레이저 클래딩 technology involves placing a selected cladding material onto the surface of a substrate using different filler methods. Through laser irradiation, a thin layer of the substrate surface melts and quickly solidifies, forming a metallurgically bonded surface coating with very low dilution. This significantly enhances the substrate material’s surface properties such as wear resistance, corrosion resistance, heat resistance, oxidation resistance, and electrical properties.

Classifications of Laser Cladding

Based on the type of materials used and their coupling with the laser beam, common 레이저 클래딩 technologies can be divided into: coaxial powder laser cladding, off-axis powder laser cladding (also called lateral powder laser cladding), high-speed laser cladding (also called ultra-high-speed laser cladding), and high-speed wire laser cladding.

동축 분말 레이저 클래딩

Coaxial powder 레이저 클래딩 typically uses a semiconductor fiber laser and a disc-type gas-fed powder feeder. The cladding head employs a circular light spot scheme with a central light beam and powder fed around it or multiple powder streams. With a specially designed protective gas channel, the powder, light beam, and protective gas converge at a single point, where a molten pool is formed. As the cladding head moves relative to the workpiece, a cladding layer forms on the surface.

동축 파우더 레이저 클래딩의 장점:

High freedom and easy automation: The cladding layer quality remains consistent regardless of the direction of movement, making it highly adaptable to automation with industrial robots or multi-axis machines.

Good inert gas protection: The molten pool is shielded by inert gases, improving process stability.

Small molten pool, even heating, and good crack resistance: The uniform interaction between powder and light ensures better quality and durability of the cladded surface.

오프축 파우더 레이저 클래딩

Also known as lateral powder 레이저 클래딩, this method uses a semiconductor or fiber laser with a gravity-fed powder feeder. The cladding head employs a rectangular light spot combined with lateral powder feeding. The alloy powder is delivered to the workpiece surface and melted by the laser beam, forming a molten pool.

오프 축 파우더 레이저 클래딩의 장점:

High material utilization: Powder is pre-deposited onto the surface before being melted by the laser, achieving material utilization rates above 95%.

High cladding efficiency: The rectangular beam allows for increased laser power and larger spot sizes, improving the cladding speed.

No inert gas consumption: This method does not consume inert gas, although it requires careful consideration of powder oxidation resistance.

초고속 레이저 클래딩

This process employs a high-quality fiber laser and high-speed cladding heads to achieve extremely high cladding speeds (up to 200 m/min). The powder is pre-heated or fully melted before entering the molten pool, dramatically shortening the time needed for powder melting.

초고속 레이저 클래딩의 장점:

High laser energy utilization: The laser beam efficiently heats the powder and workpiece, minimizing energy loss and maximizing the cladding efficiency.

Low dilution rate: With high cladding speeds and brief molten pool exposure times, the dilution rate of the cladding layer remains low.

Low surface roughness and crack resistance: The process minimizes defects in the cladded layer, ensuring high-quality results.

고속 와이어 레이저 클래딩

High-speed wire 레이저 클래딩 uses metal wire as the cladding material, which is fed into the laser beam. The metal wire is melted to form a molten pool, which solidifies to create the cladding layer.

고속 와이어 레이저 클래딩의 장점:

Environmental benefits: The use of wire instead of powder eliminates splashing and metal dust, improving environmental performance.

High material utilization: The wire is fully melted, ensuring nearly 99% material utilization.

High cladding efficiency: The controlled energy input and fast cladding speed result in high material efficiency.

The Impact of Process Parameters on Cladding Effect

레이저 클래딩 parameters, including laser power, spot diameter, cladding speed, focus offset, powder feed rate, scanning speed, and preheating temperature, significantly affect the cladding layer’s dilution rate, crack formation, surface roughness, and the overall density of the cladded parts. Improper parameter settings can lead to poor metallurgical bonding between the cladding and substrate, impeding the formation of multi-layer channels.

주요 프로세스 매개변수에는 다음이 포함됩니다:

레이저 파워: This determines the molten volume of the substrate. Increasing power leads to deeper cladding but also increases the likelihood of porosity. However, higher power can reduce cracks and porosity by improving dynamic solidification during the cooling phase.

Spot Diameter: The spot diameter of the laser affects the width of the cladding layer. While small spot sizes provide better quality, large spots are better for covering larger areas.

Cladding Speed: Cladding speed impacts how well the alloy powder melts. If too high, the powder won’t fully melt; if too low, the pool will overheat, leading to material loss.

Features of Laser Cladding Surface Formation Technology

Fast cooling speed and rapid solidification.

Low thermal deformation, with low dilution rates and excellent metallurgical bonding between the coating and substrate.

Wide material selection: Iron-based, nickel-based, copper-based, titanium-based, and more.

Precise thickness control: Cladding thickness ranges from 0.2mm to 2mm, ideal for wear part restoration.

High processing precision, suitable for small or hard-to-process areas.

Easy automation integration.

Laser Cladding Material Systems

The choice of cladding materials is crucial to achieving the desired surface quality and properties. Typically, the selection of appropriate materials depends on the substrate’s physical and chemical properties, and the cladding material must be chosen accordingly.

Material Systems:

Self-Fusing Alloy Powders: These include iron-based, nickel-based, and cobalt-based powders and are most commonly used in laser cladding. They offer excellent corrosion and oxidation resistance.

Composite Powders: These combine high-melting-point ceramics such as carbides, nitrides, and borides with metals, forming powders ideal for producing wear-resistant coatings.

Ceramic Powders: Including oxide-based ceramics like aluminum oxide and zirconium oxide, these are commonly used for producing heat-resistant coatings.

Other Alloy Powders: Copper-based, titanium-based, aluminum-based, and other specialized alloy powders are also used depending on the application requirements.

결론

레이저 클래딩 technology is widely used in industries like aerospace, automotive, petrochemical, metallurgy, and rail transportation to repair and enhance critical components. By providing a cost-effective solution for repairing damaged parts, 레이저 클래딩 reduces costs, boosts efficiency, and enhances performance. With advancements in high-power lasers and reduced manufacturing costs, 레이저 클래딩 is becoming a hot topic in both academic and industrial research.