Laser deposition welding with wire: economical and environmentally friendly
Laser Cladding – A Promising Technology for High-Quality Parts and Surface Coatings
Laser cladding is a cutting-edge technology used to manufacture high-quality components, repair worn parts, and apply protective coatings to enhance surface properties.
In this process, a laser beam melts a filler material in wire form directly onto the surface, creating a metallurgically bonded layer identical to the base material. This method offers several advantages, including high deposition rates, excellent layer quality, strong adhesion, minimal distortion, and efficient material usage, all while maintaining good contour accuracy and surface finish. Additionally, it enables the creation of complex geometries and wear-resistant coatings.
Omnidirectional Laser Cladding
With the patented "Ring Shape Beam" technology, omnidirectional cladding becomes possible, providing a significant advantage for customers by making complex manufacturing tasks far more efficient and cost-effective. This unique beam shaping approach delivers a fully homogeneous laser intensity distribution by feeding the wire coaxially into the processing head, ensuring uniform and omnidirectional deposition.
Find out more about 3D printing with metal
But how exactly does the "Ring Shape Beam" work?
In this process, the laser beam is leaded (1), expanded into a ring shape at the front of the processing head (2, 3) and then split into two half-moon shapes using prisms (4). The wire is fed coaxially to the laser beam (5), and the beam profile is closed again (6). The beam is then focused into a closed laser spot, where the wire is melted (7).
This innovative method significantly boosts the application of wire-based Laser Metal Deposition (LMD), delivering exceptional build results with consistent quality and a homogeneous internal structure of the melted wire. The wire-based process also eliminates contamination of surrounding areas or surfaces.
Key Aspects and Advantages of the Ring Shape Beam Solution
- Omnidirectional intensity distribution
- Homogeneous preheating
- Minimal material distortion due to reduced heat input
The coaxial wire feed ensures 100% material utilization. In many cases, wire is a more cost-effective alternative to powder-based materials. Depending on the material and wire diameter, deposition rates of up to 4 kg/h can be achieved. This makes the process ideal for efficient, clean, and environmentally friendly 3D printing and surface coating applications.