mixer shafts, rollers, valve seats
Taphole drills Pulp screens and sieves
Steel industry Earth moving equipment
Conveyor rollers in steel mills Wear protection

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Laser Equipment for Cladding
Equipment

Diode Laser Complete Optics Customized Spot Accesories

LDF or LDM Fiber-coupled Homogenized Special
Mobile and 1” and 2” laser focus process
flexible unit Optics Lines, Optics
Suitable rectangles
Laser power and squares
Integrated
pyrometer

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Cladding Examples
Downhole Drilling: Process Example

WC/Co + NiCrBSi on
steel
Only NiCrBSi matrix is
molten
50% (typ 63%) volume
content of coarse-
grained carbides

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Cladding Examples
Downhole Drilling: Advantages of Laser Cladding

Non-magnetic materials necessary to

avoid interference with measurement
tools are easier worked using this
technique
Less heating of the part and lower
distortion of parts, generally easier to
tailor heat profile
Less mixing between cladding and
base material allows for thinner
cladding layers

Source: Laser Welding Solutions

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Cladding Examples
Downhole Drilling: Parts

Wear Rings
Surface protection connection points
in oil string
Antenna Housings
Long tubes with slots carrying
sensors
Drill Collars
Main part of the oil string

Source: Laser
Welding Solutions

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Cladding Examples
Downhole Drilling: Parts

Stabilizers
Stabilize the drilling tool against the
drill hole wall
“Wing” geometries generate channels
for removal of drill fluids and earth
material
Multidirectional cladding required

Source: Laser Welding Solutions

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Cladding Examples
Drill Bits for Blast Furnaces

Vanadium carbide (VC) hardfacing of

steel using 4 kW diode laser
Refractory and wear resistant layer to
protect drill bit on taphole drill
Cladding powder: FeCrV15Ni7
Source:
Resulting layer has fine-grained VC Fraunhofer IWS
precipitations

1 mm

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Cladding Examples
Agricultural Parts

Cladded with carbide

Typically iron carbide, chrome
carbide or tungsten carbide
Material depends on wear and cost
requirements

Saw Blade

Counter Blade Disk harrow

Photos: Resus S.A.

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Cladding Examples
Forming Tools

Laser Cladding of Stellite 21 on Cast Iron

Repair of large metal forming tools
10 kW diode laser, rectangular spot + rectangular nozzle
Melt pool shape and power level allow optimization of process for crack
prevention

Cross section of Stellite 21 on GGG 70 L

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Cladding Examples
Forming Tools

Cross-section Stellite21 Example:

on GGG40 Tool for plastic material processing
Source: Fraunhofer IWS
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Cladding Examples
Pulp and Paper Mill Equipment

Tungsten carbide
cladding of screens
and sieves

Superior, exact
coatings

Cost effective

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Cladding Examples
Concrete Screw

Photos: Balliu

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Cladding Examples
Cladding of Stainless Steel on Carbon Steel

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Cladding Examples
Crane Shaft

Source: Matex

Data Results:
Power 3.5 kW no pore or cracks found, ultrasound proved
Fiber diameter 600 Shaft replaced and used in normal
µm operation
Base material No deformation (No finish work needed,
CK45 process always accurate and under
Cover: stainless tolerances)
steel AISI 316L 100% perfect results with no need of
preheating or glow

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Cladding Examples
Other Parts

Valve seat for the paper industry Photo: Metso

3D part for glass treatment

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Cladding Examples
Aluminum Cladding

Objective:
Substitution of anodizings

Result:
100% dense structure
homogeneously dispersed Si
precipitations
Wear resistant structure

Source: Fraunhofer IWS

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Repair Welding Examples
Laser Repair of Guide Vanes

Repair of eroded areas on guide

vanes (fixed parts in turbines)
Test on coupon material
Material: Inconel
Laser power: 1,000 W
Spot size: 0.6 mm
No cracking due to careful pre and
post heating

