In the machinery industry, the surface modification processes of workpieces mainly include surfacing, thermal spraying, plasma spraying, chrome plating and nitriding. With the change of the industry, the requirements for the traditional surface modification process are getting higher and higher, so that the traditional process cannot meet the production demand. As a new type of green remanufacturing surface modification technology, laser cladding technology is gradually replacing the traditional surface treatment process. What are the advantages of laser cladding compared with traditional surface treatment processes?
Laser Cladding VS Thermal Spray
The coating prepared by laser cladding is dense and has no pores. Moreover, the coating and the substrate are metallurgically bonded, and the bonding strength is high.
Thermal spray coating deposition rate is high, but the powder utilization rate is only 50%. The coating has a porosity of 1% to 2%, and the corrosive medium can corrode the substrate through these voids. The bonding strength of thermal spray coatings to the substrate is generally lower than 150 MPa, and coating peeling (mechanical bonding) often occurs under heavy load conditions. In addition, thermal spraying is prone to noise and dust pollution during work, which affects the environment and the health of personnel.
Laser Cladding VS Electroplating
The laser cladding process does not involve chemical processes and is environmentally friendly. A wide variety of hardcoats are available, including iron-based, nickel-based and cobalt-based alloy coatings. The coatings prepared by laser cladding are defect-free, have high bonding strength, and are much more durable than electroplated coatings.
Electroplating is one of the mainstream anti-corrosion and wear-resistant coating technologies. However, the hard chromium coating prepared by electroplating generally has microcracks, and the bonding force between the coating and the substrate is poor. Therefore, electroplating often occurs cracking and peeling, and there is a phenomenon of high pollution and high power consumption.
Laser Cladding VS Surfacing
laser cladding technology adopts high power density and rapid cladding, and the heat input, heat affected zone and distortion are small, so as to ensure that the workpiece will not be deformed.
Surfacing techniques such as TIG welding and plasma spray welding can produce high-quality, defect-free metal coatings. The surfacing bonding method is metallurgical bonding, with high bonding strength, and the thickness of the single-layer deposition can reach 2 mm to 3 mm. Compared with the deposition thickness of 25-50μm for a single layer of thermal spraying, the deposition efficiency of surfacing technology is extremely high. However, high deposition efficiency is accompanied by high energy input, which induces tissue-property transformation and thermal damage in the matrix material.
Ultra-High-Speed Laser Cladding VS Traditional Laser Cladding
The processing efficiency of traditional laser cladding technology is generally low. For example, in the traditional cladding process, the cladding line speed is generally 600-1000mm/min, and the cladding efficiency is generally 0.15㎡/h. Moreover, traditional laser cladding is mainly based on individualized single-piece processing, which is difficult to mass produce. However, the ultra-high-speed laser cladding speed is 100-250 times faster than the traditional laser cladding, and the rapid preparation of large-area coatings can be completed in a short time. At the same time, the ultra-high-speed laser cladding can minimize the thermal impact of the laser on the substrate, so that the coating preparation of heat-sensitive material parts can be realized, and there is basically no damage to the surface of the workpiece.
Senfeng, as a laser cladding machines manufacturer, is committed to the innovation and research and development of laser surface treatment of metal materials. Now high-speed laser cladding technology and supporting equipment have been gradually applied to petroleum machinery, construction machinery, coal, steel and automobile industries. After the effective verification in the market, the cladding machine produced by Senfeng has high cladding efficiency, fast delivery speed and high cladding quality, which has been widely recognized by customers, and can provide integrated technical solutions according to the specific conditions of customers. If you want to learn more about laser cladding, please contact SENFENG
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