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Germany develops new ultra-high speed laser cladding technology

At present, the corrosion-resistant and wear-resistant coatings of parts are mainly repaired by hard chromium plating, thermal spraying, or other surfacing techniques. However, the application of these technologies will gradually be replaced by environmental and health issues. Starting from September 2017, chromium (VI) coatings must be subject to strict official approval before they can be used, and will be completely banned in the future. For this reason, researchers at the Fraunhofer Institute for Laser Technology in Germany and the Aachen University of Technology have developed an ultra-high-speed laser pointer cladding technology. And won the 2017 Innovation Award.

Protecting parts from corrosion and wear is not simple. Standard processes such as hard chrome plating, thermal spraying, and overlay welding all have their own limitations. Laser cladding is a relatively common alternative process, but due to insufficient plating rate and accuracy, it has not been widely used. The ultra-high-speed laser cladding technology will revolutionize the traditional coating preparation process. Dr. Fraunhofer Institute of Laser Technology said: "Using ultra-high-speed laser cladding technology, we can complete the rapid preparation of large-area coatings in a short period of time. After the cladding layer is thick, from 0.1 to 0.25 mm adjustment, basically no damage to the surface of the workpiece, the difference from the ordinary green laser pointer cladding process is that the powder melts at a certain distance from the workpiece, and is sprayed onto the workpiece surface at high speed to form an extremely thin metallurgical layer.

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Alternative hard chrome plating technology. Hard chromium plating is one of the most commonly used techniques for the preparation of corrosion-resistant and wear-resistant coatings at present, but it consumes a lot of energy. In addition, chromium (VI) pollutes the environment, which is why chromium (VI) can only be used with special approval since September 2017. Ultra-high-speed laser cladding technology now provides us with a more economical method. The process does not require the use of chemical raw materials and is very environmentally friendly. Unlike the electroplated chromium layer, the coating prepared by this technology is a metallurgical bond between the substrate and the coating, which is not easy to peel off. In addition, the surface coating prepared by the ultra-high-speed laser cladding technology does not have the pores and crack defects common in the hard chrome layer, and its protective effect is more durable and effective.

More efficient use of resources than thermal spraying. Thermal spraying technology also has shortcomings. The powder material and gas consumption in the process of processing are large, and the material utilization rate is only about 50% at the maximum; and the bonding force between the coating and the substrate is weak. Due to the large number of pores in the coating prepared by thermal spraying, it must be prepared by multilayer deposition (each layer is about 25-50 μm thick). Compared with thermal spraying methods, the newly developed ultra-high-speed red laser pointer cladding technology has a material utilization rate of more than 90%, which significantly improves the utilization rate and economy of metal powder. Not only is there no pores in the single-layer coating, but it is also firmly bonded to the substrate.

It is faster and more widely used than surfacing. Surfacing is commonly used to produce high-quality, strong coatings. Traditional surfacing techniques such as tungsten inert gas shielded welding or plasma arc powder deposition techniques are generally thicker (approximately 2-3mm) and require a lot of material. Although conventional laser cladding technology can already prepare thinner coatings (about 0.5mm-1mm), the efficiency is still too low when processing the surface of large parts, so it has only been used in some special fields so far.

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