25 mm

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Repair Welding Examples
Laser Repair of Blade Tips: Requirements

Repair requires generation of fine

structures
Low or no pores or cracks
Added material either base material or
similar material with enhanced wear
characteristics

1 mm

Base material: Inconel 625

Added material: Inconel 738

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Repair Welding Examples
Laser Repair of Blade Tips: Introduction

Blade tips create a seal against

housing
Tight seal generates wear over time
as engine temperatures change
Blade tips engineered to be worn out
Blade tip rework more economical
than replacement

Source: IREPA

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Repair Welding Examples
In Situ Gas Turbine Repair

Source: IRIS, Melbourne

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Repair Welding Examples
In Situ Shaft Repair

Source:
Stork
Gears and
Services

Laser cladding at shipyard during preventative

maintenance of tugboat

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Repair Welding Examples
Shaft from Rotors for Petrochemical Industry

Source: TM Comas

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Repair Welding Examples
Other examples: Ship Industry

Mixer shaft. Repair of bearing surfaces,

sealing surfaces and coupling fit.

Planetary Gear: Bearing surfaces

refurbished with Nickel alloy

Photos: Stork Gears and Services

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Cladding Systems
Robot-Based Diode Laser Cladding System. IWS

Laser Power:
10 kW
Nozzle:
Fraunhofer Coax 11
widestream
Deposition Rate:
> 9 kg//h
Clad Width:
> 22 mm

Source: Fraunhofer IWS

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Cladding Systems
Robot-Based Diode Laser Cladding System. GTV

Source: GTV

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Cladding Systems
CNC System retrofitted for Laser Repair Welding. TMC

LDF 4000-100, VG4L – 4 kW diode laser

Macro Clad 45V2 (Irepa) powder nozzle
Used 4 axis CNC system

Source: TM Comas
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Cladding Systems
Cartesian Cladding Systems. IWS, Arnold, Technogenia

Machining + Repairing
Source: Fraunhofer IWS, Arnold

Repairing
Source: Technogenia

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 Photo: Erlas

Laser Heat Treatment

Background

Source: Erlas

© Laserline GmbH
Laser Heat Treatment Background

Outline
Diode Laser for Heat Treatment
Heat Treatment Process Basics
Principle
Common Parameter
Importance of Beam Profile
Laserline Beam Profile flexibility
Materials and Applications
Main Heat Treatment Technologies
Overview
Induction Hardening
Laser Hardening
Process Chain: Induction vs. Laser Hardening
Laser Equipment for Heat Treatment
Applications and Examples

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Heat Treatment Process Basics
Principle
The laser beam instantaneously heats the surface
and through conduction penetrates the material
The bulk of the material acts as a heat sink for the
extraction of heat from the surface
Formation of fine-grained microstructure
(Martensite) of high hardness due to short
temperature cycles
Very quick heating-up of the material by cw laser
radiation moving along a path
Self-quenching due to large thermal mass of bulky
base material

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Heat Treatment Process Basics
Common Parameter

“Empirical formula” for laser hardening:

1 : 1  1 kW at 1 cm²
Typical feed rates : 2-10 mm/s
Laser power utilized: 3-6 kW
Rectangle area, spot sizes: 10x10,
15x15, 15x30 mm², etc.
Fiber-coupled
diode lasers for
most homogeneous
energy distribution

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Heat Treatment Process Basics
Importance of Beam Profile

High case depth

requires top-hat
beam profile
Square focus
geometry for best
process efficiency
Focused laser
spot for
homogeneous
hardening results

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Diode Laser for Heat Treatment
Heat Treatment with Laserline

Advantages
Laser heat treatment offers high
processing speeds with precise
hardening depths
Lasers can easily heat-up a precisely
defined area, assisted by closed-loop
temperature control
Extremely minimal distortion, due to
low overall energy input
Little subsequent machining

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Heat Treatment Process Basics
Laserline Beam profile flexibility

