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Laser Cladding Services

Laser Cladding Services, Perth (LCS) provides the highest-quality laser cladding repairs and surface enhancement technologies utilising laser cladding hardware. Laser cladding is weld overlay using a high powered laser as the heat source. This makes it ideal for shaft welding repairs on grades such as AISI 4140, 4340, K1045, etc, to build up worn seal and bearing journals. Compared to conventional welding, laser cladding provides minimal dilution (less than 2%) and a small heat affected zone (HAZ).

The bond between the laser clad overlay and the base material is metallurgical, unlike metal spray processes where the bond is mechanical. Also when comparing metal spray to laser cladding, there is less heat input with laser cladding, so the shaft being repaired will not distort. All of the common thermal spray processes such as HVOF, electric arc spray & plasma spray can all transfer significant heat to the part being metal sprayed, increasing the risk of distortion to shafts that are finished machined.

laser welding shaft repair
Caterpillar Dump Truck Hitch laser clad
on the two worn journals

Common Laser Cladding Applications

  • Laser cladding of worn pump shafts
  • Pump impellors & diffusers laser clad
  • Laser hardfacing of valves and seats
  • Laser cladding of corroded gate valve stems
  • Laser cladding of gearbox & pinion shafts
  • Hydraulic shafts laser clad with SS431L for enhanced corrosion resistance
  • Laser hardfacing down-hole tools for mining, oil and gas drilling
  • Pipe Flanges clad with Super Alloys
  • Agricultural equipment
  • Extremely high-wear applications
  • Mining equipment
  • Marine applications
  • Automotive applications
  • Power generation

Laser Cladding is an emerging alternative to Plasma Transferred Arc (PTA) welding and thermal spray. A concentrated laser beam is used as the heat source, melting the surface of the base material that the powder is being applied to, resulting in a coating that is 100% dense with no voids or porosity.

Laser Cladding Advantages

One of the advantages of the laser cladding process is the highly concentrated beam of energy from the laser. Using optics the beam is focused and concentrated to a small area, keeping the HAZ of the base material very shallow, minimizing the chance of distorting, cracking or changing the metallurgy of the base material. In addition the lower total heat minimizes the dilution of the laser cladding with material from the base material.

Other advantages of Laser Cladding are:

laser welding shaft repair
Clutch shaft laser welded with tungsten carbide
on the needle roller bearing journals
  • Low dilution laser clad overlay with very high purity - Multiple passes or heavy overlay thicknesses just add expense and induce unwanted tensile stress, but with a laser clad overlay the chemistry and hardness are undiluted at the surface of the first pass, so a single pass is usually all that is required.
  • Laser cladding produces a very low heat input with low distortion - Finished machined parts with close tolerances can be laser clad with minimal risk of dimensional deviation or distortion, which is a major advantage over metal spraying.
  • Laser cladding is a fully alloyed bond - Unlike thermal spray, the bonding mechanism is metallurgical and not mechanical. Therefore external physical loads and stresses are unlikely to cause the overlay to tear off, fracture, or spall (a common problem with metal spraying). Laser clad overlays can withstand significant abrasion and direct impact.
  • laser clad worn shaft
    Stainless Steel hollow shaft laser clad with
    SS316L on worn bearing journal
  • Laser cladding provides high toughness protection - Nickel-based tungsten carbide laser clad overlays are regularly used to protect drilling tools and mining equipment. Cobalt-based laser tungsten carbide clad overlays protect against erosion and cavitation in high-pressure pumps, valves and turbines.
  • Laser cladding produces an impenetrable corrosion barrier - Uniform laser clad overlays are free of cracks and porosity, therefore preventing permeation and attack of the base material by even highly reactive liquids and gases. Because thermal sprayed overlays are only mechanically bonded, they can easily be attacked by chemicals. The range of cladding powders available ensures that most corrosive situations can be solved. Laser clad overlays can have a machined or ground surface finish, ensuring tight-fitting seals for valves and pump components.
  • Laser clad overlay / substrate combinations - With a range of laser cladding powders available and the ability to mix different powders to meet requirements, laser cladding overlays can be applied to most machineable metallic materials, allowing high-performance alloys or special property materials to be overlayed to less-expensive free machining steels or exotic alloys.

laser welding shaft repair
Worn seal journal on a hollow shaft repaired
with a laser clad single pass of SS410L

Laser Cladding Specifications

Laser cladding thicknesses can be from 0.5mm up to 3mm in a single pass and can go to any thickness with multiple passes. By comparison metal spray is usually applied in thin layers, so isn't always a suitable repair method. There is a large variety of powder / base material combinations available including pure metals, alloys, or carbides. Laser Cladding Services has available numerous laser cladding procedures for various base metal / powder combinations and production test pieces can be laser clad and tested per the customers’ requirements, such as NDT to AS4037 1999 Class 1 and mechanical testing to AS3992 1998.

For all your wear and corrosion problems call or email Laser Cladding Services in Perth and we will provide you with the best engineered laser cladding solution.



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