Project Overview

GREENSTONE has successfully delivered an open-type ultra-high-speed laser cladding system to a customer laboratory for the development and evaluation of advanced coating processes on shaft and other rotationally symmetrical components.

Unlike production systems designed primarily for continuous batch processing, this system was configured specifically for laboratory process development, parameter optimization and coating research. An integrated four-axis motion system provides precise and stable coordination between the laser cladding head and rotating workpiece, giving researchers a flexible platform for developing different laser cladding processes.

The open architecture also provides convenient access to the processing area, making it particularly suitable for laboratories where workpieces, powders, process parameters and experimental configurations need to be changed frequently.

Customer Research Requirements

The customer’s primary objective was to develop and optimize high-speed and ultra-high-speed laser cladding processes for shaft components.

For laboratory research, processing speed alone is not sufficient. Repeatability and precise control of the relative movement between the laser, powder stream and workpiece are essential when evaluating how different parameters influence coating formation.

The system therefore needed to provide:

• Precise four-axis coordinated motion
• Stable rotation at the required processing speeds
• Accurate positioning and repeatable laser trajectories
• Flexible adjustment of cladding parameters
• Convenient installation and replacement of experimental workpieces
• Easy access for process observation and research work
• Compatibility with different coating-development programs

These requirements formed the basis of GREENSTONE’s system configuration.

GREENSTONE Four-Axis Ultra-High-Speed Laser Cladding Solution

The delivered platform integrates an ultra-high-speed laser cladding head, precision powder feeding system, four-axis motion platform, workpiece rotation system, laser source, cooling system, process gas control and integrated control system.

The four-axis architecture allows the laser processing position and workpiece movement to be coordinated with high precision. For shaft coating experiments, the rotary axis controls workpiece rotation while the linear motion axes control the position and travel of the laser cladding head.

Through synchronized rotation and axial movement, the system can generate controlled helical cladding paths along cylindrical surfaces. This provides a stable basis for investigating parameters such as laser power, cladding speed, powder feed rate, track overlap, focal position and energy input.

For ultra-high-speed laser cladding research, this motion stability is particularly important because small variations in the relative motion between the laser, powder and substrate can directly influence coating consistency.

Designed for Coating Process Development

The system was developed as a research and process-development platform rather than a fixed single-purpose production machine.

Researchers can use it to evaluate different combinations of substrate materials, coating materials and processing parameters, and subsequently analyze coating characteristics such as surface morphology, dilution, microstructure, metallurgical bonding and overall coating consistency.

The open-type configuration also makes experimental work more convenient. Workpieces can be installed and changed efficiently, while the processing area remains accessible for setup, adjustment and observation under appropriate laboratory laser-safety controls.

This flexibility enables the customer to establish and optimize coating processes before transferring validated parameters to larger-scale industrial applications.

Successful Commissioning and Delivery

Following system integration, four-axis motion calibration and laser cladding process verification, the GREENSTONE open-type ultra-high-speed laser cladding system was successfully commissioned and delivered to the customer’s laboratory.

The completed system provides stable coordinated movement and precise control for shaft coating experiments, creating a reliable platform for repeatable laser cladding research and process optimization.

Rather than simply supplying individual laser components, GREENSTONE delivered an integrated research system in which the laser, cladding head, powder feeding, workpiece rotation, multi-axis motion and process control operate as a coordinated platform.

From Laboratory Research to Industrial Process Development

This project demonstrates another aspect of GREENSTONE’s laser cladding capability: developing equipment not only for industrial production, but also for laboratories, research institutes and R&D teams that require flexible and precise process-development platforms.

The four-axis ultra-high-speed laser cladding system enables the customer to systematically develop coating processes for shaft components and build a reliable foundation for subsequent industrial implementation.

For laboratory laser cladding research, GREENSTONE can configure the system around the required workpiece dimensions, substrate and coating materials, laser power range, motion requirements and research objectives, providing a dedicated platform for advanced laser cladding process development.