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Heat Treatment Process Basics
Materials and Applications
Nearly all commonly used tool steels
and cast iron grades can be treated
with laser
For hardening, carbon content needs
to be higher than 0.2%
Typical applications include:

Transmission gears
Spindles
Shaft keyway
Extruder screws
Hemming tools
Dies
Forming tools
Springs
Pliers

Source: Rudlaff

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Main Heat Treatment Technologies
Overview

Source: Erlas

Oven Flame Induction Laser

Heating of the Manual Post-processes Closed-loop
complete part process required temperature
Limited size of No temperature Additional control
the workpiece control cooling required Homogeneous
High distortion, Poor Most closely and constant
warpage repeatability matches laser case depth
hardening Almost no further
finishing process
required

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Main Heat Treatment Technologies
Induction Hardening
Customized processing head
Difficult automation
No temperature control to protect surface from
melting
Uneven (wavy) material volume increase due
to inconsistent hardening depth
Uneven surface and certain distortion
Time-consuming and costly reworking
required on already hardened material
 Hardening depth of several millimeters
necessary Source: TKDN

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Main Heat Treatment Technologies
Laser Hardening
Benefits of laser hardening
Clearly reduced energy input Source: Alotec

Partial hardening - local heat input in

dedicated areas
Low, homogeneous and constant
hardening depth
Base material characteristics are
maintained (reduced distortion)
No contamination of part surface
Short cycle times
Reproducible results, fully
automatable
Flexible process – hardening of
complex geometries possible
Temperature controlled process
Little further reworking required

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Main Heat Treatment Technologies
Process Chain: Induction vs. Laser hardening

Less mechanical wear of

costly machining tools
Reduced process time
Less process steps
 20% overall cost
reduction possible.

Source: TKDN

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Laser Equipment for Heat Treatment
Laser and Accessories

Diode Laser Complete Optics Customized Spot Zoom-Optics

LDF or LDM Fiber-coupled Homogenized Motorized
Mobile and 1” and 2” laser focus beam
flexible unit Optics Lines, expander for
rectangles X and Y axis
Suitable
Laser power and squares Dynamic
adaption of
Integrated
beam size
pyrometer

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Applications and Examples
Hardening of Deep-Drawing Tools

TKDN Erlas

Source: Alotec

Robot-based system

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Applications and Examples
Hardening of Deep-Drawing Tools

LDF 4000-100
Homogenized optics: 5 x 23 mm²

Source: Matex

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Applications and Examples
Hardening of Deep-Drawing Tools

Source: Erlas

Laser hardening of stamp Laser hardening of a blank holder of a

Material: nodular cast iron (GGG 70L) press-tool-set

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Applications and Examples
Harden Automotive Car Body Tools

Low space requirement

Operation in standard industrial
environment
No special clean area required
Complete repair of system possible
on-site
Example applications
Harden automotive car body tools
As shown
Harden construction equipment
Harden cylinder liners (Diesel engine)
Harden transmission components
Annealed wire production
Axle keyway
Multi kilowatt fibre coupled diode
lasers Source: Erlas

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Applications and Examples
Simultaneous Hardening of Top and Side Part

TKDN Fraunhofer IWS

Source: Erlas

Scanner-based hardening with diode lasers and corresponding robot

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Applications and Examples
Hardening of Turbine Blades

High-dynamic lateral adaptable track width

Source: Fraunhofer IWS

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Applications and Examples
Hardening of Cylinder Shaft

Matex Job Shop

Temperature
controlled laser
power < 4,000
W

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Applications and Examples
Various Industrial Applications

Source: Erlas Source: Matex

Gear wheel Slide rail Cutting tools Cutting tools

Case Depth 4000 W Adaptive spot Pyrometer
<500 μm Laser power geometries controlled
1500 W Continuous Laser power temperature
Laser power process from 1 to 4kW to avoid
melting of
cutting edge

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Applications and Examples
Various Industrial Applications

