Utilajele de extracție a cărbunelui funcționează în medii extrem de dure și exigente, cu cicluri de funcționare continuă îndelungate și condiții de sarcină grea. Componentele critice, cum ar fi târnăcoapele de tăiere, transportoarele, angrenajele și arborii, sunt foarte predispuse la uzură și defecțiuni, în timp ce cilindrii hidraulici de susținere și tijele de piston sunt adesea afectate de coroziune. Aceste probleme reduc semnificativ durata de viață a echipamentelor și conduc la timpi de inactivitate costisitori. Deoarece echipamentele de extracție a cărbunelui sunt de obicei mari, scumpe și dificil de dezasamblat, sarcinile de întreținere sunt substanțiale, iar orice defecțiune a pieselor cauzată de uzură sau coroziune poate duce la pierderi economice majore.

Metoda tradițională de reparare - Electroplacarea

• Rezistență scăzută la lipire; straturile se desprind ușor și au o durată de viață scurtă

• Poluarea gravă a mediului și pericole pentru siguranță

• Eliminarea treptată în aplicațiile industriale moderne

Placare cu laser - refacerea suprafețelor cu costuri reduse și eficiență ridicată

Placarea cu laser permite consolidarea suprafeței și refabricarea atât a componentelor noi, cât și a celor uzate. Aplicarea placării cu laser pe cilindrii hidraulici, coloanele de susținere și alte piese cheie îmbunătățește semnificativ rezistența la uzură și coroziune, prelungind efectiv durata de viață a componentelor.

Tehnologia de placare cu laser de mare viteză de la Chengdu Greenstone-Tech oferă viteze de prelucrare mai mari și suprafețe de acoperire mai netede și mai uniforme în comparație cu placarea cu laser convențională. Majoritatea componentelor necesită doar o finisare ușoară înainte de a fi repuse în funcțiune, reducând timpul și costurile de prelucrare. Placarea cu laser de mare viteză a devenit o tehnologie de vârf în refacerea suprafețelor cu laser pentru aplicațiile echipamentelor de extracție a cărbunelui.

Scene 1: Laser Cladding for Hydraulic Support Cylinder Inner Walls

The inner cylinder walls of hydraulic support columns in coal mining operations are prone to corrosion and pitting due to substandard emulsions or prolonged exposure after being lifted from the mine. The commonly used repair method is arc copper cladding, which provides thick, corrosion-resistant coatings but involves high heat input and elevated costs.

Inner-wall laser cladding offers an effective alternative and expansion to traditional arc copper deposition, especially for small-diameter components. Laser cladding allows precise selection and adjustment of alloy powders according to service conditions, enabling rapid fabrication of high-performance corrosion-resistant coatings.

Greenstone’s internal laser cladding heads feature high integration, excellent stability, mature process control, and strong adaptability. The resulting inner-wall cladding surface is smooth, uniform, and defect-free, significantly reducing subsequent machining requirements while minimizing thermal deformation of the component. This ensures long-term durability and enhanced performance for hydraulic support cylinders operating in harsh underground mining environments.

Scene 2: Laser Cladding for Hydraulic Support Columns

Hydraulic support columns are critical components in coal mining equipment and operate for long periods in acidic and alkaline corrosive environments. Their surfaces are continuously subjected to corrosion, wear, and impact loads. Traditional remanufacturing techniques, primarily electroplating, provide short service life, limited repair cycles, and cause environmental pollution.

Laser cladding offers a superior alternative, with strong metallurgical bonding between the coating and substrate and a dense microstructure. Extensive industrial applications show that laser-cladded support columns deliver significantly improved performance and durability compared with electroplated columns. Using a high-energy laser beam as the heat source, laser cladding melts wear-resistant and anti-corrosion alloy powders together with the substrate surface, forming a robust protective layer that dramatically extends the service life of hydraulic supports.

Compared with electroplating, laser cladding provides exceptional technical advantages, supports green and sustainable manufacturing, and delivers substantial economic and operational benefits for coal mining enterprises.

Scene 3: Laser Cladding for Cutting Picks

Cutting picks are critical components in coal mining and tunneling machines, responsible for coal breaking and fragmentation. Their performance directly affects machine productivity, power consumption, operational stability, and the service life of associated components. During operation, cutting picks are subjected to high cyclic compressive stress, shear stress, and impact loads. Typical failure modes include tip detachment, chipping, wear of the pick tip and body, and, under severe conditions, body fracture. Therefore, efficient repair and reinforcement of worn picks is a key concern for equipment manufacturers and mining operators.

Applying tehnologie de placare cu laser to cutting pick refurbishment and remanufacturing significantly increases surface hardness and wear resistance, extending service life and reducing replacement frequency. Greenstone has successfully implemented high-performance laser cladding on cutting picks. A single cladding layer typically reaches 1–3 mm thickness cu hardness up to HRC 65, free of cracks and porosity defects. The resulting wear-resistant coating dramatically reduces wear and breakage, lowers pick consumption, and minimizes spark generation during cutting, improving safety and boosting equipment availability and mining machine uptime.

Avantaje cheie

• Substantially enhanced wear resistance for cutting picks and pick holders, longer service life, reduced operating costs

• Dense, uniform cladding microstructure with controlled thickness and coverage; minimal micro-defects

• Strong metallurgical bonding with controlled dilution rate for superior durability

• Rapid cooling rate, minimal heat-affected zone, and extremely low thermal deformation

This advanced laser cladding solution provides a robust and sustainable method to upgrade cutting tools for modern coal mining operations.

Scene 4: Laser Cladding for Gears and Shaft Components

Coal mining machinery operates under heavy loads, high rotational speeds, and prolonged high-temperature conditions. As a result, gears, shafts, and other transmission components are highly susceptible to wear, corrosion, and fatigue-related failures. When these critical parts fail, whether through factory repair or complete replacement, mining operations incur substantial downtime and economic losses.

Laser cladding provides an efficient and cost-effective solution for restoring and strengthening worn gears and shafts. By selecting specialized alloy powders based on material composition, hardness, and performance requirements, laser cladding restores original dimensions and mechanical properties while significantly enhancing wear and corrosion resistance. This technology not only extends component service life but also delivers strong economic benefits by reducing replacement frequency, maintenance time, and overall operating costs in coal mining applications.