Surface hardening is essential for enhancing the durability and wear resistance of industrial components. Traditional methods such as carburizing, nitriding, and induction hardening have been widely used, but they come with limitations, including high heat distortion and inconsistent results.
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Meanwhile, laser hardfacing applies a thin, uniform layer of welded metal with embedded super-hard particles, offering a cutting-edge alternative for creating wear-resistant coatings. Its low-heat process guarantees minimal distortion and achieves hard particle densities, which makes it a superior choice for extending the lifespan of material components in super abrasive high wear environments.
This article explores various industrial applications and technical aspects of the laser hard facing process.
Listed below are the technical aspects of hardfacing with lasers, including the equipment used and the types of materials best suited for this process:
The most commonly used lasers include the following:
Fiber coupled lasers are widely used in laser facing for their high efficiencies and short wavelengths making excellent absorption quality. These lasers also provide a stable and concentrated heat source, making them ideal for precise coating applications.
The choice of materials is crucial for achieving optimal results. Some of the materials include:
Here are the specialized equipment utilized to guarantee precise and consistent application:
The laser source provides the necessary energy to melt the surface of the workpiece and the hardfacing material. The choice of laser source depends on the specific application and material requirements.
Computer numerical control (CNC) machines are essential for controlling the laser movement and the component. CNC technology ensures high precision and repeatability, allowing complex geometries to be accurately coated.
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Powder feeders supply the hardfacing material to the laser beam. The feeder must consistently deliver the powder to achieve a uniform coating. Advanced systems can adjust the feed rate in real time based on process conditions.
We tackle below how laser hardfacing provides superior quality in various industries where wear resistance is crucial:
Laser hardening significantly improves the surface hardness of engine valves, camshafts, and crankshafts. The precision and control provided by laser technology ensure minimal distortion and maintain the integrity of these components. As a result, the extended lifespan of these parts reduces maintenance costs and increases the vehicle's overall reliability.
In aerospace, components such as turbine blades face harsh conditions of high temperatures and friction. Laser hardfaced materials can withstand extreme temperatures in turbine engines, which enhances fatigue strength. Moreover, precisely applying wear-resistant materials with lasers maintains tight tolerances, which are critical for aircraft safety.
The oil and gas industry operates in some of the harshest environments, constantly exposing equipment to abrasive materials and corrosive substances. Laser processing provides a robust barrier against the corrosive conditions encountered in drilling operations. It increases wear resistance and cutting maintenance by extending equipment lifespan.
Heavy machinery components such as buckets, blades, and wear plates benefit significantly from laser hardfacing. This imparts high hardness to surfaces, greatly improving abrasion resistance. Moreover, this process can enhance the toughness of components, allowing them to withstand severe impact.
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First off, let me say this isn't the typical hard-as-a-rock hard weld that most know. It was specifically designed for an application in which it's supposed to be machined (turned specifically). We're using it to build up a cutting edge and then trying to mill it to a sharp 90 degree edge by facing one side and then peripherally milling the other.
Right now we're using a negative rake, 6 flute, 3" face mill and the inserts are hexagonal and flat with a small raised edge (grade ACP300 from Sumitomo). The mill is a Mori Duravertical .
The problem we're having is after the second or third pass, the insert is chipping. I already know part of the problem is rigidity due to the design of the part, which we plan on fixing, but I also think we need to change the cutter we're using.
I'm looking for any suggestions on a face mill/insert that would be good for this application. Milling weld, which means it can be pretty interrupted at times, taking .04-.100 depth cuts, and can do 50-55 Rc and not break down. I think we need to get away from the negative rake, but none of us have any experience with milling like this.
Any help is appreciated.
Josh
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