Side Cutters Car door spring Spring Spigot,

Case Depth 1000 W Gear wheels
<200 μm Laser power
300 W Cycle time
Laser power <1.7s
Feed rate Rectangular
0.3 m/min Beam profile
Ø 4 mm

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Applications and Examples
Pinch-edge

Source: Matex

Hardening of a cutting tool for the Data

automotive industry. Steel 1.2311
Pinch-edge: used to produce sandwich Laser 3,5kW
panels for the interior in the car, roof, door, Fiber 600µm
floor, etc.
T controlled with Pyrometer
The edge is hardened in the final state with
no further rework needed
Control of temperature is very important to
avoid melting of the edges. The system must
be 100% reliable.

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Applications and Examples
Cable Drum Hardening

Source: Matex

Data: Induction failed in this part: Benefits

Cable drum HRc 40-45 Low distortion
Diameter = 2 m After laser treatment: Highly reliable
Weight = 2.5T process
HRc 60-62
Material: cast iron EN JS Regular
2060 (GGG60) hardness
Laser Power 3.5 kW No cracks in the
surface
Fiber diameter 600µm
T control with pyrometer

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Applications and Examples
Cutting tools

Laser power:
2.000 W
Spot size:
5 x 5 mm²
Feed rate:
5 mm/s

Source: Matex

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Applications and Examples
Cutting tools

Laser power: 3.000 W

Spot: 5 x 5 mm²

Source: Matex

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Applications and Examples
Cutting Tools

Melting of edge avoided by pyrometer assisted

closed-loop temperature control

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Applications and Examples
Hardening of Chain-Wheel and Shaft

Laser power: < 3.500 W

Spot size: 23 x 5 mm²

Source: Matex

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Applications and Examples
Steering rack

Laser power: 3.500 W

Spot: 10 x 25 mm²

Source: Matex

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Applications and Examples
Selective Hardening of Car Door Spring
at B- and C-pillar

Laserline internal tests

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Applications and examples
Hardening of Flexible Dies

Avoid melting of cutting edge

Mass production part - high process
speeds required
Utilization of scan system possible

Flex steel (CK60)

Case depth at the cutting edge < 150 µm
Laser power < 50 Watts
Feed rate approx. 50 mm/s (scan system)
Focus diameter approx. 0.4 mm

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Applications and Examples
Hardening of linear bearings

Source: Alotec

Temperature controlled hardening tracks

on slide rails

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Applications and Examples
Hardening of Bending Tools

Hardening of bending tools

Spot size 17x17 mm², temperature guided

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Applications and Examples
Automotive BIW improved strength: ILT

Source: Fraunhofer ILT

Specific strengthening applied to certain Avoids the use of high cost UHSS’s steel
areas of car body panels Alternative to press hardening (hot
Weight reduction possible through stamping) of car body panels
enhanced strength

www.laserline.de © Laserline GmbH

Applications and Examples
Hardening of Stressed Areas

Source: Alotec

Robot and corresponding tilt-and-turn table

Hardening on tribologically stressed areas only

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Applications and Examples
Forming:Increased ductility of high strength metal sheets
Hot-stamping produces LHT (Laser heat treatment) high strength part, but
fully martensitic part to locally increase ductility ductile in a desired zone

Mechanical
joining

Deformation
zone

Tensile strength ~ 1500MPa Tensile strength down to 600 MPa

Max. elongation ~5% Max. elongation up to 25%
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Optics Products
Background

© Laserline GmbH
Laserline Modular Optics System

Outline
Optics Basics
Numerical Aperture Homogenizing Optics
Collimation Array Module
Focusing Square Spot Sizes
Spot size calculation Line Spot Sizes
Laserline Optics Components Zoom Homogenizer
System Overview Rectangle Spots
Optics for each Application Line Spots
Basic components Results
Fiber Coupling Module LLK-B Customized Spots
Fiber Coupling Module LLK-D Hardening Example 1
Collimating Lens Module (fcol) Hardening Example 2
Focus Lens Module (ffoc)
Cover Slide
Working distance (wd) calculation
Accessories
Beam Cube
Adaptor for Additional Components
Cross Jet

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Optics Basics
Numerical Aperture

Numerical Aperture NA is a measure for the

angle of the beam out of the fiber
Brightness / beam parameter product (BPP) is
NA * beam diameter
Brightness is the second number in model
number, i.e. LDF 4000-60
Laserline lasers have
Standard: NA = sin θ
NA = 0.22  θ = 12.7 degrees
(θ = 220 mrad)
or
High Brightness:
NA = 0.12  θ = 6.9 degrees
(θ = 120 mrad)
All LDMs are standard NA=0,12 and 0,22
Only LDF xxxx-30 have low 0.12 NA

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Laserline Optics Components
2 Inch Optics System

Single outside water connection

Inside tubing and improved cooling for
higher laser power
All stainless steel for higher
performance
Improved dust protection
Inherent distortion protection
Inherent lenses centering and
improved reproducibility
Improved cross jet
All known components available plus:
Adaptor for 250 mm base plate
Adaptor for M64x1.5 thread

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Laserline Optics Components
New 2 Inch Optics System: Examples

Cladding Welding Welding Hardening / heat

LLK-D fiber 1-inch optics 2-inch optics treatment
connector LLK-D fiber LLK-D connector LLK-B connector
cover slide as connector cross jet homogenizing
drawer cross jet element
CCD camera
cladding nozzle CCD camera 90° element Pyrometer
base plate

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Laserline Optics Components
Homogenizing Optics: Array Module
1” and 2” homogenizing lens assembly
Max. power allowed 1” = 4 kW
Max. power allowed 2” = 10 kW
Options:
1 axis: Line optics
smaller spot
higher intensity
typically for cladding
2 axis: Rectangular / square optics
larger spot
lower intensity
typically for heat treatment

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Laserline Products
Homogenizing Optics: Zoom Homogenizer

Up to 10 kW optical output power

Active water cooling
Motor control:
Analog positioning
Sequence programming
Stepper motor drive mode
Fiber connector B, D (Automotive)
NA<0,22
<8kg
Dimensions 135x137x300mm
Configuration examples :
3x10 -> 14x38, f=250mm
5x5 -> 45x45, f=400mm
15x15 -> 15x120, f=600mm

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Laserline Optics Components
Zoom Homogenizer: Variable Lines

LL-Line 2.35
fixed array group: Y axis

or
LL-Line 2.70
LL-Line 2.146
no homogenizer, 66 mm mrad,
or f_coll = 100 mm

For a given width of the line, we

or expand the spot continuously in
the X direction
Example 1: f200, 1.3x6->1.3x59
Example 2: f200, 3x6->3x59
Choose reduced max line length
for better homogeneity
Integrated focusing lens or
reduced line length with external
moveable array group: X axis focusing lens

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Laserline Optics Components
Zoom Homogenizer: Variable Rectangles
1st moveable array group: Y axis

For a given width of the spot, we

expand it continuously and
independently in the X and Y
directions
Example 1: f200, 4x4->4x38 and
4x4->38x4 and 4x4->38x38
Choose reduced max line length
for better homogeneity
Integrated focusing lens or
reduced line length with external
focusing lens
2nd moveable array group: X axis

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Laserline Optics Components
Zoom Homogenizer: Results
feed rate:
10 mm/s

Output power:
2,3 to 5,5 kW (red)
pyrometer-controlled
for constant
temperature 800 °C
1500 6000 (blue line)
1250 5000

1000 4000
Temperatursignal

Leistung / W
750 3000

500 2000

250 1000

0 0
0 20 40 60 80 100 120 140 160 180 200 220 240 260
Strecke / mm

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Laserline Optics Components
Customized Spots

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Laserline Optics Components
Customized Spots

Line Spots up to Ring spots Top Hat circular Homogeneous

> 130 mm length spots rectangular spots

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